Results for “porous ablator”

NASA NTRS2016

X-ray Micro-Tomography of Ablative Heat Shield Materials

X-ray micro-tomography is a non-destructive characterization technique that allows imaging of materials structures with voxel sizes in the micrometer range. This level of resolution makes the technique very attractive for imaging porous ablators used in hypersonic entry systems. Besides providing a high fidelity description of the material architecture, micro-tomography enables computations of bulk material properties and simulations of micro-scale phenomena. This presentation provides an overview of a collaborative effort between NASA Ames Research Center and Lawrence Berkeley National Laboratory, aimed at developing micro-tomography experiments and simulations for porous ablative materials. Measurements are carried using x-rays from the Advanced Light Source at Berkeley Lab on different classes of ablative materials used in NASA entry systems. Challenges, strengths and limitations of the technique for imaging materials such as lightweight carbon-phenolic systems and woven textiles are discussed. Computational tools developed to perform numerical simulations based on micro-tomography are described. These enable computations of material properties such as permeability, thermal and radiative conductivity, tortuosity and other parameters that are used in ablator response models. Finally, we present the design of environmental cells that enable imaging materials under simulated operational conditions, such as high temperature, mechanical loads and oxidizing atmospheres.Keywords: Micro-tomography, Porous media, Ablation

tomography↗

NASA NTRS1991

Phenomenological and experimental study of the thermal response of low density silica ablators to high enthalpy plasma flows

A complete analysis of the melting-ablator governing equations is carried out for porous ablators with the purpose of establishing an approximate analytical model capable of determining surface recession, temperature, and heat flux as well as in-depth temperature profiles. A detailed dimensional analysis of the melt-flow governing equations is performed for parameters applicable to high-enthalpy flows. Results of arc-jet flow experiments performed on NASA Reusable Surface Insulation materials of different densities and over a range of stagnation pressures and heat fluxes are discussed. A dimensionless correlation for melt run-offs is derived in terms of material and flow parameters; however, it is pointed out that the accuracy of the current data is sufficient to conclude the compliance with the model.

Henline, William D.↗

NASA NTRS1971

On chemical reactions in the char zone during ablation

Analysis of reacting flow of pyrolysis products through char layer of low density, nylon phenolic resin, charring ablators and porous graphite

April, G. C.↗

NASA NTRS2014

Ballistic Performance Model of Crater Formation in Monolithic, Porous Thermal Protection Systems

Porous monolithic ablative systems insulate atmospheric reentry vehicles from reentry plasmas generated by atmospheric braking from orbital and exo-orbital velocities. Due to the necessity that these materials create a temperature gradient up to several thousand Kelvin over their thickness, it is important that these materials are near their pristine state prior to reentry. These materials may also be on exposed surfaces to space environment threats like orbital debris and meteoroids leaving a probability that these exposed surfaces will be below their prescribed values. Owing to the typical small size of impact craters in these materials, the local flow fields over these craters and the ablative process afford some margin in thermal protection designs for these locally reduced performance values. In this work, tests to develop ballistic performance models for thermal protection materials typical of those being used on Orion are discussed. A density profile as a function of depth of a typical monolithic ablator and substructure system is shown in Figure 1a.

Miller, J. E.↗

NASA NTRS2016

Tribological Studies of Dynamic Thermal Seal Materials

Thermal seals are required on high-speed vehicles in many dynamic applications such as variable inlets in propulsion systems and control surfaces. These seals, often referred to as dynamic thermal seals, must not only mitigate inboard heat transfer, but must also exhibit sufficient durability when scrubbed against mating surfaces. For high-temperature high-speed vehicle applications, the mating surfaces are often made from thermal protection system (TPS) materials, which are typically rougher and more abrasive than TPS materials used at lower temperatures. The high-temperature TPS materials used can include non-ablative (e.g., lightweight porous oxides, ceramic matrix composites) andor ablative systems (e.g., phenolic systems). Due to the increased need for durable high-temperature dynamic seals, researchers working with the NASA Glenn Research Center embarked on an effort to (a) characterize the tribological performance of state-of-the-art thermal seal materials against a variety of TPS materials and (b) develop approaches for improved wear resistance. Tests were conducted using a recently upgraded high-temperature tribometer to assess wear resistance for a variety of tribopairs under multiple conditions. This data will begin to frame the challenges of using these materials and eventually permit an improved ability to design and implement these critical TPS components.

thermal protection↗

NASA NTRSDate not supplied

arcjetCV: automating recession extraction from video

Arc jet Computer Vision (arcjetCV)[1][2] is a software application built to automate time-resolved recession tracking of edges in test videos, specifically for tracking material recession and the shock-material standoff. This provides a new capability to resolve and validate new physics associated with non-linear processes and an essential step to reduce testing, modeling, and validation uncertainties for heatshield material performance. ArcticCV uses several types of machine learning (convolutional neural net: CNN, decision tree: DT, k-means unsupervised clustering: KM) to automate the video processing pipeline. These include inferring the start/stop of time segments of interest (1D CNN), measuring the time-dependent 2D recession of the material samples (2D CNN, DT), measuring the time-dependent shock standoff distance (2D CNN, DT), and post-processing cleaning of the recession data (KM). The software also provides a graphical user interface for ease of use. The results of using this tool on arc jet videos show non-linear time-dependent effects can be important for certain materials and characterizing certain failure modes.

Recession tracking↗

NASA NTRSDate not supplied

ArcjetCV: Automating Recession Tracking

Arc jet Computer Vision (arcjetCV) is a software application built to automate time-resolved recession tracking of edges in test videos, specifically for tracking material recession and the shock-material standoff. This provides a new capability to resolve and validate new physics associated with non-linear processes and an essential step to reduce testing, modeling, and validation uncertainties for heatshield material performance. ArcticCV uses several types of machine learning (convolutional neural net: CNN, decision tree: DT, k-means unsupervised clustering: KM) to automate the video processing pipeline. These include inferring the start/stop of time segments of interest (1D CNN), measuring the time-dependent 2D recession of the material samples (2D CNN, DT), measuring the time-dependent shock standoff distance (2D CNN, DT), and post-processing cleaning of the recession data (KM). The software also provides a graphical user interface for ease of use. The results of using this tool on arc jet videos show non-linear time-dependent effects can be important for certain materials and characterizing certain failure modes.

Recession tracking↗

NASA NTRSDate not supplied

ArcjetCV: Automating Arc Jet Analysis

Arc jet Computer Vision (arcjetCV) is a software application built to automate time-resolved recession tracking of edges in test videos, specifically for tracking material recession and the shock-material standoff. This provides a new capability to resolve and validate new physics associated with non-linear processes and an essential step to reduce testing, modeling, and validation uncertainties for heatshield material performance. ArcticCV uses several types of machine learning (convolutional neural net: CNN, decision tree: DT, k-means unsupervised clustering: KM) to automate the video processing pipeline. These include inferring the start/stop of time segments of interest (1D CNN), measuring the time-dependent 2D recession of the material samples (2D CNN, DT), measuring the time-dependent shock standoff distance (2D CNN, DT), and post-processing cleaning of the recession data (KM). The software also provides a graphical user interface for ease of use. The results of using this tool on arc jet videos show non-linear time-dependent effects can be important for certain materials and characterizing certain failure modes.

Recession tracking↗

NASA NTRS2018

Multi-Scale Modeling of Low-Density Carbon-Phenolic Ablators

Protecting a spacecraft during atmospheric entry is one of highest risk factors that needs to be mitigated during design of a space exploration mission. At entry speeds from space, air turns into high-temperature plasma, and spacecraft Thermal Protection Systems (TPS) are needed to protect the vehicle payload. Modern successful material architectures of spacecraft shields use a porous carbon fiber substrate impregnated with phenolic as an ablator material. In the lecture, efforts to build a Predictive Material Modeling framework for porous ablators from micro-scale to macro-scale will be presented. Several numerical methods and techniques will be summarized that use voxelized images to compute geometrical properties of the porous substrate. These computed properties include porosity, specific surface area and tortuosity that are otherwise indirectly measured through experimental techniques. Direct simulation Monte Carlo (DSMC), a particle-based method for approximating the Boltzmann equation, is used to compute the permeability coefficient of the porous substrate based on its digitized representation. The method computes the flow within the microstructure, where the size of the pores may approach the mean-free-path of the flow. Finally, a high-fidelity model implemented in PATO (Porous-material Analysis Toolbox) is discussed, and some examples of ablative material response are presented, including for the first time 3D simulations of the full tiled heat shield for the Mars Science Laboratory (MSL) capsule.

Ablators↗

NASA NTRSDate not supplied

Towards Quantifying and Correlating RTV Intumescence to Entry-Relevant Conditions

Room Temperature Vulcanizing silicone (RTV) is a high-temperature adhesive used as a gap-filler between Thermal Protection System (TPS) tiles for heatshields on numerous missions. It is also adopted to bond instrumentation plugs of temperature and pressure sensors into heatshield’s tiles. While RTV has been traditionally assumed to be a non-porous and non-ablating material, numerous experiments have shown that RTV pyrolyzes and becomes highly porous as it is heated. Experimental data has also shown heating rate-dependent swelling (or intumescence) and shrinking of RTV, these volume changes may cause roughness-induced boundary layer transition. Outgassing and surface oxide formation of RTV upon decomposition also occur, which can be sources of contamination of heat shield sensors. This combination of detrimental effects motivates a critical need to develop a high-fidelity model for RTV ablation. As a first critical step in RTV modeling, a comprehensive material properties database for RTV was collected that account for the lack of data in properties such as pyrolysis char yield, shape change, virgin and char porosity. The next step is to quantify the volume change of RTV as a function of temperature. While this was done in previous campaigns, limited data was collected which showed a possible heating rate dependent intumescent behavior. To further understand the intumescence phenomenon of RTV, numerous dedicated experiments were performed at Beamline 8.3.2 of the Advanced Light Source, where RTV samples were heated while X-ray scans were taken in situ. Micro-Computed Tomography scans were taken in situ for low heating rates (≤ 60 °C/min), whereas continuous radiography scans were taken for higher heating rates (≤ 1500 ºC/min). Unconstrained samples and samples constrained in different holders (quartz, graphite, FiberForm and PICA) were tested to determine the change in intumescence due to confinement. Using deep learning techniques, the tomographies and radiographies are segmented to obtain volume change, porosity, pore size distributions and connectivity. From the results obtained, modifications to the previous RTV intumescence model are proposed, along with preliminary comparisons to testing RTV at high-enthalpy facilities.

RTV↗

NASA NTRSDate not supplied

Material Characterization and Modeling of Room Temperature Vulcanizing Silicone

Room Temperature Vulcanizing silicone (RTV) is a high-temperature adhesive that has successfully been used as a gap-filler between Thermal Protection System (TPS) tiles for heatshields on numerous missions. It is also used to bond instrumentation plugs such as temperature and pressure sensors into the heatshields. While RTV has been traditionally assumed to be a non-porous and non-ablating material, numerous experiments have shown that RTV pyrolyzes and becomes highly porous as it is heated. Heating RTV has also shown swelling, or intumescence, which can pose unique problems that lead to roughness induced boundary-layer transition, surface oxide formation and contamination of heat shield sensors. Therefore, it is crucial to understand and model the intumescence phenomenon of RTV. As data for RTV material properties is limited, the first step in modeling RTV is to collect material properties such as pyrolysis mass-loss, microstructure change, virgin and char porosity, etc. which was performed in our initial study. Additionally, thermomechanical properties such as Young’s modulus and Poisson ratio are required for modeling the intumescence of RTV, which were taken from literature and the coefficient of thermal expansion was collected using in-situ heating and Micro Computed Tomography (µ-CT) in previous studies. Finally, numerous other properties such as pyrolysis gas properties, virgin and char thermal conductivity and specific heat were compiled from previous experiments and literature into a material database that can be used for simulations. In Porous Material Analysis Toolbox based on OpenFOAM (PATO) [4], structural mechanics coupled with material response was used for simulating the intumescence of RTV as it is heated. However, since the permeability of the material is very low, the pyrolysis gas creates an internal pressure build-up as the material is being heated, significantly contributing to the deformation of the material. To correctly characterize this phenomenon, additional physics models were implemented into PATO's stress analysis solver, and results were compared with RTV dilatometry test data as a preliminary verification case. Future work will include experiments of RTV at the Plasmatron X facility and the in-situ heating cell with µ-CT, and improvement of simulation tools to more accurately model RTV intumescence.

TPS↗

NASA NTRSDate not supplied

Material Properties and Modeling of Room Temperature Vulcanizing Silicone

Room Temperature Vulcanizing silicone (RTV) is a high-temperature adhesive that has successfully been used as a gap-filler between Thermal Protection System (TPS) tiles for heatshields on numerous missions. It is also used to bond instrumentation plugs such as temperature and pressure sensors into the heatshields. While RTV has been traditionally assumed to be a non-porous and non-ablating material, numerous experiments have shown that RTV pyrolyzes and becomes highly porous as it is heated. Heating RTV has also shown swelling, or intumescence, which can pose unique problems that lead to roughness induced boundary-layer transition, surface oxide formation and contamination of heat shield sensors. Therefore, it is crucial to understand and model the intumescence phenomenon of RTV. As data for RTV material properties is limited, the first step in modeling RTV is to collect material properties such as pyrolysis mass-loss, microstructure change, virgin and char porosity, etc. which was performed in our initial study. Additionally, thermomechanical properties such as Young’s modulus and Poisson ratio are required for modeling the intumescence of RTV, which were taken from literature and the coefficient of thermal expansion was collected using in-situ heating and Micro Computed Tomography (µ-CT) in previous studies. Finally, numerous other properties such as pyrolysis gas properties, virgin and char thermal conductivity and specific heat were compiled from previous experiments and literature into a material database that can be used for simulations. In Porous Material Analysis Toolbox based on OpenFOAM (PATO) [4], structural mechanics coupled with material response was used for simulating the intumescence of RTV as it is heated. However, since the permeability of the material is very low, the pyrolysis gas creates an internal pressure build-up as the material is being heated, significantly contributing to the deformation of the material. To correctly characterize this phenomenon, additional physics models were implemented into PATO's stress analysis solver, and results were compared with RTV dilatometry test data as a preliminary verification case. Future work will include experiments of RTV at the Plasmatron X facility and the in-situ heating cell with µ-CT, and improvement of simulation tools to more accurately model RTV intumescence.

PATO↗

NASA NTRS1994

Development of lightweight ceramic ablators and arc-jet test results

Lightweight ceramic ablators (LCA's) were recently developed at Ames to investigate the use of low density fibrous substrates and organic resins as high temperature, high strength ablative heat shields. Unlike the traditional ablators, LCA's use porous ceramic/carbon fiber matrices as substrates for structural support, and polymeric resins as fillers. Several substrates and resins were selected for the initial studies, and the best performing candidates were further characterized. Three arcjet tests were conducted to determine the LCA's thermal performance and ablation characteristics in a high enthalpy, hypersonic flow environment. Mass loss and recession measurements were obtained for each sample at post test, and the recession rates were determined from high speed motion films. Surface temperatures were also obtained from optical pyrometers.

Tran, Huy K.↗

NASA NTRS2017

Radiative Heat Transfer Modeling in Fibrous Porous Media

Phenolic-Impregnated Carbon Ablator (PICA) was developed at NASA Ames Research Center as a lightweight thermal protection system material for successful atmospheric entries. The objective of the current work is to compute the effective radiative conductivity of fibrous porous media, such as preforms used to make PICA, to enable the efficient design of materials that can meet the thermal performance goals of forthcoming space exploration missions.

Radiative↗

NASA NTRS1972

Transient, compressible heat and mass transfer in porous media using the strongly implicit iteration procedure.

Coupled nonlinear partial differential equations describing heat and mass transfer in a porous matrix are solved in finite difference form with the aid of a new iterative technique (the strongly implicit procedure). Example numerical results demonstrate the characteristics of heat and mass transport in a porous matrix such as a charring ablator. It is emphasized that multidimensional flow must be considered when predicting the thermal response of a porous material subjected to nonuniform boundary conditions.

Curry, D. M.↗

NASA NTRS2006

Gallium Electromagnetic (GEM) Thrustor Concept and Design

We describe the design of a new type of two-stage pulsed electromagnetic accelerator, the gallium electromagnetic (GEM) thruster. A schematic illustration of the GEM thruster concept is given in Fig. 1. In this concept, liquid gallium propellant is pumped into the first stage through a porous metal electrode using an electromagneticpump[l]. At a designated time, a pulsed discharge (approx.10-50 J) is initiated in the first stage, ablating the liquid gallium from the porous electrode surface and ejecting a dense thermal gallium plasma into the second state. The presence of the gallium plasma in the second stage serves to trigger the high-energy (approx.500 I), send-stage puke which provides the primary electromagnetic (j x B) acceleration.

Polzin, Kurt A.↗

NASA NTRS2005

Galium Electromagnetic (GEM) Thruster Concept and Design

We describe the design of a new type of two-stage pulsed electromagnetic accelerator, the gallium electromagnetic (GEM) thruster. A schematic illustration of the GEM thruster concept is given. In this concept, liquid gallium propellant is pumped into the first stage through a porous metal electrode using an electromagnetic pump. At a designated time, a pulsed discharge (approx. 10-50 J) is initiated in the first stage, ablating the liquid gallium from the porous electrode surface and ejecting a dense thermal gallium plasma into the second state. The presence of the gallium plasma in the second stage serves to trigger the high-energy (approx. 500 J), second-stage pulse which provides the primary electromagnetic (j x B) acceleration.

Polzin, Kurt A.↗

NASA NTRS1974

Evaluation of the energy transfer in the char zone during ablation. Part 2: In-depth response of ablative composites, volume 1

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.

Pike, R. W.↗