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A study was made of the effects of the conditions of char formation on the physical properties of charred phenolic nylon of 0.577 gm/cu cm density. It was found that the thermal conductivity and several of the monitors correlate well with degradation conditions. The monitors included electrical resistivity, sonic velocity, porosity, lattice spacing and crystallite size.
Coking reactions of pyrolysis gas in charring ablation material
Experimental simulation to establish accuracy of nonequilibrium flow model with system simulating charring during ablation
Thermochemical and thermophysical properties and ablation test data for three charring ablators
Thermophysical property data for ablation materials - aerodynamic heating of low density phenolic nylon and filled silicone resin
Computer program for finite difference equation analysis of in-depth response of materials exposed to high temperature environment
Comparison of the char yield after occurrence of a flash fire in the pyrolysis gases from various materials indicates that increased char yield appears to be associated with reduced flash-fire propensity for certain types of materials. For certain other materials, flash-fire propensity appears to be independent of char yield. The mechanisms of thermal decomposition and char formation may be more important factors in flash-fire propensity than the quantitative degree of char formation.
The decomposition of ablative composites is described along with the transport phenomena of pyrolysis gases which result from the decomposition of these plastics as they flow through the porous char of char-forming ablators. The pyrolysis products are those formed by the thermal degradation of nylon-phenolic resin and silicone elastomer composites. Emphasis is placed on the nature and extent of chemical reactions of the pyrolysis products and the char, along with the energy absorbed by the combined pyrolysis and char zone. Chemical reactions with thermodynamically consistent kinetic data are determined in order to develop a realistic analysis for predicting the thermal performance of ablative heat shields.
Following the successful Artemis I skip reentry on December 11, 2022, unexpected char liberation from the Orion heat- shield prompted formation of an Anomaly Response Team to determine root cause and establish flight rationale and corrective actions for subsequent missions. Through a comprehensive investigation including detailed hardware analysis, modeling & simulation, and ground testing, the team determined that the low permeability Avcoat experienced extreme internal gas pressure buildup during the skip entry that could not adequately outgas, leading to crack formation and char liberation. Key discoveries included significant performance differences between permeable and impermeable heatshield regions and successful replication of the anomaly through ground testing. Based on extensive ground testing and analysis, Artemis II flew a modified trajectory without the skip entry to minimize crack-inducing conditions, and successfully splashed down on April 10, 2026 with significantly reduced char loss. For Artemis III and beyond, a corrective action was implemented to produce a more permeable version of Avcoat that will substantially reduce internal pressure accumulation during entry.
Reactions of the silica reinforcement fiber and ablation char of the Apollo heat shield have been investigated by laboratory tests in an arc image furnace (at temperature levels up to 5000 R, pressures up to 0.7 atm, and heat flux similar to reentry) and by an actual reentry test. Microchemical analyses and X-ray diffraction studies have been made to determine the presence of SiC formation in the char. Experimental data and analytical predictions of thermal and density profiles have been compared for the ablation of virgin heat shield and precharred materials to determine the effects of SiC formation on ablation performance. In all analyses, general agreement was found between chemical composition and the thermal predictions for laboratory tests and reentry materials. In all ablated materials, SiC was formed in the front surface of the char. The highest SiC content found was 58% by weight and found in a high-pressure environment. The SiC formed was found to act as a heat sink in the ablation process and can lower the front surface temperature by 300 R.
The differential equations governing the transient response of a one-dimensional ablative thermal protection system are presented for thermal nonequilibrium between the pyrolysis gases and the char layer and with finite rate chemical reactions occurring. The system consists of three layers (the char layer, the uncharred layer, and an optical insulation layer) with concentrated heat sinks at the back surface and between the second and third layers. The equations are solved numerically by using a modified implicit finite difference scheme to obtain solutions for the thickness of the charred and uncharred layers, surface recession and pyrolysis rates, solid temperatures, porosity profiles, and profiles of pyrolysis-gas temperature, pressure, composition, and flow rate. Good agreement is obtained between numerical results and exact solutions for a number of simplified cases. The complete numerical analysis is used to obtain solutions for an ablative system subjected to a constant heating environment. Effects of thermal, chemical, and mass transfer processes are shown.
A brief investigation of the combustion characteristics of a solid propellant containing a binder which chars, as opposed to melting or volatizing, has been made. The burning rate of the propellant with the charring binder was significantly higher than similar propellants containing non-charring binders. High speed motion pictures of the burning propellant showed that the aluminum burned on the regressing surface, rather than a short distance from it as is typical with composite propellants.
Composites containing carbon and graphite fibers can release fibers into the atmosphere during a fire. This release can potentially cause failure in some types of electrical equipment. Reduced fiber dispersion during and after combustion will reduce risks. Epoxidized char forming systems were synthesized which will react with commercially available surface treated carbon fiber. Fibers modified with these char formers retained adhesion in a specific epoxy matrix resin. Small scale combustion testing indicates that using these char former modified fibers in laminates will help to reduce the dispersement of fibers resulting from exposure to fire without sacrificing resin to fiber adhesion.
Curing epoxy resins with novalac phenolic resins is a feasible approach for increasing intact char of the resin system. Char yields above 40% at 700 C were achieved with epoxy novalac (DEN 438)/novalac phenolic (BRWE 5833) resin systems with or without catalyst such as ethyl tri-phenyl phosphonium iodide. These char yields are comparable to commercially used epoxy resin systems like MY-720/DDS/BF3. Stable prepregs are easily made from a solvent solution of the epoxy/phenolic system and this provides a feasible process for fabrication of same into commercial laminates.
Charring ablator char zone nonequilibrium flow and chemical reaction kinetics as function of temperature, using thermal environment simulator
Energy transfer in reacting flow of pyrolysis products through char layer of nylon-phenolic resin charring ablator
Analysis of reacting flow of pyrolysis products through char layer of low density, nylon phenolic resin, charring ablators and porous graphite
The differential equations governing the transient response of the char layer of an ablating axisymmetric body, internal pyrolysis gas flow effects being considered, have been derived. These equations have been expanded into finite difference form and programed for numerical solution on a digital computer. Numerical results compare favorably with simplified exact solutions. The complete numerical analysis was used to obtain solutions for two representative body shapes subjected to a typical entry heating environment. Pronounced effects of the lateral flow of pyrolysis gases on the mass flow field within the char layer and the associated surface and pyrolysis interface recession rates are shown.