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All sourcesNASA NTRSDOE OSTI
NASA NTRS2018

A Case for High-Fidelity Material Response Modeling

Material response modeling of heatshields for planetary entry vehicles has remained largely unchanged since Aerotherm Corp. introduced the CMA program in 1967. Modern models, like FIAT, have tread the same path, introducing efficiencies and better material property data along the way, but otherwise following the same underlying model paradigm. The CMA approach has worked well for heatshield design up to this point. However, there are three motivations for the material response community to pursue higher fidelity beyond simplified, CMA-derived models. The first motivation is that missions are becoming increasingly demanding and complex and, as they do, confidence in simplified models naturally decreases. Second, reliability of materials is now as much or more of a driving concern for mission designers than thermal response. Third, NASA and other agencies are increasingly interested in flight instrumentation for engineering science. This latter motivation places far stricter requirements on model accuracy in order to meet requirements for flight environment reconstruction.

Barnhardt, Michael D.↗
NASA NTRSDate not supplied

Recent Advancements in the PATO Material Response Code

Introduction: Predicting the complicated multiphysics phenomena during atmospheric entry requires high-fidelity modeling tools to refine estimates of mission risks during entry. To this end, new capabilities are being added to the Porous-material Analysis Toolbox based on OpenFOAM (PATO). PATO is an open-source software for Computational Material Response (CMR) of reactive porous materials submitted to high-temperature environments. The objective of this work is to highlight current efforts to add to and improve upon the modeling capabilities of PATO. These include efforts to loosely couple PATO with other discipline specialized codes including hypersonic Computational Fluid Dynamics (CFD), to assess the interaction effects between pyrolysis gas blowing and the boundary layer, and Computational Solid Mechanics (CSM), to address modeling of mechanical erosion. Other refinements include surface phenomena modeling capabilities to address the effects of silicone-based coatings applied to the TPS during flight preparation, and a unified multiphase solver for a mixed porous-material and plain-fluid domain. Coupling CMR with CFD (CMR/CFD): A loose coupling between PATO and the Data Parallel Line Relaxation (DPLR) CFD code has been achieved by making use of a blowing boundary condition at the heatshield surface available in DPLR. Starting with heat flux estimates with no pyrolysis gas blowing at the surface, blowing gases are computed by the CMR and passed to the CFD such that aerothermal properties of the environment can be recomputed for a new CMR computation. This leads to an iterative process which is supplemented with an estimate of the radiative heat flux using the Nonequilibrium air radiation (NEQAIR) program. The entire iterative process is illustrated in Figure 1. This coupling strategy has been utilized in computing the MSL material response. The goal is to compare the coupled CMR/CFD results with material response results obtained using traditional blowing corrections. Coupling CMS with CMR: A mechanical erosion model is currently being implemented in PATO to account for the additional mass removal induced by high shear conditions. The modeling process at each timestep consists of updating the mechanical properties as a function of temperature and computing the stress tensor and displacement fields of the material. Then, a failure criteria model determines the regions in which the stress exceeds the ultimate strength values resulting in mesh movement to account for mass removal. This model allows the material response simulation to compute the recession due to both oxidation and shear-induced erosion. The model is demonstrated by computing material response of sphere-cone arc jet samples. Surface Modeling Capabilities: NuSil, a silicone-based coating, was sprayed onto the MSL and Mars 2020 heatshields to mitigate shedding of phenolic dust. To better understand the effects of the NuSil coating on the material response, a novel model has been implemented in PATO. In this model, the equilibrium of the charred NuSil surface is modeled as pure silica, and a constant offset, inspired by the classical spallation model, is added to the the char blowing rate and wall enthalpy to reproduce HyMETS experimental results. The model has also been used to estimate the 3D material response of the MSL heatshield. Unified Solver: In addition to the iterative loose coupling approach mentioned above, a multiphase unified solver is being developed to couple the environment (plain-fluid phase) and the porous-material phase. The solver is based on the volume averaged conservation of mass, momentum, and energy for the macroscale with closure models which include microscale effects through effective physicochemical properties. The unified solver has been used to compute flow through a porous plug and solve the Beavers and Joseph problem. Since the strong coupling between phases is inherent to this solver, modeling assumptions present in other coupling methods of material response are mitigated. This strategy also makes it feasible to capture the competition between surface and volume ablation in the same computational domain, which is usually not possible with other coupling approaches.

Material Response↗
NASA NTRSDate not supplied

Recent Advancements in the PATO Material Response Code

Introduction: Predicting the complicated multiphysics phenomena during atmospheric entry requires high-fidelity modeling tools to refine estimates of mission risks during entry. To this end, new capabilities are being added to the Porous-material Analysis Toolbox based on OpenFOAM (PATO) [1,2,3]. PATO is an open-source software for Computational Material Response (CMR) of reactive porous materials submitted to high-temperature environments. The objective of this work is to highlight current efforts to add to and improve upon the modeling capabilities of PATO. These include efforts to loosely couple PATO with other discipline specialized codes including hypersonic Computational Fluid Dynamics (CFD), to assess the interaction effects between pyrolysis gas blowing and the boundary layer, and Computational Solid Mechanics (CSM), to address modeling of mechanical erosion. Other refinements include surface phenomena modeling capabilities to address the effects of silicone-based coatings applied to the TPS during flight preparation, and a unified multiphase solver for a mixed porous-material and plain-fluid domain. Coupling CMR with CFD (CMR/CFD): A loose coupling between PATO and the Data Parallel Line Relaxation (DPLR) [4] CFD code has been achieved by making use of a blowing boundary condition at the heatshield surface available in DPLR. Starting with heat flux estimates with no pyrolysis gas blowing at the surface, blowing gases are computed by the CMR and passed to the CFD such that aerothermal properties of the environment can be recomputed for a new CMR computation. This leads to an iterative process which is supplemented with an estimate of the radiative heat flux using the Nonequilibrium air radiation (NEQAIR) [5] program. The entire iterative process is illustrated in Figure 1. This coupling strategy has been utilized in computing the MSL material response. The goal is to compare the coupled CMR/CFD results with material response results obtained using traditional blowing corrections. Coupling CMS with CMR: A mechanical erosion model is currently being implemented in PATO to account for the additional mass removal induced by high shear conditions. The modeling process at each timestep consists of updating the mechanical properties as a function of temperature and computing the stress tensor and displacement fields of the material. Then, a failure criteria model determines the regions in which the stress exceeds the ultimate strength values resulting in mesh movement to account for mass removal. This model allows the material response simulation to compute the recession due to both oxidation and shear-induced erosion. The model is demonstrated by computing material response of sphere-cone arc jet samples. Surface Modeling Capabilities: NuSil, a silicone-based coating, was sprayed onto the MSL and Mars 2020 heatshields to mitigate shedding of phenolic dust. To better understand the effects of the NuSil coating on the material response, a novel model has been implemented in PATO. In this model, the equilibrium of the charred NuSil surface is modeled as pure silica, and a constant offset, inspired by the classical spallation model, is added to the the char blowing rate and wall enthalpy to reproduce HyMETS experimental results. The model has also been used to estimate the 3D material response of the MSL heatshield [6]. Unified Solver: In addition to the iterative loose coupling approach mentioned above, a multiphase unified solver is being developed to couple the environment (plain-fluid phase) and the porous-material phase. The solver is based on the volume averaged conservation of mass, momentum, and energy for the macroscale with closure models which include microscale effects through effective physicochemical properties. The unified solver has been used to compute flow through a porous plug and solve the Beavers and Joseph problem [7]. Since the strong coupling between phases is inherent to this solver, modeling assumptions present in other coupling methods of material response are mitigated. This strategy also makes it feasible to capture the competition between surface and volume ablation in the same computational domain, which is usually not possible with other coupling approaches.

Thermal Protection Systems↗
NASA NTRS1997

Analysis of Mars Pathfinder Entry Data, Aerothermal Heating, and Heat Shield Material Response

The Mars Pathfinder heatshield contained several thermocouples and resistance thermometers. A description of the experiment, the entry data, and analysis of the entry environment and material response is presented. In particular, the analysis addresses uncertainties of the data and the fluid dynamics and material response models. The calculations use the latest trajectory and atmosphere reconstructions for the Pathfinder entry. A modified version of the GIANTS code is used for CFD (computational fluid dynamics) analyses, and FIAT is used for material response. The material response and flowfield are coupled appropriately. Three different material response models are considered. The analysis of Pathfinder entry data for validation of aerothermal heating and material response models is complicated by model uncertainties and unanticipated data-acquisition and processing problems. We will discuss these issues as well as ramifications of the data and analysis for future Mars missions.

Milos, Frank↗
NASA NTRSDate not supplied

Analysis of Mars 2020 Entry with Coupled Material Response and CFD

When computing the response of an ablating thermal protection system during entry, the aerothermal environment and material response are traditionally computed independently, with the introduction of a blowing correction term in the material response model to account for the outgassing of char and pyrolysis gases. This study presents an approach, where the pyrolysis blowing gases, calculated within the PATO material response code, are integrated into the DPLR hypersonic CFD code via a blowing boundary condition. This methodology employs an iterative process, whereby the blown pyrolysis gas products from PATO are incorporated into DPLR, refining surface heating predictions. The NEQAIR code is used to compute radiative heating. The method is applied in computing 3D material response of the Mars 2020 entry. When compared with uncoupled material response, the coupled simulations show a lower surface heat flux initially and a higher heat flux at peak heating as shown in Fig. 1. This is in agreement with previous work using a sphere case with environments from MSL.

Heat Transfer↗
NASA NTRSDate not supplied

Analysis of Mars 2020 Entry with Coupled Material Response and CFD

When computing the response of an ablating thermal protection system during entry, the aerothermal environment and material response are traditionally computed independently, with the introduction of a blowing correction term in the material response model to account for the outgassing of char and pyrolysis gases. This study presents an approach, where the pyrolysis blowing gases, calculated within the PATO material response code [1], are integrated into the DPLR hypersonic CFD code [2] via a blowing boundary condition. This methodology employs an iterative process, whereby the blown pyrolysis gas products from PATO are incorporated into DPLR, refining surface heating predictions. The NEQAIR code is used to compute radiative heating [3]. The method is applied in computing 3D material response of the Mars 2020 entry. When compared with uncoupled material response, the coupled simulations show a lower surface heat flux initially and a higher heat flux at peak heating as shown in Fig. 1. This is in agreement with previous work using a sphere case with environments from MSL [4].

Heat Transfer↗
NASA NTRS2011

A Short Review of Ablative-Material Response Models and Simulation Tools

A review of the governing equations and boundary conditions used to model the response of ablative materials submitted to a high-enthalpy flow is proposed. The heritage of model-development efforts undertaken in the 1960s is extremely clear: the bases of the models used in the community are mathematically equivalent. Most of the material-response codes implement a single model in which the equation parameters may be modified to model different materials or conditions. The level of fidelity of the models implemented in design tools only slightly varies. Research and development codes are generally more advanced but often not as robust. The capabilities of each of these codes are summarized in a color-coded table along with research and development efforts currently in progress.

Lachaud, Jean↗
NASA NTRS2018

Material Response Analysis of a Titan Entry Heatshield

Accurate calculation of thermal protection material response is critical to the vehicle design for missions to the Saturn moon Titan. In this study, Icarus, a three-dimensional, unstructured, finite-volume material response solver under active development at NASA Ames Research Center, is used to compute the in-depth material response of the Huygens spacecraft along its November 11 entry trajectory. The heatshield analyzed in this study consists of a five-layer stack-up of Phenolic Impregnated Carbon Ablator (PICA), aluminum honeycomb, adhesive, and face sheetmaterials. During planetary entry, the PICA outer layer is expected to undergo pyrolysis. A surface energy balance boundary condition that captures both time- and spatial-variance of surface properties during entry is used in the simulation.

material response↗
NASA NTRSDate not supplied

3D Material Response of the MSL Heatshield Using NuSil-Coated PICA

The Mars Science Laboratory (MSL) was protected during its atmospheric entry by an instrumented heatshield that used NASA's Phenolic Impregnated Carbon Ablator (PICA) material [1]. PICA is a lightweight carbon fiber/polymeric resin material that offers outstanding performance for protecting probes during planetary entry. Data from the Mars Entry Descent and Landing Instrument (MEDLI) suite on MSL offers unique in-flight validation data for models of material response and atmospheric entry. MEDLI recorded, among other things, time-resolved in-depth temperature data of PICA using thermocouple sensors assembled in the MEDLI Integrated Sensor Plugs (MISP) [2]. A space-grade silicone-based coating commercially known as NuSil CV-1144-0 [3] was applied to the entire MSL heatshield, including the MEDLI plugs, to mitigate the spread of dust from PICA. Modeling the thermal response of PICA-NuSil (PICA-N) system is still an open challenge. Ground testing of PICA-N models exhibited surface temperature jumps of the order of 150 K due to oxide scale formation and sub-sequent NuSil burn-off. It is therefore critical to include a validated model for the material response of the coating in engineering codes. A test campaign has been conducted at the NASA’s Langley HyMETS [4] facility to screen the response of PICA-N and gather detailed data on its behavior [5]. A first model of PICA-N thermal response has been developed using the Hy-METS experiments [6]. The objective of this work is to analyze the material response of the latest PICA-N model compared to the engineering model used to simulate the entry of MSL. The environment and material response around the MSL aeroshell during Mars atmospheric entry is simulated using a collection of tools. The Direct Simulation Monte Carlo SPARTA code [7] is used in the rarefied regime, the Data Parallel Line Relaxation (DPLR) code [8] is used in the continuum regime and radiative heating conditions are provided by the Nonequilibrium air radiation (NEQAIR) code [9] to estimate the environmental conditions. The thermal response inside the material is computed using the Porous material Analysis Toolbox based on Open-FOAM (PATO) [10,11,12]. Thermodynamic and chemistry properties are estimated using the Mutation++ library [13]. The approach implemented in PATO as a first cut PICA-N thermal response model is outlined in Figure 1. While the recession is less than the coating thickness, the Surface mass and energy balance Boundary Condition (SBC) uses the NuSil B’ tables. Once the recession removes the coating, the usual PICA B’ tables are used for the SBC. The B’ tables are computed using an equilibrium solver implemented in Mutation++, given the temperature, pressure, blowing rate, composition of the pyrolysis and environment gases, and the condensed species at the surface. Preliminary results of the 3D material response of the MSL heat-shield at the peak heating (80 sec after Entry Interface) are shown in Figure 2. Current NASA’s mission to Mars, Mars 2020, used the spare heatshield of MSL for thermal protection during entry, descent, and landing. In preparation for Mars 2020 post-flight analysis, the PATO high-fidelity material response capability was benchmarked against flight data from MEDLI. This effort represents an important milestone toward the development of validated predictive capabilities for designing thermal protection systems for planetary probes. This bench-marking is awaiting the final release of the MEDLI-2 data.

Aerospace↗
NASA NTRSDate not supplied

Coupling CFD and Material Response for Analysis of Mars Entry

In computing the response of an ablating thermal protection system during atmospheric entry, the aerothermal environment and material response are generally computed separately with a blowing correction term in the material response model to account for the blowing of char and pyrolysis gases. In this work, we apply a coupled approach in which pyrolysis blowing gases, computed in the PATO material response code, are used with a blowing boundary condition in the DPLR hypersonic CFD code. This leads to an iterative method in which blowing products from PATO are input into DPLR to update surface heating estimates. The full iterative method, with the addition of radiative heating estimates using the NEQAIR radiation solver, is shown in Fig. 1. The method is demonstrated on a sphere case with the environment and material properties based on the Mars Science Laboratory entry. Future work includes utilizing this method in computing full 3D material response during the Mars 2020 entry.

Ablation↗
NASA NTRSDate not supplied

Coupling CFD and Material Response for Analysis of Mars Entry

In computing the response of an ablating thermal protection system during atmospheric entry, the aerothermal environment and material response are generally computed separately with a blowing correction term in the material response model to account for the blowing of char and pyrolysis gases [1]. In this work, we apply a coupled approach in which pyrolysis blowing gases, computed in the PATO material response code [2], are used with a blowing boundary condition in the DPLR hypersonic CFD code [3]. This leads to an iterative method in which blowing products from PATO are input into DPLR to update surface heating estimates. The full iterative method, with the addition of radiative heating estimates using the NEQAIR radiation solver [4], is shown in Fig. 1. The method is demonstrated on a sphere case with the environment and material properties based on the Mars Science Laboratory entry. Future work includes utilizing this method in computing full 3D material response during the Mars 2020 entry.

Heat Transfer↗
NASA NTRSDate not supplied

MEDLI2 Material Response Model Development and Validation

During the entry of Mars Science Laboratory (MSL) the heatshield was equipped with the instrumentation suite Mars Entry, Descent, and Landing Instruments (MEDLI). In-depth thermocouple (TC) data was used to reconstruct the surface heating and temperatures. Discrepancies between MEDLI’s recorded in-depth heating data and the predicted thermal response and recession led to a campaign to characterize and test Mars Entry, Descent, and Landing Instrument 2 (MEDLI2) flight lot thermal protection materials (TPS) at relevant temperatures and pressures for Martian entry conditions. This paper covers the development and validation of MEDLI2 flight lot material response models for the heatshield material Phenolic Impregnated Carbon Ablator (PICA) and the backshell material Super-Lightweight Ablator (SLA-561V). Virgin and char thermal conductivities were updated as a function of temperature and pressure in the MEDLI2 specific material response models. Other material properties such as virgin and char density, emissivity, absorptivity, and specific heat capacitance was also characterized and compared to the “Heritage” models used during the TPS design phase of Mars 2020. Fully Implicit Ablation and Thermal response (FIAT) simulations were completed using the Heritage and MEDLI2 material response models to provide evidence of the increased accuracy of the MEDLI2 model. FIAT predicted in-depth temperatures were compared to flight lot certification ground-test arc jet test data and MEDLI2 flight thermocouple data.

Material response↗
NASA NTRSDate not supplied

Analysis of MSL/MEDLI Entry Data with Coupled CFD and Material Response

The Mars Science Laboratory (MSL) was protected during its atmospheric entry by an instrumented heatshield using NASA's Phenolic Impregnated Carbon Ablator (PICA) material [1]. PICA is a lightweight carbon fiber/polymeric resin material that offers outstanding performances for protecting probes during planetary entry. The Mars Entry Descent and Landing Instrument (MEDLI) suite on MSL offers unique in-flight validation data for models of material response and atmospheric entry. MEDLI recorded, among other things, time-resolved in-depth temperature data of PICA using thermocouple sensors assembled in the MEDLI Integrated Sensor Plugs (MISP) [2]. The objective of this work is to showcase and analyze the coupling between the material response and the aerothermal environment. As shown in Figure 1, the workflow is divided into the following steps. First, the aerothermal properties are computed in the Data Parallel Line Relaxation (DPLR) code [3] and used with the Nonequilibrium air radiation (NEQAIR) program [8] to compute radiative heating. Second, the thermal response inside the material is computed in the Porous material Analysis Toolbox based on OpenFOAM (PATO) [4,5,6] using a fixed blowing correction parameter. Third, the pyrolysis gases computed in PATO are used as inputs to a blowing boundary condition within DPLR. Fourth, the new environment properties from DPLR are used in NEQAIR to provide an updated solution, then both the updated aerothermal environment and radiative heating are used in PATO without blowing correction. The third and fourth steps are then repeated until convergence in surface temperature is obtained. Convergence in the radiative heating is generally achieved before surface temperature, at which point the radiative heating is no longer updated. Char mass loss rates are forced to zero to produce a non-receding surface condition. For early time points in the trajectory, where flow around the MSL aeroshell is rarefied, the Direct Simulation Monte Carlo (DSMC) code, SPARTA [7], is used to compute the aerothermal environment. Iteration between PATO and SPARTA is not performed due to the computational cost of DSMC simulations. Preliminary results of the coupling between PATO and DPLR for the MSL heatshield atmospheric entry model are presented in Figures 2-4 at 65 seconds after entry interface. Figure 2 shows the surface temperature results from an uncoupled simulation in PATO with the blowing correction parameter applied (left) along with the coupled surface temperature after iteration (right). Figure 3 shows the surface temperature along the centerline from windward to leeward for easier comparison. Figure 4 shows the coupled and uncoupled pyrolysis gas blowing rate. Mars 2020 used a similar heatshield consisting of PICA for thermal protection during entry, descent, and landing. In preparation for Mars 2020 post-flight analysis, the predictive material response capability is benchmarked against flight data from MEDLI. This work represents an important milestone toward the development of validated predictive capabilities for designing thermal protection systems for planetary probes.

Thermal Protection Systems↗
NASA NTRSDate not supplied

Overview of the Material Response Code Icarus

Icarus is a material response code capable of modeling the in-depth heat transfer for multi-dimensional, ablative and non-ablative thermal protection systems. Since the initial release of Icarus, several improvements have been made to increase the robustness, performance, and modeling capability of the tool. This paper will review the capabilities of Icarus, discuss results from recent validation exercises highlighting current modeling capability, and summarize the current and future development efforts.

material response↗
NASA NTRS2017

Verification of the Icarus Material Response Tool

Due to the complex physics encountered during reentry, material response solvers are used for two main purposes: improve the understanding of the physical phenomena; and design and size thermal protection systems (TPS). Icarus, is a three dimensional, unstructured material response tool that is intended to be used for design while maintaining the flexibility to easily implement physical models as needed. Because TPS selection and sizing is critical, it is of the utmost importance that the design tools be extensively verified and validated before their use. Verification tests aim at insuring that the numerical schemes and equations are implemented correctly by comparison to analytical solutions and grid convergence tests.

ablation↗
NASA NTRSDate not supplied

ANALYSIS OF THE MSL/MEDLI ENTRY DATA WITH COUPLED CFD AND MATERIAL RESPONSE.

The Mars Science Laboratory (MSL) was protected during its atmospheric entry by an instrumented heat-shield using NASA's Phenolic Impregnated Carbon Ablator (PICA) material. PICA is a lightweight carbon fiber/polymeric resin material that offers out-standing performances for protecting probes during planetary entry. The Mars Entry Descent and Landing Instrument (MEDLI) suite on MSL offers unique in-flight validation data for models of material response and atmospheric entry. MEDLI recorded, among other things, time-resolved in-depth temperature data of PICA using thermocouple sensors assembled in the MEDLI Integrated Sensor Plugs (MISP). The objective of this work is to showcase and analyze the coupling between the material response and the aerothermal environment. As shown in Figure 1, the workflow is divided into the following steps. First, the aerothermal properties are computed in the Data Parallel Line Relaxation (DPLR) code [3] and used with the Nonequilibrium air radiation (NEQAIR) program [8] to compute radiative heating. Second, the thermal response inside the material is computed in the Porous material Analysis Toolbox based on Open-FOAM (PATO) using a fixed blowing correction parameter. Third, the pyrolysis gases computed in PATO are used as inputs to a blowing boundary condition within DPLR. Fourth, the new environment properties from DPLR are used in NEQAIR to provide an updated solution, then both the updated aerothermal environment and radiative heating are used in PATO without blowing correction. The third and fourth steps are then repeated until convergence in surface temperature is obtained. Convergence in the radiative heating is generally achieved before surface temperature, at which point the radiative heating is no longer updated. Char mass loss rates are forced to zero to produce a non-receding surface condition. For early time points in the trajectory, where flow around the MSL aeroshell is rarefied, the Direct Simulation Monte Carlo (DSMC) code, SPARTA, is used to compute the aerothermal environment. Iteration between PATO and SPARTA is not performed due to the computational cost of DSMC simulations. Preliminary results of the coupling between PATO and DPLR for the MSL heatshield atmospheric entry model are presented in Figures 2-4 at 65 seconds after entry interface. Figure 2 shows the surface temperature results from an uncoupled simulation in PATO with the blowing correction parameter applied (left) along with the coupled surface temperature after iteration (right). Figure 3 shows the surface temperature along the centerline from windward to leeward for easier comparison. Figure 4 shows the coupled and uncoupled pyrolysis gas blowing rate. Mars 2020 used a similar heatshield consisting of PICA for thermal protection during entry, descent, and landing. In preparation for Mars 2020 post-flight analysis, the predictive material response capability is benchmarked against flight data from MEDLI. This work represents an important milestone toward the development of validated predictive capabilities for designing thermal protection systems for planetary probes.

Mars Science Laboratory↗
NASA NTRSDate not supplied

Coupled Material Response Simulations of Dragonfly Capsule and DrEAM Reconstruction

Icarus is a three-dimensional, unstructured, finite-volume material response solver developed at NASA Ames Research Center and has been recently used to analyze the material response of the Dragonfly capsule for a variety of problems. Since the Dragonfly capsule will be instrumented in a similar manner to the Mars 2020 and MSL capsules, it is important to assess how our current simulation tools can aid in understanding Dragonfly Entry Aerosciences Measurements (DrEAM). In this presentation, the Ares multi-physics tool that couples Icarus to the flow and radiation physics of the aerothermal environment will be used to better understand how modeling sensitivities might affect environment reconstructions and our understanding of measured data. Ares couples Icarus to the US3D flow solver and NERO, a reduced-order, finite-volume radiation transport solver and uses a customized time-scale management to enable coupled simulations for a large portion of the Dragonfly trajectory. As a result of the coupling, a more accurate and consistent assessment of modelling sensitivities to aerothermal reconstruction can be assessed. For example, the radiometer is sensitive to the quantity of CN in the flow, which is a byproduct of the free-stream methane but also the pyrolysis gas products injected into the boundary layer due to ablation of the heatshield. Ares will be used to conduct a simulation of the full Dragonfly capsule for 50 seconds of the trajectory. The different aerothermal and material response models will be discussed and the key results will be presented in terms of the simulated thermocouple and radiometer measurements on the backshell.

Ablation↗
NASA NTRSDate not supplied

Material Response Analysis of PICA-NuSil at the Hypersonic Materials Environmental Test System

Phenolic impregnated carbon ablator (PICA) is a thermal protection system (TPS) that gained heritage during the Stardust mission and is the baseline TPS material for expeditions to Mars (e.g., Mars Science Laboratory and Mars 2020).1 PICA is friable; therefore, a polysiloxane resin (NuSil CV-1144-0) is deposited onto the surface of flight hardware before assembly, test, and launch operations (ATLO) to mitigate particle shedding. Furthermore, the Mars Science Laboratory (MSL) and Mars 2020 heatshields were instrumented with an array of thermocouple plugs (MEDLI Integrated Sensor Plugs or MISP) designed to measure the in-depth thermal response of PICA during flight. Post-flight analysis of MISP data suggests that recession was lower than predicted, and NuSil is suspected as a reasonable cause. NuSil primarily consists of a copolymer blend of dimethyl and diphenyl-substituted polysiloxane resin. Four decades of research in the field of polymer-derived ceramics demonstrate that polysiloxane resins form oxidation-resistant silicon oxycarbide materials at pyrolysis temperatures as low as 800 °C. -2 Furthermore, silicon oxycarbide materials exhibit excellent thermal stability at relatively high-temperatures (< 1200 °C) but eventually decompose via carbothermal reduction. -3 Therefore, it is reasonable to suggest that NuSil forms an oxidation-resistant thermal barrier coating on the TPS surface and influences the material response during atmospheric entry. Evidence for this notion was observed during prior arc-jet testing at both the Aerodynamic Heating Facility (AHF) and the Panel Test Facility (PTF) at the NASA Ames Research Center. Articles of PICA were subjected to testing in airflow, and a temperature discontinuity was recorded at the surface of coupons coated with NuSil. A glassy coating was observed to form at the surface in shear flow configurations (wedge and panel) under moderate heat fluxes. Furthermore, state-of-the-art material response models have yet to account for the underlying physics and chemistry of the temperature discontinuity. To this end, a pathfinder test campaign was executed at the Hypersonic Materials Environmental Test System (HyMETS) to enhance the fundamental understanding of PICA-NuSil ablation phenomena and provide a preliminary data set to aid in the development of material response models.

PICA↗