ALBERT

Description: The EFT-1 Avcoat heatshield was instrumented with 34 plugs containing multiple thermocouples in-depth with an objective being to measure the flight aerothermal environment. This paper presents a discussion of the instrumentation and the techniques used to reconstruct the heating environment from the measured in-depth temperatures. The inverse heat transfer problem algorithms, models and assumptions will be outlined, and available results will be presented.

Description: No abstract available

Description: On December 5, 2014 NASA conducted the first flight test of its next generation human-class Orion spacecraft. The flight was called the Exploration Flight Test -1 (EFT-1) which lasted for 4 hours and culminated into a re-entry trajectory at 9 km/s. This flight test of the 5-meter Orion Crew Module demonstrated various sub-systems including the Avcoat ablative thermal protection system (TPS) on the heat shield. The Avcoat TPS had been developed from the Apollo-era recipe with a few key modifications. The engineering for thermal sizing was supported by modeling, analysis, and ground tests in arc jet facilities. This paper will describe a postlfight analysis plan and present results from post-recovery inspections, data analysis from embedded sensors, TPS sample extraction and characterization in the laboratory. After the recovery of the vehicle, a full photographic survey and surface scans of the TPS were performed. The recovered vehicle showed physical evidence of flow disturbances, varying degrees of surface roughness, and excessive recession downstream of compression pads. The TPS recession was measured at more than 200 locations of interest on the Avcoat surface. The heat shield was then processed for sample extraction prior to TPS removal using the 7-Axis Milling machine at Marshall Space Flight Center. Around 182 rectangular TPS samples were extracted for subsequent analysis and investigation. The final paper will also present results of sample analysis. The planned investigation includes sidewall imaging, followed by image analysis to characterize TPS response by quantifying different layers in the char and pyrolysis zones. A full postmortem of the instrumentation and sensor ports will also be performed to confirm no adverse effects due to the sensors themselves. A subset of the samples will undergo structural testing and perform detailed characterization of any cracks and integrity of gore seams. Finally, the material will be characterized with layer-by-layer density measurements and SEM investigations to evaluate material morphology at microstructural level including identification of elements and compounds.

Description: The objective of the Heatshield for Extreme Entry Environment Technology (HEEET) projects is to mature a 3-D Woven Thermal Protection System (TPS) to Technical Readiness Level (TRL) 6 to support future NASA missions to destinations such as Venus and Saturn. Destinations that have extreme entry environments with heat fluxes up to 5000 watts per square centimeter and pressures up to 5 atmospheres, entry environments that NASA has not flown since Pioneer-Venus and Galileo. The scope of the project is broad and can be split into roughly four areas, Manufacturing/Integration, Structural Testing and Analysis, Thermal Testing and Analysis and Documentation. Manufactruing/Integration covers from raw materials, piece part fabrication to final integration on a 1-meter base diameter 45-degree sphere cone Engineering Test Unit (ETU). A key aspect of the project was to transfer as much of the manufacturing technology to industry in preparation to support future mission infusion. The forming, infusion and machining approaches were transferred to Fiber Materials Inc. and FMI then fabricated the piece parts from which the ETU was manufactured. The base 3D-woven material consists of a dual layer weave with a high density outer layer to manage recession in the system and a lower density, lower thermal conductivity inner layer to manage the heat load. At the start of the project it was understood that due to weaving limitations the heat shield was going to be manufactured from a series of tiles. And it was recognized that the development of a seam solution that met the structural and thermal requirements of the system was going to be the most challenging aspect of the project. It was also recognized that the seam design would drive the final integration approach and therefore the integration of the ETU was kept in-house within NASA. A final seam concept has been successfully developed and implemented on the ETU and will be discussed. The structural testing and analysis covers from characterization of the different layers of the infused material as functions of weave direction and temperature, to sub-component level testing such as 4-pt bend testing at sub-ambient and elevated temperature. ETU test results are used to validate the structural models developed using the element and sub-component level tests. Given the seam has to perform both structurally and aerothermally during entry a novel 4-pt bend test fixture was developed allowing articles to be tested while the front surface is heated with a laser. These tests are intended to establish the system's structural capability during entry. A broad range of aerothermal tests (arcjet tests) are being performed to develop material response models for predicting the required TPS thickness to meet a mission's needs and to evaluate failure modes. These tests establish the capability of the system and assure robustness of the system during entry. The final aspect of the project is to develop a comprehensive Design and Data Book such that a future mission will have the information necessary to adopt the technology. This presentation will provide an overview and status of the project and describe the status of the tehnology maturation level for the inner and outer planet as well as earth entry sample return missions.

Description: This paper introduces the Mars Entry Descent and Landing Instrumentation 2 (MEDLI2) concept for NASAs Mars 2020 mission. Mars 2020 is a flagship-class mission, scheduled for launch in 2020, with science and technology objectives to help answer questions about habitability of Mars as well as to demonstrate technologies for future human expedition. MEDLI2 is a suite of instruments embedded in the heatshield and backshell thermal protection systems (TPS) of the Mars 2020 entry vehicle. The objectives of MEDLI2 are to gather critical aerodynamics, aerothermodynamics and TPS (Thermal Protective System) performance data during the Entry Descent and Landing (EDL) phase of the mission.

Description: Planetary entry vehicles employ ablative TPS materials to shield the aeroshell from entry aeroheating environments. To ensure mission success, it must be demonstrated that the heat shield system, including local features such as seams, does not fail at conditions that are suitably margined beyond those expected in flight. Furthermore, its thermal response must be predictable, with acceptable fidelity, by computational tools used in heat shield design. Mission assurance is accomplished through a combination of ground testing and material response modelling. A material's robustness to failure is verified through arcjet testing while its thermal response is predicted by analytical tools that are verified against experimental data. Due to limitations in flight-like ground testing capability and lack of validated high-fidelity computational models, qualification of heat shield materials is often achieved by piecing together evidence from multiple ground tests and analytical simulations, none of which fully bound the flight conditions and vehicle configuration. Extreme heating environments (〉2000 W/sq. cm heat flux and 〉2 atm pressure), experienced during entries at Venus, Saturn and Ice Giants, further stretch the current testing and modelling capabilities for applicable TPS materials. Fully-dense Carbon Phenolic was the material of choice for these applications; however, since heritage raw materials are no longer available, future uses of re-created Carbon Phenolic will require re-qualification. To address this sustainability challenge, NASA is developing a new dual-layer material based on 3D weaving technology called Heat shield for Extreme Entry Environments (HEEET). Regardless of TPS material, extreme environments pose additional certification challenges beyond what has been typical in recent NASA missions. Scope of this presentation: This presentation will give an overview of challenges faced in verifying TPS performance at extreme heating conditions. Examples include: (1) Bounding aeroheating parameters (heat flux, pressure, shear and enthalpy) in ground facilities. How to certify TPS if environments can't be bounded or aeroheating parameters can't be simultaneously achieved. (2) Higher uncertainties in ground test environments (facility calibration and analytical predictions) at extreme conditions. (3) Testing in flows similar to planetary atmosphere composition (H2/He for Gas and Ice Giants). (4) Test sample size limitations for qualifying seam designs. (5) Lack of computational tools capable of simulating all significant aspects of TPS performance (including initiation and propagation of failures). This presentation will provide recommendations on how the EDL community can address these challenges and mitigate some of the risks involved in flying TPS materials at extreme conditions. Examples include: (1) Dedicated activity to understanding TPS failure modes. Develop computational tools capable of modelling fluid interaction with material's thermostructural response. Validate these tools through failure testing. A better understanding of failure mechanisms may eliminate the need to fully bound all aeroheating parameters in ground testing. (2) Enhancements to current testing facilities to simulate flight-like ablation mechanism (ex. testing in Nitrogen at Ames Interaction Heating Facility to limit oxidation in favor of more sublimation). (3) Improved characterization of test conditions with new diagnostic methods and determination of environment uncertainty through rigorous statistical analysis of available data. (4) Design margin policies that are directly tied to uncertainties in ground test environments and modelling fidelity

Description: The heat shield of the Mars Science Laboratory (MSL) was equipped with thermocouplestacks to measure in-depth heating of the thermal protection system during atmosphericentry. The heat load derived from the thermocouples in the stagnation region was found tobe 33 lower than corresponding post-flight predictions of convective heating alone. It washypothesized that this difference could be attributed to radiation from the shock-heated gas,a mechanism not considered in post-flight analyses of flow fields. In order to test thehypothesis and quantify the contribution of shock-layer radiation to total surface heating,ground tests and simulations (both flow and radiation) were performed at several pointsalong the best-estimated entry trajectory of MSL. The present paper provides anassessment of the quality of the radiation model and its impact to stagnation point heating.Although the impact of radiative heating is shown to be significant, it only accounts for 43of the discrepancy. Additional factors behind the remaining discrepancy are discussed.

Description: This presentation introduces a new sizing and margin methodology for dual-layer Thermal Protection Systems (TPS). The methodology has been tailored for application to a dual-layer 3D-woven TPS called Heat-shield for Extreme Entry Environments Technology (HEEET). Sizing is performed for a reference Saturn probe mission to show how uncertainties in trajectory, aerothermal modelling and TPS response impact the sizing of each layer.

Description: Dragonfly is a proposed spacecraft and mission that would send a mobile robotic rotorcraft lander to Titan, the largest moon of Saturn, in order to study prebiotic chemistry and extraterrestrial habitability at various locations. Titan is unique in having an abundant, complex, and diverse carbon-rich chemistry on the surface of a water-ice-dominated world with an interior water ocean, making it a high priority target for astrobiology and origin of life studies. The mission was initially proposed in April 2017 to NASA's New Frontiers program by the Johns Hopkins Applied Physics Laboratory. In December 2017, it was selected as one of two finalists (out of twelve proposals) to further refine the mission's concept. NASA Ames Research Center and NASA Langley Research Center are partnering as the leads for the Dragonfly's entry system to provide the completed EDL Assembly. The aerothermal analysis for Dragonfly utilizes four simulation tools from NASA Ames Research Center. Traj for calculating the trajectory, DPLR 4.04.0 for calculating the flowfield around the vehicle and convective heating, NEQAIR V15.0 for calculating the radiative heating, and FIAT for calculating the material response and thermal protection system (TPS) sizing for the heatshield. The entry conditions are relatively benign and can readily be accommodated with a tiled PICA heatshield similar to MSL and a number of flight proven materials for the backshell. This work will demonstrate that the aerothermal entry environments can be readily solved using heritage materials and techniques.