Thermal Protection Materials and Systems: Past, Present, and Future
Thermal Protection Materials and Systems: Past, Present, and Future
Sylvia M. Johnson
Entry Systems and Technology Division
NASA Ames Research Center
Sylvia.m.johnson@nasa.gov
Presented at Missouri University of Science and Technology
Rolla, MO
April 4, 2013
Acknowledgements
2
Outline
• Introduction
– NASA and TPS
• Thermal Protection Materials and Systems (TPS)
– Reusable materials
– UHTCs
– Ablative materials
• Characterization of TPS for Performance and Design
• A Tale of Two Heat Shields
– Recent Uses and Development of Heat Shields and Materials
Issues
• New Trends in TPS
• Modeling of TPS
3
NASA Ames Research Center
• Science
– Space, Earth, Biological Sciences
– Astrobiology, Lunar Science
• Exploration Systems
– Exploration Technology Development
– Entry System Technology
– Supercomputing
• Projects and Missions
• Aeronautics & Aviation
– NextGen Airspace Systems
– Fundamental Aeronautics
• Located in Moffett Field (Mountain – Aviation Safety
View) California
– Green Aviation
• 2480 employees* • Affordable Small Satellites
• !900M + annual revenue • Innovation, Education, & Entrepreneurial
(including reimbursable) Collaborations
*in addition, 900 students, – NASA Research Park
summer 2012" 4
NASA Entry Vehicles / Missions
Supported by Ames
5
Introduction to TPS
• NASA Ames focused on:
– Qualifying and certifying TPS for current missions
– Developing new TPS for upcoming missions
• Approaches to TPS development differ with risk —
crewed vs. robotic missions:
– Crewed
• Loss of life must be avoided
• What must be done to qualify and certify TPS?
– Robotic missions
• Can take more risk
• But scientific knowledge can be lost too
• Goal for all TPS is efficient and reliable performance
• Need to understand materials to enable design and use
6
Earth Reentry Overview
• Atmospheric reentry vehicles require thermal protection systems
(TPS) because they are subjected to intense heating
7
Reentry Heating Parameters
• Magnitude of stagnation heating is dependent on a variety of
parameters, including reentry speed (V), vehicle effective radius (R),
and atmospheric density (!)
0.5
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q˙ conv "V & ) q˙ rad " V 8 #1.2 R 0.5
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Convective Heating Shock Radiation Heating
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Thermal Protection Systems
• Protect vehicle structure and contents (people and
things) from the heat of entry through an
atmosphere
• Rely on materials response to environment
• Response depends on
– Material properties
– Configuration of the system
– Specific conditions (heat flux, pressure, flow)
One size does not fit all!
Different TPS for different vehicles, location
on vehicles, and mission conditions
9
Reusable (Insulative) vs. Ablative TPS
10!
Insulative TPS
Energy management through storage and re-radiation — material unchanged
•Re-radiation and
convective cooling under
post-flight conditions backup or
structure material
11!
Reusable TPS: Tiles
• Effort started in 1970’s by ARC to provide NASA with TPS
materials and processing expertise
• Insulation materials used to protect the aluminum sub-structure
of the shuttle.
• High purity silica, aluminoborosilicate, and alumina fibers
• LI-900, FRCI-12, AETB-8
• Open porous structure
• Used on over 100 shuttle missions
Starting materials for tiles
10µm 100 µm
10µm
Silica fibers
Alumina fibers 10µm AETB (35% Al2O3) Tile
Nextel® fibers
Tiles are heterogeneous with regions of low density
and clumps of fibers with some nonfibrous inclusions 12
Development of Advanced TUFROC TPS
(Toughened Unipiece Fibrous Oxidation Resistant Ceramic)
• Developed TUFROC for X-37 application
• Advanced TUFROC developed recently
• Currently transferring technology to Boeing
• System parameters:
– Lightweight (similar to LI-2200)
– Dimensionally stable at surface temperatures up to1922 K
– High total hemispherical emittance (0.9)
– Low catalytic efficiency
– In-depth thermal response is similar to single piece Shuttle-type fibrous insulation
ROCCI
Base Insulator
UHTC
High
Thermal Leading Edges
Conductivity
Sharp Nose
Dean Kontinos, Ken Gee and Dinesh Prabhu. “Temperature Constraints at the Sharp Leading Edge of a
Crew Transfer Vehicle.” AIAA 2001-2886 35th AIAA Thermophysics Conference, 11-14 June 2001,
Anaheim CA 15
Ultra High Temperature Ceramics (UHTCs) :
A Family of Materials
• Borides, carbides and nitrides of
transition elements such as hafnium,
zirconium, tantalum and titanium
• Some of highest known melting
points
• High hardness, good wear
resistance, good mechanical
strength
Hf-B Phase Diagram
• Good chemical and thermal stability
under certain conditions
– High thermal conductivity
– Good thermal shock resistance
• Considerable effort in many
institutions to improve properties and
processing of UHTCs
16
Ablative TPS
Energy management through material consumption
When exposed to
atmospheric entry heating
conditions, material will
pyrolyze (char), and reject
heat in the following ways:
•Pyrolysis of polymer
•Blowing in boundary layer
•Formation of char layer
and re-radiation
17!
PICA Processing
Carbon Fiberform™
Resin Impregnation
Phenolic Resin!
Fiberform™ before impregnation
20
Example: Ablator Properties
• Evaluating:
– Virgin/char strength
– Recession rate
– Thermal conductivity
• Evaluating the
interconnection between
properties
– Tradeoffs
– Greater density = greater
strength, but generally
increased thermal
conductivity
21
Material Properties
• Thermal properties
– Thermal conductivity, specific heat, thermal
expansion
• Physical properties
– Density, hardness, emissivity
• Mechanical properties
– Strength, elastic modulus, toughness
• Properties may vary with temperature and/
or pressure (porous materials)
• Microstructure depends on processing and
composition 22
Properties for Modeling and Design of
Ablators
23
Need for Arc Jet Testing
• Arc jet testing is the best ground-
based method of evaluating a
material’s oxidation/ablation
response in re-entry environments
• Oxidation/ablation behavior on
heating in static or flowing air at
ambient pressures is likely to be
significantly different than in a re-
entry environment.
– O2 and N2 may be dissociated
• Catalycity of the material
• Recombination of O and N atoms
adds to surface heating
– Stagnation pressures may be <1 atm.
• active to passive transitions in
oxidation
– SiC : protective SiO2 layer is
removed as SiO
24
Arc Jet Schematic
Simulates reentry conditions in a ground-based facility
Method: Heat a test gas (air) to plasma temperatures by an electric arc, then
accelerate into a vacuum chamber and onto a stationary test article
Stine, H.A.; Sheppard, C.E.; Watson, V.R. Electric Arc Apparatus. U.S. Patent 3,360,988, January 2, 1968.
25
Selection of Appropriate Material
• Historical approach:
– Use heritage materials: “It’s worked before…”
– Risk-reduction strategy
– Limited number of flight-qualified ablative materials
– Different vehicle configurations and reentry conditions
(need to qualify materials in relevant environments)
• As missions become more demanding, we need
higher capability materials — necessary to have a
robust research and development program
• Reusable and ablative materials are both needed
• Must test materials in relevant environments
• Provide path for insertion/use of new materials
26
Technology Readiness Levels
https://www.spacecomm.nasa.gov/spacecomm/images//technology_TRLS.gif 27
A Tale of Two Heatshields
• 2 Vehicles
– CEV/Orion/MPCV
– Mars Science Lab (MSL)
• 2 destinations
– Earth from the moon
– Mars from Earth
• 2 materials
– PICA
– Avcoat
28
MPCV (Orion) TPS Requirements
29
PICA Background
• Phenolic Impregnated Carbon Ablator
(PICA) was an enabling TPS material for
the Stardust mission (sample return from a
comet) where it was used as a single
piece heatshield
30
From PICA ……..
• PICA had heritage…for Stardust
– Needed development effort for new applications
• PICA was to be used in a tiled configuration
– Tiles require gap fillers or a way to deal with
gaps
– PICA is a rigid material with a relatively low
strength and strain to failure
– Risk analysis and design indicated that many
small tiles would be required, increasing the
number of gaps.
• PICA was extensively characterized and
considerable effort was put into scale-up and
manufacturing 31
…..to Avcoat
• Avcoat was used on the
Apollo vehicles:
“heritage” material
• Consists of a honeycomb
filled with an ablative
mixture
• Reduces gaps
• Complex material
requiring hand assembly
Before and after
• Not made for many years Avcoat arc jet models
32
Heatshield Comparison
34
Avcoat for MPCV Heatshield
• Avcoat construction schematic showing the various steps and
processes involved in building the honeycombed ablator
• Red arrows indicate areas were process changes were implemented
35
Issues with “Heritage” Materials
• Know-how may be lost over time
• Materials/components may no longer be
available
• Environmental/safety regulations may not
allow the use of certain processes
• Recreation of materials can be time and
money-consuming
– $25+million and 5 years has been spent on
recreating Avcoat
• Is it really “Avcoat”?
36
Meanwhile, Mars Science Lab in
Development
• MSL was being fabricated
simultaneously with CEV/Orion
(MPCV)
• Initial choice for a heatshield TPS was
SLA-561V, a heritage honeycomb-
based material from Lockheed
• SLA-561V was used on all previous
NASA Mars entry missions
• However, MSL was much larger …..
37
SLA Subjected to Shear in Arc-Jet
During test 38
Change of TPS Late in the Game
Cruise Stage
Backshell
Descent
Stage
Rover
Heatshield
Entry
Vehicle
41
Heatshield Fabrication in Process
RASB: 42
Heatshield Fabricated (gaps filled)
RASB: 43
Spacecraft Assembled
RASB: 44
MSL/Curiosity Landed Successfully
on August 5, 2012 (PDST)
• http://
Landing sequence
http://www.nasa.gov/images/content/ 48
545955main_mpcvstack_full.jpg
Exploration Flight Test One
Orion will launch atop a Delta IV Heavy rocket for the test flight, as shown in this configuration. The planned
two orbit flight will send Orion out farther into space than any human spaceflight vehicle since the Apollo 17
49
mission in 1972.
Crew Module in Construction
52
What are Rigid, Conformable and
Flexible Ablative Materials?
• Rigid – fabricated in a rigid form and usually
applied in a tiled configuration to a rigid
substructure
• Conformable – fabricated in a flexible form
and shaped to a rigid substructure; final
form may be rigid or compliant
• Flexible – fabricated and used in a flexible
form, where flexibility is an essential
component of the heatshield, e.g.,
deployable systems, stowable systems
• Woven – can be any of the above
53
Conformable/Flexible Ablators
• Fibrous substrate, such as felt or woven cloth
• Matrix of various resins and fillers
• Significant design, system integration, and
performance advantages over rigid ablators
– Manufacturability
– Reduction in piece-parts
– Ease of assembly
– Enables larger diameter aeroshells
– Eliminates gap and seam issues
54
Conformable PICA Flexible PICA
Conformable Ablator (C-PICA) Testing
During Testing
C-SICA
Post Test
55
Carbon Phenolic TPS
• Carbon Phenolic TPS
– 1960s: fully dense (1.45-1.5 g/cm3) carbon
phenolics were optimized
– only materials available for use at very high
heat fluxes and high pressure conditions,
yet the least favorable
in terms of density
• Carbon phenolic material made from
carbon fiber weaves fully infiltrated with
phenolic resin
• Carbon phenolic TPS was used on Gallileo
heat shield for very demanding entry
into Jupiter’s atmosphere
• Current effort to investigate approaches to
fabricating carbon phenolic materials
– Issues with fiber supplies
– Entry Grade CP needs Avtex Rayon – not
56
produced since 1986
TPS for Saturn and Uranus Probes
TPS GAP
• The only flight proven TPS that can meet the extreme entry
environment (heat-flux, pressure, etc) for Saturn and Uranus
Probes, is heritage, entry grade carbon phenolic (HEGCP)
POC: Ethiraj.Venkatapathy-1@nasa.gov 57
What is Woven TPS?
An approach to the design and manufacturing of ablative TPS by the
combination of weaving precise placement of fibers in an optimized
3D woven manner and then resin transfer molding when needed
• Design TPS for a specific mission
• Tailor material composition by weaving together different
types of fibers and by exact placement using computer
controlled, automated, 3-D weaving technology
• One-step process for making a mid-density dry woven
TPS
• Ability to infiltrate woven preforms with polymeric resins
for highest density TPS to meet more demanding thermal
requirements
Woven TPS Project Goals:!
• Develop and prove feasibility of woven TPS manufacturing
technique "
• Demonstrate via testing low, mid and high-density WTPS to fill
the mid-density gap as well as finding a superior replacement for
the heritage carbon phenolic"
58
POC: Ethiraj.Venkatapathy-1@nasa.gov
Arc Jet Tested Woven TPS
3-D WTPS materials recess more uniformly and have better recession
performance than traditional chop molded carbon phenolic
59
POC: Ethiraj.Venkatapathy-1@nasa.gov
Outline
• Introduction
– NASA and TPS
• Thermal Protection Materials and Systems (TPS)
– Reusable materials
– UHTCs
– Ablative materials
• Characterization of TPS for Performance and Design
• A Tale of Two Heat Shields
– Recent Uses and Development of Heat Shields and Materials
Issues
• New Trends in TPS
• Modeling of TPS
60
Instrumentation
• All atmospheric entries are essentially
“experiments” from which we should gather
data
• Data used to validate models and
understand materials behavior better
• MSL was instrumented
– MEDLI: Mars Entry Descent Landing
Instrumentation
61
Importance of MSL Instrumentation
Goals
• Reduce materials development time
• Optimize material properties/tailor materials
• Guide processing of materials
• Develop design approaches
Approach
• Develop models integrated across various length
scales
• Correlate models with experiment whenever
possible
63
Modeling UHTCs – What’s Next?
• Accomplishments
– Ab initio calculations of lattice structure, bonding
characteristics, elastic constants, phonon spectra and
thermal properties of ZrB2 and HfB2
– Ab initio calculations of formation and migration energies
for simple defects (vacancies)
– Development of interatomic potentials for ZrB2 and HfB2 for
atomistic simulations
• Opportunities
– Ab initio calculations of simple/ideal grain boundary
structures with and without chemical impurities
– No UHTC atomistic simulations exist in the literature. New
potentials mean the field is wide open!
– FEM modeling of microstructure to relate processing and
properties
64
Fundamental Modeling of Ablators
• Ablators for most demanding atmospheric entries
• Intrinsically multi-scale materials and phenomena
• Pyrolysis chemistry (ab initio)
– Pyrolysis simulation is very challenging: no
current solution
• Phenolic networks (atomistic)
– Virtual mechanical and thermal testing
– Phenolic network design parameters:
Linkage Sites and Cross-linking
• Microstructure Modeling (continuum)
– X-ray CT images gives 3D micron scale, PICA - carbon fiber/phenolic matrix
realistic microstructure
– FEM models for thermal/mechanical
analysis
65
Summary
• Two main classes plus specialized materials
– Insulating, e.g. space shuttle tiles
– Ablators for higher heat fluxes
– New materials for new missions – woven, conformable, etc.
• TPS needs to fit the application—location on vehicle,
expected environment
• Heritage materials may not always be heritage
– Substantial effort required to recreate
• Need to gain full data value from flights/experiments:
instrumentation is key
• Critical to characterize materials and archive data
– For selecting appropriate material
– To ensure material demonstrates desired behavior
– To have materials ready for new missions
• Modeling and analysis are critical to better understanding and
prediction of material behavior in reentry
Goal of all TPS is reliable and efficient performance! 66
The End
67
Manufacturing Variability
• Real-world manufacturing processes have
inherent variability.
– These variations can lead to scatter in the
material properties.
• Necessary to quantify allowable lot-to-lot
and in-lot variability of properties.
– This may also include acceptable flaw and
inclusion size.
68
TPS for Outer Planet Missions: Carbon Phenolic
Current Status
• Heritage Entry Grade Carbon Phenolic (HEGCP) CMCP
– Most capable and robust TPS
– Baseline TPS for the Saturn and Uranus Probe Missions
– HEGCP is very capable, robust and enabled P-V & Galileo &
is flight proven
• Carbon Phenolic (CP) heat-shield is made of two types !
– Chop Molded and Tape Wrapped CP" TWCP
• Tape wrap manufacturing needed for Rocket nozzles and DoDʼs !
slender entry body missiles – sustainable !
• Chop Molded CP is needed only for NASA entry missions!
• HEGCP needs Avtex Rayon – no longer produced (since 1986)!
• NASA held two CP workshops (2010, 2012) to assess the SOA!
– Heritage rayon based CP no longer viable for Venus (or Saturn) "
– The industry is shrinking; especially for CMCP and longer term sustainability of any
CP is a ??!
C-PICA
C-SICA
Examples of conAblators Under Development
Carbon phenolic
Graded Ablators Flexible SIRCA replacement
71
Completed SPRITE 250
Models
Models After Testing @ 500 W/cm2 on flank – 30 sec
C-PICA
C-SICA