ALBERT

Description: The dimensional stability of ceramic coated thermal protection materials developed for use on advanced entry vehicles is evaluated. Dimensional stability of these ceramic materials were studied as a function of temperature and pressure during exposure to simulated atmospheric entry in an arc-jet facility.

Description: The heatshield material requirements for future space vehicles (Aerobraking Orbital Transfer Vehicle & National Aerospace Plane) will depend upon the desired flight capability, configuration and location on the vehicle. These requirements will be more demanding and different from those derived for the materials used in the Shuttle Orbiter thermal protection system. Research was therefore initiated into improving the thermal efficiency of this class of materials by first characterizing their thermal and structural capabilities. Alternate material systems have been developed, tested, and compared with the baseline Shuttle system. This research resulted in the development of several very low density, high porosity (80-90%) materials with enhanced durability and temperature capability. One of the developments was a family of materials referred to as Fibrous Refractory Composite Insulation (FRCI) utilizing a mixture of fibers, each serving a unique purpose. One composition of the FRCI family with two fibers was adopted as a baseline material for use on the third and fourth Orbiters in selected areas due to its strength at a lower density compared to earlier materials. A further improvement in the FRCI family of materials is the Alumina Enhanced Thermal Barrier (AETB), a three-fiber composite. It has a higher temperature capability (composition dependent) than the baseline FRCI as proven by convective heating tests of one composition. AETB was studied to better characterize its performance at high temperature and the mechanisms by which its properties change. In conclusion, the shrinkage of AETB is a factor of six better than baseline FRCI at 1260 C (2300 F) with about a 20% improvement in mechanical properties. This improvement could translate into a 110 C (200 F) higher temperature capability in use as a heat shield material, but further testing in a convective heating environment is required to determine the actual improvement attainable.

Description: Laminated composite insulations developed for potential use on advanced spacecraft operating between GEO and LEO were tested in an aerothermodynamic environment simulating an AOTV aerobraking maneuver (altitude 82.3 km and velocity = 9.0 km/s). Comparisons are discussed between these data and predictions of in-depth temperature response using dynamical thermal conductivity values to 2000 K.

Description: Lightweight, monolithic ceramics resistant to oxidation in air at high temperatures are made by impregnating a porous carbon preform with a sol which contains a mixture of tetraethoxysilane, dimethyldiethoxysilane and trimethyl borate. The sol is gelled and dried on the carbon preform to form a ceramic precursor. The precursor is pyrolyzed in an inert atmosphere to form the ceramic which is made of carbon, silicon, oxygen and boron. The carbon of the preform reacts with the dried gel during the pyrolysis to form a component of the resulting ceramic. The ceramic is of the same size, shape and form as the carbon precursor. Thus, using a porous, fibrous carbon precursor, such as a carbon felt, results in a porous, fibrous ceramic. Ceramics of the invention are useful as lightweight tiles for a reentry spacecraft.

Description: A porous body of fibrous, low density silica-based insulation material is at least in part impregnated with a reactive boron oxide containing borosilicate glass frit, a silicon tetraboride fluxing agent and a molybdenum silicide emittance agent. The glass frit, fluxing agent and emittance agent are separately milled to reduce their particle size, then mixed together to produce a slurry in ethanol. The slurry is then applied to the insulation material and sintered to produce the porous body.

Description: Silica (LI-900) Reusable Surface Insulation (RSI) tile have been used on the majority of the Shuttle since its initial flight. Its overall performance with Reaction Cured Glass (RCG) coating applied will be reviewed. Improvements in insulations, Fibrous Refractory Composite Insulation (FRCI-12) and Alumina Enhanced Thermal Barrier (AETB-8) and coatings/surface treatments such as Toughened Uni-Piece Fibrous Insulation (TUFI) have been developed and successfully applied. The performance of these enhancements on the Shuttle Orbiters over the past few years along with the next version of tile materials, High Efficiency Tantalum-based Ceramic (HETC) with even broader applicability will also be discussed.

Description: The proposed first through fourth generation of future NASA Reusable Launch Vehicles (RLV) within NASA will be described, in general, along with their relative goals for improvement in performance (i.e., cost, safety, life, and turnaround time). A brief description of Spaceliner 100 activities representing a means to achieve those goals will be included. Some of the families of thermal protection materials with widely varying characteristics that are being developed for first generation space vehicles at Ames Research Center will be described as well as potential materials and composites for second and third generation applications as systems. These families of materials include functionally gradient material composites that are made from a variety of low-density substrates and moderate to fully dense surface treatments providing the resultant material with both toughness and higher temperature capability opening the envelope of Thermal Protection Systems (TPS) capabilities. Some of the materials truly represent enabling technologies that are required to achieve substantially enhanced thermal protection system performance thereby reducing vehicle risk. Finally the needs for integrated vehicle health monitoring (IVHM) of future vehicles thermal protection systems relative to achieving the goals for third generation reusable launch vehicles and for improving vehicle performance and capabilities reducing risk will be described along with the state of the art in TPS.

Description: The flight performance of a new class of low density, high temperature thermal protection materials (TPM) is described and compared to "standard" Space Shuttle TPM. This new functionally gradient material designated as Toughened Uni-Piece Fibrous Insulation (TUFI), was bonded on a removable panel attached to the base heat shield of Orbiter 105, Endeavour.