Anomalous swelling behavior of FM 5055 carbon phenolic composite
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Stokes, E. H.↗
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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Comparison of Mechanical Properties of Flat Sheets, Molded Shapes, and Postformed Shapes of Cotton-fabric Phenolic Laminates
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Reinhart, F W↗
Mechanical Tests of Macerated Phenolic Molding Material
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MATERIALS, PLASTIC - STRENGTH↗
Modeling of outgassing and matrix decomposition in carbon-phenolic composites
A new release rate equation to model the phase change of water to steam in composite materials was derived from the theory of molecular diffusion and equilibrium moisture concentration. The new model is dependent on internal pressure, the microstructure of the voids and channels in the composite materials, and the diffusion properties of the matrix material. Hence, it is more fundamental and accurate than the empirical Arrhenius rate equation currently in use. The model was mathematically formalized and integrated into the thermostructural analysis code CHAR. Parametric studies on variation of several parameters have been done. Comparisons to Arrhenius and straight-line models show that the new model produces physically realistic results under all conditions.
Mcmanus, Hugh L.↗
Modeling of outgassing and matrix decomposition in carbon-phenolic composites
Work done in the period Jan. - June 1994 is summarized. Two threads of research have been followed. First, the thermodynamics approach was used to model the chemical and mechanical responses of composites exposed to high temperatures. The thermodynamics approach lends itself easily to the usage of variational principles. This thermodynamic-variational approach has been applied to the transpiration cooling problem. The second thread is the development of a better algorithm to solve the governing equations resulting from the modeling. Explicit finite difference method is explored for solving the governing nonlinear, partial differential equations. The method allows detailed material models to be included and solution on massively parallel supercomputers. To demonstrate the feasibility of the explicit scheme in solving nonlinear partial differential equations, a transpiration cooling problem was solved. Some interesting transient behaviors were captured such as stress waves and small spatial oscillations of transient pressure distribution.
Mcmanus, Hugh L.↗
Arc Jet Testing of Carbon Phenolic for Mars Sample Return and Future NASA Missions
The objective of the Mars Sample Return (MSR) Mission is to return a sample of MArtian soil to Earth. The Earth Entry Vehicle (EEV) brings te samples through the atmosphere to the ground.The program aims to: Model aerothermal environment during EEV flight; On the basis of results, select potential TPS materials for EEV forebody; Fabricate TPS materials; Test the materials in the arc jet environment representative of predicted flight environment;Evaluate material performance; Compare results of modeling predictions with test results.
Laub, Bernard↗
Robust and Mass Efficient Thermal Protection Systems for Future Venus Missions
Several international Venus missions, both orbiter, and in-situ probe are in the works after a prolonged absence. Future missions are expected to be long-duration lander missions and balloon missions to investigate the cloud layer. The entry mass for these in-situ missions will be significantly higher, and the aeroshell will be larger, than previous missions. Two cardinal requirements govern the selection and use of thermal protection systems (TPS), namely, robustness to assure mission safety during entry and mass efficiency so that the useful mass for science is maximized. One cannot trade mission safety for mass when it comes to TPS. The robustness of the TPS is a paramount requirement as it is a single point of system failure. At the same time, TPS mass is carried for the entire mission duration prior to entry, and any excess TPS mass is at the cost of science payload. Future missions will benefit enormously from TPS options with mass and performance benefits far beyond advanced carbon-carbon (ACC) that is currently proposed for the DAVINCI mission. NASA STMD, and SMD jointly invested in the development of 3-D woven thermal protection systems in the last decade, and as a result, the Heat-shield for Extreme Entry Environment Technology (HEEET) TPS has been matured to TRL 6. It is ready for future mission use including Venus. The HEEET project focused on developing a broad technology base, applicable for missions not only to Venus, but also to Saturn, the Ice Giants, and higher speed sample return missions such as Mars Sample Return requiring extreme robustness due to bio-hazards. The dual-layer HEEET (DL-HEEET) is proven to be extremely robust. DL-HEEET performed well in arc jet and laser testing conditions where heritage carbon-phenolic failed. HEEET also proved to be more mass efficient compared to Carbon-Phenolic. Recently, the principal author was invited to present his perspectives to the 2023-2032 Planetary Sciences Decadal Venus subcommittee on the current state of TPS for future Venus missions [1]. In addition to pointing out successful TPS and other developments in the last decade in support of entry systems, the principal author made two findings: 1) importance of and need to sustain TPS capabilities that took nearly a decade to develop and 2) the opportunity to further optimize TPS mass without sacrificing robustness to further enable future in-situ missions. This talk will focus on the above two recommendations and provide the rationale for them. The intent of the talk is to seek advocacy from the VEXAG community for the criticality of TPS sustainment and the benefits of 3D woven TPS optimization. TPS Capability Sustainment: HEEET development was necessitated by the atrophy of heritage carbon-phenolic. Atrophy has impacted other TPS materials as well. Avcoat, the TPS that successfully allowed astronauts to explore the Moon in the 1960s and 70s, took nearly a decade and $10’sM to recover in support of Orion/Artemis. One of the most used TPS materials, SLA 561V, had to be recovered prior to its use on Mars Pathfinder. Phenolic Impregnated Carbon Ablator (PICA), the TPS that replaced SLA 561V on MSL, has undergone multiple replacements and recovery due to constituent rayon changes. Recently, NASA invested in a domestic rayon replacement program and also invested in FMI to consolidate PICA capability for NASA missions, as a result of FMI’s decision to discontinue commercial FiberForm, which is needed for PICA. TPS used for planetary missions are unique and have no other commercial or defense use. In addition, low mission cadence is also a driver for TPS atrophy. Hence, NASA, as the steward, must take steps to ensure and sustain TPS capabilities. In this talk, we outline steps NASA can take to keep abreast of emerging risks and target risk mitigation steps to ensure TPS capability sustainment for Venus and other extreme environment missions. Next Generation of Mass efficient and Robust TPS: NASA invested in an alternate TPS to PICA based on felt-technology called Conformal-PICA which has the potential to save 30% - 50% mass over PICA. The development was discontinued at a Technology Readiness Level (TRL) of ~ 5. 3D Mid-Density Carbon Phenolic (3MDCP) is a single layer variant of HEEET, based on the insulating layer only (SL-HEEET) and currently baselined for the Mars Sample Return Mission Earth Entry System due to its mass efficiency (30% more mass efficient than DL- HEEET). Currently, SL-HEEET is limited to aeroshell diameters of < 1.3m. The SL-HEEET was compared to DL-HEEET in the recent ADVENT flag-ship class mission study in support of the Planetary Science Decadal. SL HEEET was the recommended TPS based on 30% mass savings for both the balloon and lander missions. Given C-PICA and SL-HEEET have superior reliability and mass efficiency, advocacy from VEXAG is sought for completing their further development to TRL 5/6 in this decade so as to enable TPS readiness for future missions.
Thermal Protection Systems↗
Measurements of the response of transport aircraft ceiling panels to fuel pool fires
Tests were performed to characterize the responses of various aircraft ceiling panel configurations to a simulated post-crash fire. Attention was given to one currently used and four new ceiling configurations exposed to a fuel pool fire in a circulated air enclosure. The tests were controlled to accurately represent conditions in a real fire. The panels were constructed of fiberglass-epoxy, graphite-phenolic resin, fiberglass-phenolic resin, Kevlar-epoxy, and Kevlar-phenolic resin materials. The phenolic resin-backed sheets performed the best under the circumstances, except when combined with Kevlar, which became porous when charred.
Bankston, C. P.↗
Structure and energetics of model amphiphilic molecules at the water liquid-vapor interface - A molecular dynamics study
A molecular dynamics study of adsorption of p-n-pentylphenol at infinite dilution at the water liquid-vapor interface is reported. The calculated free energy of adsorption is -8.8 +/- 0.7 kcal/mol, in good agreement with the experimental value of -7.3 kcal/mol. The transition between the interfacial region and the bulk solution is sharp and well-defined by energetic, conformational, and orientational criteria. At the water surface, the phenol head group is mostly immersed in aqueous solvent. The most frequent orientation of the hydrocarbon tail is parallel to the interface, due to dispersion interactions with the water surface. This arrangement of the phenol ring and the alkyl chain requires that the chain exhibits a kink. As the polar head group is being moved into the solvent, the chain length increases and the tail becomes increasingly aligned toward the surface normal, such that the nonpolar part of the molecule exposed to water is minimized. The same effect was achieved when phenol was replaced by a more polar head group, phenolate.
Pohorille, Andrew↗
Thermal Stability of Jet Fuels: Kinetics of Forming Deposit Precursors
The focus of this study was on the autoxidation kinetics of deposit precursor formation in jet fuels. The objectives were: (1) to demonstrate that laser-induced fluorescence is a viable kinetic tool for measuring rates of deposit precursor formation in jet fuels; (2) to determine global rate expressions for the formation of thermal deposit precursors in jet fuels; and (3) to better understand the chemical mechanism of thermal stability. The fuels were isothermally stressed in small glass ampules in the 120 to 180 C range. Concentrations of deposit precursor, hydroperoxide and oxygen consumption were measured over time in the thermally stressed fuels. Deposit precursors were measured using laser-induced fluorescence (LIF), hydroperoxides using a spectrophotometric technique, and oxygen consumption by the pressure loss in the ampule. The expressions, I.P. = 1.278 x 10(exp -11)exp(28,517.9/RT) and R(sub dp) = 2.382 x 10(exp 17)exp(-34,369.2/RT) for the induction period, I.P. and rate of deposit precursor formation R(sub dp), were determined for Jet A fuel. The results of the study support a new theory of deposit formation in jet fuels, which suggest that acid catalyzed ionic reactions compete with free radical reactions to form deposit precursors. The results indicate that deposit precursors form only when aromatics are present in the fuel. Traces of sulfur reduce the rate of autoxidation but increase the yield of deposit precursor. Free radical chemistry is responsible for hydroperoxide formation and the oxidation of sulfur compounds to sulfonic acids. Phenols are then formed by the acid catalyzed decomposition of benzylic hydroperoxides, and deposit precursors are produced by the reaction of phenols with aldehydes, which forms a polymer similar to Bakelite. Deposit precursors appear to have a phenolic resin-like structure because the LIF spectra of the deposit precursors were similar to that of phenolic resin dissolved in TAM.
Naegeli, David W.↗
PICA Variants with Improved Mechanical Properties
Phenolic Impregnated Carbon Ablator (PICA) is a member of the family of Lightweight Ceramic Ablators (LCAs) and was developed at NASA Ames Research Center as a thermal protection system (TPS) material for the Stardust mission probe that entered the Earth s atmosphere faster than any other probe or vehicle to date. PICA, carbon fiberform base and phenolic polymer, shows excellent thermal insulative properties at heating rates from about 250 W/sq cm to 1000 W/sq cm. The density of standard PICA - 0.26 g/cu cm to 0.28 g/cu cm - can be changed by changing the concentration of the phenolic resin. By adding polymers to the phenolic resin before curing it is possible to significantly improve the mechanical properties of PICA without significantly increasing the density.
Thornton, Jeremy↗
Aerothermal Testing of Woven TPS Ablative Materials
Woven Thermal Protection Systems (WTPS) is a new TPS concept that is funded by NASAs Office of the Chief Technologist (OCT) Game Changing Division. The WTPS project demonstrates the potential for manufacturing a variety of TPS materials capable of wide ranging performances demanded by a spectrum of solar system exploration missions. Currently, missions anticipated to encounter heat fluxes in the range of 1500 4000 Watts per square centimeter are limited to using one proven material fully dense Carbon Phenolic. However, fully dense carbon phenolic is only mass efficient at heat fluxes greater than 4000 Watts per square centimeter, and current mission designs suffer this mass inefficiency for lack of an alternative mid-density TPS. WTPS not only bridges this gap but also offers a replacement for carbon phenolic, which itself requires a significant and costly redevelopment effort to re-establish its capability for use in the high heat flux missions recently prioritized in the NRC Decadal survey, including probe missions to Venus, Saturn and Neptune. This poster will summarize some recent arc jet testing to evaluate the performance of WTPS. Both mid density and fully dense WTPS test results will be presented and results compared to heritage carbon phenolic where applicable.
Stackpoole, Mairead↗
Cyanate Ester and Phthalonitrile Impregnated Carbon Ablative TPS
Phenolic resin has extensive heritage as a TPS (Thermal Protection Systems) material, however, alternative resin systems such as Cyanate Ester and Phthalonitrile may offer improved performance compared to state-of-the-art phenolic resin. These alternative resin systems may have higher char yield, higher char strength, lower thermal conductivity and improved mechanical properties. In current work at NASA Ames alternative resin systems were uniformly infused into fibrous substrates and preliminary properties characterized. The density of the cyanate ester infused in fibrous substrate ranged from 0.25-0.3 grams per cubic centimeter compared to PICA (Phenolic resin impregnated carbon ablative) having a density of approximately 0.25 grams per cubic centimeter. The density of Phthalonitrile varies from 0.22-0.25 grams per cubic centimeter. Initial formulations of these new resin systems were recently tested at the LARC HyMETs (Hypersonic Materials Environmental Test System) facility to evaluate their performance and data such as back face temperature, char yield, and recession are compared to PICA. Cyanate Ester and Phthalonitrile impregnated carbon ablative samples showed comparable performance to phenolic resin impregnated carbon ablative samples.
Polymer↗
Matrix Microcracking Effect on the Structural Response of a Thermal Protection System
The effect of microcracking in the phenolic matrix of a three-dimensional woven thermal protection system (TPS) and resulting material stiffness reduction was studied via a comparison of finite element results from linear and iterative linear analyses. A dual-layer continuous dry weave material with a low-density phenolic resin matrix has been developed for use in extreme environments. Due to high stresses in the through-the-thickness direction, microcracks may form in the matrix. The matrix does not have structural load transfer requirements, and testing has shown that microcracked phenolic resin satisfies thermal requirements. Microcracks in the matrix would result in a reduction of stiffness, which could alter the structural performance. A study was conducted to determine if reduction in material stiffness would change the load paths or structural margins. A linear finite element analysis that did not account for microcracking and an iterative linear finite element analysis that accounted for propagation microcracks were compared. Four subcases were analyzed with results indicating that the assumed propagation strength for the microcracking is the critical parameter for determining the extent of microcracking. Phenolic microcracking does not appear to have an adverse effect on the structural response and is not a critical failure for the modeled TPS.
Thermal Protection System↗
Studies of nozzle ablative material performance for large solid boosters Final report
Carbon phenolic, graphite phenolic, and silica phenolic nozzle ablative materials performance for large solid propellant rocket boosters
NOZZLE EFFICIENCY↗
Analysis of Pyrolysis Products from Ablative Thermal Protection Systems
NASA’s state-of-the-art ablative materials are composed of a three-dimensional network of carbon fibers impregnated with polymers that dissipate thermal energy through pyrolysis. A fundamental understanding of the decomposition mechanisms and pyrolysis product distributions of various classes of polymers is instrumental in the design of new ablative materials. Furthermore, innovative experiments are essential to the continuous modernization of material response models by providing high-fidelity data. Thus, an apparatus has been designed to measure pyrolysis products from polymers and composite materials by implementing in-situ mass spectrometric techniques. Initial results from experiments performed on siloxane resins and a common phenolic resin will be discussed. Both classes of polymers exhibit heating-rate-dependent decomposition mechanisms. At the onset of heating, phenolic polymers decompose through competitive reactions to form gaseous products and a carbonaceous char. Gas phase products of phenolic resins are typically composed of molecular hydrogen, water, and aromatic hydrocarbons. Pyrolysis products from siloxane polymers include molecular hydrogen, small molecules, and cyclic oligomers from the polymer backbone.
Pyrolysis↗
Thermally conductive polymers
A thermally conductive polymer is provided having physical and chemical properties suited to use as a medium for potting electrical components. The polymer is prepared from hydroquinone, phenol, and formaldehyde, by conventional procedures employed for the preparation of phenol-formaldehyde resins. While the proportions of the monomers can be varied, a preferred polymer is formed from the monomers in a 1:1:2.4 molar or ratio of hydroquinone:phenol:formaldehyde.
Byrd, N. R.↗