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Results for “Thermal Protection System (TPS)”

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At least 127 records · Page 7

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NASA NTRS1990

Remtech SSME nozzle design TPS

Thermal damage to the Space Shuttle Main Engine (SSME) aft manifold Thermal Protection System (TPS) has been observed for flights STS-8 through STS-13. This damaged area is located on the ME2 and ME3 and extends over a region of approximately one square foot. Total failure or burn-through of the TPS could lead to severe thermal damage of the SSME manifold and loss of an engine nozzle necessitating nozzle replacement causing significant schedule delays and cost increases. Thermal damage to the manifold can be defined as a situation where the manifold temperature becomes greater than 1300 F; thereby causing loss of heat treatment in the nozzle. Results of Orbiter/nozzle wind tunnel tests and Hot Gas Facility tests of the TPS are presented. Aerothermal and thermal analysis models for the SSME aft manifold are discussed along with the flight predictions, design trajectory and design environment. Finally, the TPS design concept and TPS thermal response are addressed.

Bancroft, Steven A.↗

NASA NTRS2003

Ceramic Foams for TPS Applications

Ceramic foams have potential in many areas of Thermal Protection Systems (TPS) including acreage and tile leading edges as well as being suitable as a repair approach for re-entry vehicles. NASA Ames is conducting ongoing research in developing lower-density foams from pre-ceramic polymer routes. One of the key factors to investigate, when developing new materials for re-entry applications, is their oxidation behavior in the appropriate re-entry environment which can be simulated using ground based arc jet (plasma jet) testing. Arc jet testing is required to provide the appropriate conditions (stagnation pressures, heat fluxes, enthalpies, heat loads and atmospheres) encountered during flight. This work looks at the response of ceramic foams (Si systems) exposed to simulated reentry environments and investigates the influence of microstructure and composition on the material? response. Other foam properties (mechanical and thermal) will also be presented.

Stockpoole, Mairead↗

NASA NTRS1980

An assessment of the readiness of ablative materials for preflight application to the shuttle orbiter

The shuttle orbiter relies primarily on a reusable surface insulation (RSI) thermal protection system (TPS). The RSI is very efficient in its thermal performance; however, the RSI tile system has shown poor mechanical integrity. The state-of-the-art of the ablative TPS is reviewed, and an assessment made of the ablator's readiness for use on the shuttle orbiter. Unresolved technical issues with regard to the ablative TPS are identified. Short time, highly focused analytical and experimental programs were initiated to: (1) identify candidate ablation materials; (2) assess the data base for these materials; (3) evaluate the need and kind of waterproof coating; (4) calculate thermal and other stresses in an ablator tile; (5) identify an acceptable ablator/RSI tile joint filler; and (6) assess the sensitivity of the ablator to sequential heat pulses. Results from some of these programs are discussed.

Tompkins, S. S.↗

NASA NTRS1997

Development of Processing Techniques for Advanced Thermal Protection Materials

During the period June 1, 1996 through May 31, 1997, the main effort has been in the development of materials for high temperature applications. Thermal Protection Systems (TPS) are constantly being tested and evaluated for thermal shock resistance, high temperature dimensional stability, and tolerance to environmental effects. Materials development was carried out by using many different instruments and methods, ranging from intensive elemental analysis to testing the physical attributes of a material. The material development concentrated on two key areas: (1) development of coatings for carbon/carbon composites, and (2) development of ultra-high temperature ceramics (UHTC). This report describes the progress made in these two areas of research during this contract period.

Selvaduray, Guna↗

NASA NTRS1998

Aerothermal Test of Metallic TPS for X-33 Reusable Launch Vehicle

An array of metallic Thermal Protection System (TPS) panels including the seals developed for the windward surface of the X-33 vehicle is being tested in the Eight Foot High Temperature Tunnel at the NASA Langley Research Center. These tests are the first aerothermal tests of an X-33 TPS array and will be used to validate the TPS for the X-33 flight program. Specifically, the tests will be used to evaluate the structural and thermal performance of the TPS, the effectiveness of the high temperature seals between adjacent tiles and the durability of the TPS under realistic aerothermal flight conditions. The effect of varying step heights, damage to the seals between adjacent panels, and the use of secondary seals will also be investigated during the test program. The metallic TPS developed for the windward surface of the X-33 and the test program in the Eight Foot High Temperature Tunnel is presented and discussed.

Sawyer, James Wayne↗

NASA NTRS1977

Experimental subsonic drag properties of the space shuttle orbiter TPS tiles

The drag characteristics of the space shuttle orbiter thermal protection system (TPS) tiles were studied experimentally in subsonic flow. Full-scale tiles were mounted to a 3.05 x 3.5 m test board in four configurations plus a completely smooth case. Pressure gradients were produced by tilting the board relative to the freestream. The drags due to steps, slots, and gaps between the tiles were evaluated at various orientations, pressure gradients, and Reynolds numbers. Results showed that the contribution of gaps and slots were minor compared to those of typical steps. The results for skin friction did not correlate as a fully rough surface. Thus, the surface area of the TPS tiles was sufficient to allow smooth-wall Reynolds number effects even though the steps between tiles could double the skin friction.

Norton, D. J.↗

NASA NTRS1998

Arcjet Semi-Elliptic Nozzle Simulations and Validation in Support of TPS Testing

Much of the ground based testing of advanced thermal protection system (TPS) components for the X33 program is done in arc-heated wind tunnels such as those located in the Arc-Jet Complex at NASA Ames Research Center. These facilities are capable of simulating the high temperature, chemically reacting flow environment experienced by the vehicle during flight. This allows one to test critical design issues such as maximum reuse temperatures, seals, gaps, and increases in heating due to interfaces between different materials. Computational fluid dynamics (CFD) has evolved to the point where it now can be used in the vehicle design process for accurate and timely prediction of trajectory based aerothermal heating environments for re-entry vehicles. It can also be used for simulation of the flow environments in ground based facilities such as arcjets. By utilization of the same CFD code and solution methodology, the important differences between ground test and flight may be quantified. The goal of this paper is to utilize CFD to provide validated simulations of the flow environment in the NASA-Ames semi elliptic nozzle arcjet facilities. The validation of the ground simulations will come From comparison to existing calibration data. Specific tests in support of the X33 TPS test program will ilso be simulated. In this manner, the differences between the ground test simulation and the flight environment can be identified for a measure of ground test to flight traceability.

Loomis, Mark↗

NASA NTRS2013

Micromechanical Characterization and Testing of Carbon Based Woven Thermal Protection Materials

Woven thermal protection system (TPS) materials are one of the enabling technologies for mechanically deployable hypersonic decelerator systems. These materials can be simultaneously used for thermal protection and as structural load bearing members during the entry, descent and landing operations. In order to ensure successful thermal and structural performance during the atmospheric entry, it is important to characterize the properties of these materials, once they have been subjected to entry like conditions. The present paper focuses on mechanical characteristics of pre-and post arc-jet tested woven TPS samples at different scales. It also presents the observations from scanning electron microscope and computed tomography images, and explains the changes in microstructure after being subjected to combined thermal-mechanical loading environments.

Agrawal, Parul↗

NASA NTRS1981

Thermal design of the Space Shuttle External Tank

The history of the engineering and manufacturing requirements leading to the final Thermal Protection System (TPS) for the External Tank (ET) is presented. The thermal design for the ET must be optimized, based on considerations of cost, weight, and application of the TPS. The significant thermal requirements include the structural and component temperature limits, the propellant quality, the minimization of ice and frost, no air liquefaction, and no film boiling. The TPS materials selected to meet the requirements are a low density closed cell foam (CPR-488) and two light-weight ablators (SLA-56 and MA-25s). The first four flights of the Space Shuttle (1981) will measure and evaluate external environmental, structural, propulsion, electrical, and engine performance data. The ET will be instrumented to measure acoustics, pressures, heat transfer, vibration, temperatures, and structural strains. TPS weight reductions are planned for future ETs through the use of a comprehensive thermal instrumentation system.

Warmbrod, J. D.↗

NASA NTRS2007

TPS In-Flight Health Monitoring Project Progress Report

Progress in the development of new thermal protection systems (TPS) is reported. New approaches use embedded lightweight, sensitive, fiber optic strain and temperature sensors within the TPS. Goals of the program are to develop and demonstrate a prototype TPS health monitoring system, develop a thermal-based damage detection algorithm, characterize limits of sensor/system performance, and develop ea methodology transferable to new designs of TPS health monitoring systems. Tasks completed during the project helped establish confidence in understanding of both test setup and the model and validated system/sensor performance in a simple TPS structure. Other progress included complete initial system testing, commencement of the algorithm development effort, generation of a damaged thermal response characteristics database, initial development of a test plan for integration testing of proven FBG sensors in simple TPS structure, and development of partnerships to apply the technology.

Kostyk, Chris↗

NASA NTRS1972

The degradation of space shuttle TPS metals in dissociated oxygen.

The interaction of space shuttle orbiter Thermal Protection System (TPS) metals with the chemical environment to which it is exposed during reentry is considered with emphasis on the effects of dissociated oxygen. Experimental results comparing the interactions of atomic (dissociated) and molecular oxygen with five candidate shuttle TPS metals, Ni-20Cr-2ThO2, Ni-20Cr-3.5Al-2ThO2, Ni-16Cr-15Fe-2Mn-.5Si-.3La-2ThO2, Haynes Alloy Number 188, and Ti-6Al-4V at their maximum planned use temperature are presented. As measured by metal recession, weight change, rate of oxide scale formation, and scale spalling, the first four metals show enhanced degradation in a dissociated oxygen environment. The enhanced degradation appears to result from differing rates of alloy constituent reactions in the two environments. The dissociated oxygen environmental tests are found to better assess the usefulness of shuttle skin materials for the planned mission than do conventional molecular (either flowing or static) oxidation experiments.-

Gilbreath, W. P.↗

NASA NTRS2024

Bringing the Heat: Thermal Protection Systems for Low Earth Orbit Transportation and Lunar Exploration

Thermal protection systems (TPS) protect spacecraft from the heating associated with hypersonic flight through a planet’s atmosphere. The materials are subjected to extreme heating and the overall system must be engineered to reliably protect the spacecraft structure during atmospheric entry. The talk will introduce TPS and describe three NASA-led efforts to develop TPS materials and manufacturing processes. The first effort studied thermally stable ceramic aerogels for use in thermal barriers and high temperature seals. A design framework for such materials is proposed, linking the thermal stability performance data with existing material property measurements. The second project, Additive Manufacturing of Thermal Protection Systems (AMTPS), developed an automated, additive approach for ablative heat shield manufacturing. Novel material systems and manufacturing methods were developed to reduce the time required to manufacture ablative TPS heat shields. The third effort tackles a critical challenge of material obsolescence for silica fiber based reusable TPS. The properties and performance of heritage silica fiber are quantified and compared to modern alternatives to support qualification for flight. The talk will also describe other work in TPS conducted by the Thermal Design Branch at NASA JSC and opportunities for students and faculty to get involved with NASA.

Nathaniel Olson↗

NASA NTRSDate not supplied

Development and Sizing of the Mars 2020 Thermal Protection System

The Mars 2020 entry vehicle successfully delivered the Perseverance rover to the Martian surface on 18 February 2021. The entry vehicle aeroshell was shielded from aerodynamic heating with a thermal protection system (TPS) made of three different ablative materials. This paper provides an overview of the methodology and assumptions employed for the thermal sizing and design of the Mars 2020 aeroshell TPS. The sizing results demonstrate that the as-built thicknesses of the TPS materials were sufficient to withstand the predicted aerothermal environments without exceeding temperature limits of the underlying aeroshell structure. This paper also provides an overview of the ground testing performed in NASA arc jet facilities to verify the performance of flight lot TPS materials. Finally, temperature data returned by thermocouples embedded in the flight vehicle TPS are compared with predictions by the thermal response models used in pre-flight TPS sizing.

Mars2020↗

NASA NTRSDate not supplied

Development and Sizing of the Mars 2020 Thermal Protection System

Mars2020↗

NASA NTRS1993

Thermal protection systems for aerobrakes

In summary, advantages of the ablative thermal protection system (TPS) for aerobrakes are: (1) proven reliable TPS systems; (2) well characterized (thermally) with good, existing thermal analysis capability; (3) good candidate materials are available; (4) not sensitive to defects and more difficult to damage then RSI or C-C; (5) design program which demonstrated simple (direct bond) application of large panels; (6) thermal excursions not catastrophic; and (7) no SIP required.

Tompkins, Stephen S.↗

NASA NTRS1997

Laser Shearographic Inspection for Debonds in Sprayed On Foam Insulation (SOFI)

Preliminary results of shearographic inspections of the test panels simulating the Space Shuttle's external tank (ET) spray on foam insulation (SOFI) are presented. Debonding of SOFI may introduce flight debris that may damage the orbiter's thermal protection system (TPS) exposing the orbiter (as well as the ET) to thermal loading. It is estimated that 90 percent of the TPS damage on the orbiter's 'belly' results from debonded SOFI during ascent. A series of test panels were fabricated, with programmed debonds of different geometries and sizes, to determine the sensitivity of shearography as a function of debond size, SOFI thickness,'and vacuum excitation. Results show that a Probability of Detection (POD) of 0.95 or better can be expected for debonds with a diameter equal to the SOFI thickness as less than 0.4-psi pressure reduction. More testing will be required to validate the laser shearography imaging process for certifying its use in nondestructive evaluation (NDE) of Space Shuttle space flight components.

Adams, F. W.↗

NASA NTRS2000

Thermal Analysis Methods for an Earth Entry Vehicle

Thermal analysis of a vehicle designed to return samples from another planet, such as the Earth Entry vehicle for the Mars Sample Return mission, presents several unique challenges. The Earth Entry Vehicle (EEV) must contain Martian material samples after they have been collected and protect them from the high heating rates of entry into the Earth's atmosphere. This requirement necessitates inclusion of detailed thermal analysis early in the design of the vehicle. This paper will describe the challenges and solutions for a preliminary thermal analysis of an Earth Entry Vehicle. The aeroheatina on the vehicle during entry would be the main driver for the thermal behavior. and is a complex function of time, spatial position on the vehicle, vehicle temperature, and trajectory parameters. Thus. the thermal analysis must be closely tied to the aeroheating analysis in order to make accurate predictions. Also, the thermal analysis must account for the material response of the ablative thermal protection system TPS. For the exo-atmospheric portion of the mission, the thermal analysis must include the orbital radiation fluxes on the surfaces. The thermal behavior must also be used to predict the structural response of the vehicle (the thermal stress and strains) and whether they remain within the capability of the materials. Thus, the thermal analysis requires ties to the three-dimensional geometry, the aeroheating analysis, the material response analysis, the orbital analysis. and the structural analysis. The goal of this paper is to describe to what degree that has been achieved.

Amundsen, Ruth M.↗

NASA NTRS2000

Thermal Analysis Methods For Earth Entry Vehicle

Thermal analysis of a vehicle designed to return samples from another planet, such as the Earth Entry vehicle for the Mars Sample Return mission, presents several unique challenges. The Earth Entry Vehicle (EEV) must contain Martian material samples after they have been collected and protect them from the high heating rates of entry into the Earth's atmosphere. This requirement necessitates inclusion of detailed thermal analysis early in the design of the vehicle. This paper will describe the challenges and solutions for a preliminary thermal analysis of an Earth Entry Vehicle. The aeroheating on the vehicle during entry would be the main driver for the thermal behavior, and is a complex function of time, spatial position on the vehicle, vehicle temperature, and trajectory parameters. Thus, the thermal analysis must be closely tied to the aeroheating analysis in order to make accurate predictions. Also, the thermal analysis must account for the material response of the ablative thermal protection system (TPS). For the exo-atmospheric portion of the mission, the thermal analysis must include the orbital radiation fluxes on the surfaces. The thermal behavior must also be used to predict the structural response of the vehicle (the thermal stress and strains) and whether they remain within the capability of the materials. Thus, the thermal analysis requires ties to the three-dimensional geometry, the aeroheating analysis, the material response analysis, the orbital analysis, and the structural analysis. The goal of this paper is to describe to what degree that has been achieved.

Amundsen, Ruth M.↗