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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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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Error Sources and Mitigation Strategies for Thermocouples Integrated in Flexible Thermal Protection System Materials

• The flexible thermal protection system (FTPS) on NASA’s Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) vehicle will be instrumented with thermocouples (TCs) to measure the in-depth thermal response during entry into Earth’s atmosphere. Accurate flight temperature measurements are critical for verifying vehicle performance and reducing thermal model uncertainties. • The TC leads are routed from the measurement location to the data acquisition system within the same FTPS layer that they are monitoring the temperature. This approach eliminates the need to put holes in the FTPS layers. However, the insulated TC leads are exposed to high temperatures and large thermal gradients. • The baseline TCs were commercially available 30 AWG Type K TCs with a binder impregnated glass braid insulation. The glass braid is rated to a maximum continuous use temperature of 482°C. LOFTID’s heat pulse will be on the order of minutes and the maximum predicted temperature beneath the outermost FTPS layers is 1350°C.

R. A. Miller↗
NASA NTRSDate not supplied

Aerothermodynamic Analysis of a Flexible Thermal Protection System under Reentry Loads

The Carryall Block 1 reentry vehicle being developed by Outpost Space utilizes a strut supported semirigid deployable heatshield. This consists of a flexible thermal protection system, a heat-resistant fabric stack, stretched over actuated spars. The advantages of a deployable heatshield include reduced heat loading and earlier deceleration in the trajectory. However, the nature of the flexible thermal protection system necessitates considering the loaded shape of the heat shield. The flexible thermal protection system will deflect under reentry loads leading to areas of higher heating rates as well as a reduced axial coefficient as compared to the nominal shape. The Carryall Block 1 is analyzed using NASA’s FUN3D and DPLR CFD solvers with a deflected shape based on the catenary equations. The aerodynamic results are found to be within a percent for both solvers and both structured and unstructured mesh types. Fluid Structure Interaction (FSI) analysis is currently a work in progress, using file I/O to communicate between FUN3D and LS-DYNA, a commercial nonlinear structural solver. Challenges in deforming the geometry, mesh, and initial results are presented here.

thermal protection system↗
NASA NTRS1977

Flexible thermal laminate

Lightweight flexible laminate of interwoven conducting and insulating yarns, designed to provide localized controlled heating for propellant tanks on space vehicles, is useful for nonspace applications where weight, bulk, and flexibility are critical concerns.

Dawn, F. S.↗
NASA NTRS1984

High temperature performance of flexible thermal protection materials

Aero convective tests of several flexible thermal protection system (FTPS) concepts were conducted in the NASA Ames Research Center 20 MW arcjet aero heating wind tunnel. The concepts consisted of quilted insulation blankets with nextel AB312 felt insulation stitched between cover cloths with AB312 thread. The cover cloths were commercially available nextel AB312 and nicalon fabrics. The specimens were subjected to convective heat fluxes ranging from 7 to 35 Btu/per sq ft per sec at stagnation pressures of .005 to .02 atm. Specimens were tested both with and without transpiration cooling. Results indicated that both the nextel and nicalon fabrics offer the potential for higher temperature applications than current FTPS, and nicalon appears to be capable of withstanding temperatures well above 2500 degrees F with minimal degradation.

Savage, R. T.↗
DOE OSTI2025

Design of a System Interface for Flexible Thermal Power Extraction from Two Advanced Reactors

This report presents the design of system interfaces enabling flexible thermal power extraction from two advanced nuclear reactor concepts: a sodium-cooled fast reactor (SFR) operating on a Rankine cycle, and a gas-cooled reactor (GCR) utilizing a Brayton cycle. The study addresses the dual challenge of ensuring reliable base-load electricity generation while meeting the variable high-temperature steam demands of industrial processes (IPs).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1991

Characterization and modeling of an advanced flexible thermal protection material for space applications

This paper describes experimental and analytical characterization of a new flexible thermal protection material known as Tailorable Advanced Blanket Insulation (TABI). This material utilizes a three-dimensional ceramic fabric core structure and an insulation filler. TABI is the leading candidate for use in deployable aeroassisted vehicle designs. Such designs require extensive structural modeling, and the most significant in-plane material properties necessary for model development are measured and analytically verified in this study. Unique test methods are developed for damping measurements. Mathematical models are developed for verification of the experimental modulus and damping data, and finally, transverse properties are described in terms of the inplane properties through use of a 12-dof finite difference model of a simple TABI configuration.

Clayton, Joseph P.↗
NASA NTRS1995

Effect of Cyclic Aeroconvective Heating on Flexible Thermal Insulations

This paper describes the effect of cyclic aeroconvective heating on the thermal performance of ceramic flexible insulations considered for potential use as thermal protection systems or thermal insulations for future hypersonic vehicles such as the Reusable Launch Vehicles (RLV's) and other applications where structures require thermal protection from severe heating. The thermal response of these materials after exposure to cyclic aeroconvective heating from a plasma arc is described. The thermal insulations evaluated were Composite Flexible Blanket Insulations composed of an outer layer of aluminoborosilicate fabric and alumina insulation. The insulations were evaluated with and without a high emissivity coating. These insulations were exposed to the plasma arc stream for nine minutes reaching surface temperatures of 1150 C and a heat flux of 10.5 W/sq cm. Insulations were exposed three, six, or nine times in order to demonstrate reusability and to determine the effect oi coatings on the surface durability of these insulations. Test results demonstrated the capability of these insulations to protect either composite or metallic structures from high heating environments. It is shown that high emittance coatings reduce backface temperatures. The durability of these insulations when impacted at low velocities was also demonstrated. The interaction of the coatings with the ceramic fibers was characterized. An analytical thermal model was utilized to correlate experimental thermal test results with calculated values.

Kourtides, Demetrius A.↗
NASA NTRS2014

CFD Analysis of Flexible Thermal Protection System Shear Configuration Testing in the LCAT Facility

This paper documents results of computational analysis performed after flexible thermal protection system shear configuration testing in the LCAT facility. The primary objectives were to predict the shear force on the sample and the sensitivity of all surface properties to the shape of the sample. Bumps of 0.05, 0.10,and 0.15 inches were created to approximate the shape of some fabric samples during testing. A large amount of information was extracted from the CFD solutions for comparison between runs and also current or future flight simulations.

Ferlemann, Paul G.↗
NASA NTRS1991

Flexible thermal apparatus for mounting of thermoelectric cooler

A flexible heat transfer apparatus used to flexibly connect and thermally couple a thermoelectric cooler to an object to be cooled is disclosed. The flexible heat transfer apparatus consists of a pair of flexible corrugated sheets made from high thermal conductivity materials such as copper, aluminum, gold, or silver. The ridges of the corrugated sheets are oriented perpendicular to one another and bonded sandwich-fashion between three plates to define an upper section and a lower section. The upper section provides X flexure, the lower section provides Y flexure, and both sections together provide Z flexure.

Jones, Jack A.↗
NASA NTRSDate not supplied

Error Sources and Mitigation Strategies for Thermocouples Integrated in Flexible Thermal Protection System Materials

Brief Presenter Biography:Ruth Miller is an aer-ospace systems engineer in the Entry Systems and Ve-hicle Development Branch at NASA Ames Research Center.Introduction:The flexible thermal protection sys-tem (FTPS) on NASA’s Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) vehicle will be in-strumented with thermocouples (TCs) to measure the in-depth thermal response during entry into Earth’s atmos-phere[1, 2]. Accurate flight temperature measurements are critical for verifying vehicle performance during the flight test and reducing uncertainties in the thermal models.However,the deployable nature of inflatable decelerator technology presents challengesfor integrat-ing TCs, specifically the TCsneed to be compactableand cannot damage the FTPSnor the inflatable structure(IS).Unlike traditional rigid aeroshells, routing TCsthrough the thickness of the FTPS could cause signifi-cant damage during packing of the deployable aeroshellbecause the different layers may shift small amounts in relation to each other imparting strain on the TCsand FTPS materials. The LOFTID TCleads are routed from the measurement location back to the data acquisition system in the vehicle centerbody within the same FTPS layer that they are monitoring the temperature. This ap-proach eliminates the need to put holes in the FTPS lay-ers,butas a consequence,the insulated TCleads travel for an appreciable distance through a region that will expose them to high temperaturesand large thermal gra-dients.LOFTID’s TCswere baselined to be commercially available Type K TCswith a binder impregnated glass braid insulation. These TCswere chosen because they had been used successfully on IRVE-3 and in ground-based arc jet testing. Additionally, these TCsdid notdamage the FTPS nor IS during packing and deploy-ment testing. However, the glass braid insulation is only rated to a maximum continuous use temperature of 482ºC. For reference, the duration of the heat pulse on the LOFTID vehicle is on the order of minutes and themaximum predicted temperaturebeneaththe outermost FTPS layersis 1350ºC.Ground-based testing in a tube furnace at NASA Ames Research Centerwas conducted to determine if the baseline TCsrouted through FTPS samples would survive and provide accurate temperature measure-mentsat LOFTID flight-relevant temperatures[3].The test results showed large measurement errors occurred beginning at approximately 400°C due to conductive deposits on the TCinsulation electrically shorting the TCleads.The conductive deposits and thus electrical shorting weredetermined to be caused by twoerror sources:1.The organic binder on the TCinsulation carbon-izingin a high temperature, low oxygen envi-ronment2.Decomposition products from the FTPSperme-atingthe braided TC insulationFurther testing in the tube furnace demonstrated that heat cleaning the TCinsulation effectivelyremovedthe organic binder andeliminatedthe first error source.The second error sourcewas shown to be mitigated by the addition of amica wraparound each individual TCleadtoact as an impermeable barrier.To understand the applicability of theground-based tube furnace test results to flight,anarc jet testseriesat Boeing’s Large Core Arc Tunnel (LCAT) facilitywas conducted[4].The error sourcesand mitigation strate-giesidentified in the tube furnace testing were substan-tiatedin the arc jet testing.However, the arc jet testing also revealed three new error sources:1.Glass TCinsulation meltingwhich resultsin electrical shorting of the TCeither through di-rect contact between the two leads or through the electrically conductive FTPS materials2.TCwire meltingwhich results in a noisy and/or open-loop TCresponse3.Type K TCwire green-rotwhich results in large calibration errors Scope of the Presentation:This presentation will include a brief discussion onthe effect of electrical shorting on the output of a TC(i.e. how to identify elec-trical shorting in TCdataand what the associated erroris).The tube furnace and arc jet test resultswill be dis-cussedand the solutions LOFTID is implementing to mitigate the error sourcesidentified in the tube furnace and arc jet testingwill be presented.Additionally, futureresearch and development work to eliminateTCerror sourcesfor future missionswill be recommended.

R A Miller↗
NASA NTRS2009

Deployable Aeroshell Flexible Thermal Protection System Testing

Deployable aeroshells offer the promise of achieving larger aeroshell surface areas for entry vehicles than otherwise attainable without deployment. With the larger surface area comes the ability to decelerate high-mass entry vehicles at relatively low ballistic coefficients. However, for an aeroshell to perform even at the low ballistic coefficients attainable with deployable aeroshells, a flexible thermal protection system (TPS) is required that is capable of surviving reasonably high heat flux and durable enough to survive the rigors of construction handling, high density packing, deployment, aerodynamic loading and aerothermal heating. The Program for the Advancement of Inflatable Decelerators for Atmospheric Entry (PAIDAE) is tasked with developing the technologies required to increase the technology readiness level (TRL) of inflatable deployable aeroshells, and one of several of the technologies PAIDAE is developing for use on inflatable aeroshells is flexible TPS. Several flexible TPS layups were designed, based on commercially available materials, and tested in NASA Langley Research Center's 8 Foot High Temperature Tunnel (8ft HTT). The TPS layups were designed for, and tested at three different conditions that are representative of conditions seen in entry simulation analyses of inflatable aeroshell concepts. Two conditions were produced in a single run with a sting-mounted dual wedge test fixture. The dual wedge test fixture had one row of sample mounting locations (forward) at about half the running length of the top surface of the wedge. At about two thirds of the running length of the wedge, a second test surface drafted up at five degrees relative to the first test surface established the remaining running length of the wedge test fixture. A second row of sample mounting locations (aft) was positioned in the middle of the running length of the second test surface. Once the desired flow conditions were established in the test section the dual wedge test fixture, oriented at 5 degrees angle of attack down, was injected into the flow. In this configuration the aft sample mounting location was subjected to roughly twice the heat flux and surface pressure of the forward mounting location. The tunnel was run at two different conditions for the test series: 1) 'Low Pressure', and 2) 'High Pressure'. At 'Low Pressure' conditions the TPS layups were tested at 6W/cm2 and 11W/cm2 while at 'High Pressure' conditions the TPS layups were tested at 11W/cm2 and 20W/cm2. This paper details the test configuration of the TPS samples in the 8Ft HTT, the sample holder assembly, TPS sample layup construction, sample instrumentation, results from this testing, as well as lessons learned.

Hughes, Stephen J.↗
NASA NTRS2013

Methodology for Flight Relevant Arc-Jet Testing of Flexible Thermal Protection Systems

A methodology to correlate flight aeroheating environments to the arc-jet environment is presented. For a desired hot-wall flight heating rate, the methodology provides the arcjet bulk enthalpy for the corresponding cold-wall heating rate. A series of analyses were conducted to examine the effects of the test sample model holder geometry to the overall performance of the test sample. The analyses were compared with arc-jet test samples and challenges and issues are presented. The transient flight environment was calculated for the Hypersonic Inflatable Aerodynamic Decelerator (HIAD) Earth Atmospheric Reentry Test (HEART) vehicle, which is a planned demonstration vehicle using a large inflatable, flexible thermal protection system to reenter the Earth's atmosphere from the International Space Station. A series of correlations were developed to define the relevant arc-jet test environment to properly approximate the HEART flight environment. The computed arcjet environments were compared with the measured arc-jet values to define the uncertainty of the correlated environment. The results show that for a given flight surface heat flux and a fully-catalytic TPS, the flight relevant arc-jet heat flux increases with the arc-jet bulk enthalpy while for a non-catalytic TPS the arc-jet heat flux decreases with the bulk enthalpy.

Mazaheri, Alireza↗
NASA NTRS2011

Two-Arm Flexible Thermal Strap

Airborne and space infrared cameras require highly flexible direct cooling of mechanically-sensitive focal planes. A thermal electric cooler is often used together with a thermal strap as a means to transport the thermal energy removed from the infrared detector. While effective, traditional thermal straps are only truly flexible in one direction. In this scenario, a cooling solution must be highly conductive, lightweight, able to operate within a vacuum, and highly flexible in all axes to accommodate adjustment of the focal plane while transmitting minimal force. A two-armed thermal strap using three end pieces and a twisted section offers enhanced elastic movement, significantly beyond the motion permitted by existing thermal straps. This design innovation allows for large elastic displacements in two planes and moderate elasticity in the third plane. By contrast, a more conventional strap of the same conductance offers less flexibility and asymmetrical elasticity. The two-arm configuration reduces the bending moment of inertia for a given conductance by creating the same cross-sectional area for thermal conduction, but with only half the thickness. This reduction in the thickness has a significant effect on the flexibility since there is a cubic relationship between the thickness and the rigidity or bending moment of inertia. The novelty of the technology lies in the mechanical design and manufacturing of the thermal strap. The enhanced flexibility will facilitate cooling of mechanically sensitive components (example: optical focal planes). This development is a significant contribution to the thermal cooling of optics. It is known to be especially important in the thermal control of optical focal planes due to their highly sensitive alignment requirements and mechanical sensitivity; however, many other applications exist including the cooling of gimbal-mounted components.

Urquiza, Eugenio↗
NASA NTRS1992

Thermal degradation study of silicon carbide threads developed for advanced flexible thermal protection systems

Silicon carbide (SiC) fiber is a material that may be used in advanced thermal protection systems (TPS) for future aerospace vehicles. SiC fiber's mechanical properties depend greatly on the presence or absence of sizing and its microstructure. In this research, silicon dioxide is found to be present on the surface of the fiber. Electron Spectroscopy for Chemical Analysis (ESCA) and Scanning Electron Microscopy (SEM) show that a thin oxide layer (SiO2) exists on the as-received fibers, and the oxide thickness increases when the fibers are exposed to high temperature. ESCA also reveals no evidence of Si-C bonding on the fiber surface on both as-received and heat treated fibers. The silicon oxide layer is thought to signal the decomposition of SiC bonds and may be partially responsible for the degradation in the breaking strength observed at temperatures above 400 C. The variation in electrical resistivity of the fibers with increasing temperature indicates a transition to a higher band gap material at 350 to 600 C. This is consistent with a decomposition of SiC involving silicon oxide formation.

Tran, Huy Kim↗
NASA NTRS2012

Aerothermal Ground Testing of Flexible Thermal Protection Systems for Hypersonic Inflatable Aerodynamic Decelerators

Flexible TPS development involves ground testing and analysis necessary to characterize performance of the FTPS candidates prior to flight testing. This paper provides an overview of the analysis and ground testing efforts performed over the last year at the NASA Langley Research Center and in the Boeing Large-Core Arc Tunnel (LCAT). In the LCAT test series, material layups were subjected to aerothermal loads commensurate with peak re-entry conditions enveloping a range of HIAD mission trajectories. The FTPS layups were tested over a heat flux range from 20 to 50 W/cm with associated surface pressures of 3 to 8 kPa. To support the testing effort a significant redesign of the existing shear (wedge) model holder from previous testing efforts was undertaken to develop a new test technique for supporting and evaluating the FTPS in the high-temperature, arc jet flow. Since the FTPS test samples typically experience a geometry change during testing, computational fluid dynamic (CFD) models of the arc jet flow field and test model were developed to support the testing effort. The CFD results were used to help determine the test conditions experienced by the test samples as the surface geometry changes. This paper includes an overview of the Boeing LCAT facility, the general approach for testing FTPS, CFD analysis methodology and results, model holder design and test methodology, and selected thermal results of several FTPS layups.

Bruce, Walter E., III↗
NASA NTRS1993

Flexible thermal protection materials for entry systems

Current programs addressed in aeroassist flight experiment are: (1) evaluation of thermal performance of advanced rigid and flexible insulations and reflective coating; (2) investigation of lighter than baseline materials; (3) investigation of rigid insulations which perform well; (4) study of flexible insulations which require ceramic coating; and (5) study of reflective coating effective at greater than 15 percent. In National Aerospace Plane (NASP), the programs addressed are: (1) high and low temperature insulations; and (2) attachment/standoff methodology critical which affects thermal performance.

Kourtides, Demetrius A.↗
NASA NTRS1985

An assessment of wind tunnel test data on flexible thermal protection materials and results of new fatigue tests of threads

Advanced Flexible Reusable Surface Insulation (AFRSI) was developed as a replacement for the low-temperature (white) tiles on the Space Shuttle. The first use of the AFRSI for an Orbiter flight was on the OMS POD of Orbiter (OV-099) for STS-6. Post flight examination after STS-6 showed that damage had occurred to the AFRSI during flight. The failure anomaly between previous wind-tunnel tests and STS-6 prompted a series of additional wind tunnel tests to gain an insight as to the cause of the failure. An assessment of all the past STS-6 wind tunnel tests pointed out the sensitivity of the test results to scaling of dynamic loads due to the difference of boundary layer thickness, and the material properties as a result of exposure to heating. The thread component of the AFRSI was exposed to fatigue testing using an apparatus that applied pulsating aerodynamic loads on the threads similar to the loads caused by an oscillating shock. Comparison of the mean values of the number-of-cycles to failure showed that the history of the thread was the major factor in its performance. The thread and the wind tunnel data suggests a mechanism of failure for the AFRSI.

Coe, Charles F.↗