A Statistics-Based Material Property Analysis to Support Ablation Simulation UQ Efforts

Accurate characterization of entry capsule heat shield material properties is a critical component in modeling and simulating Thermal Protection System (TPS) response in a prescribed aerothermal environment. The thermal decomposition of the TPS material during the pyrolysis and charring processes is typically poorly characterized and results in large uncertainties in material properties as inputs for ablation models. These material property uncertainties contribute to large design margins on flight systems and cloud re-construction efforts for data collected during flight and ground testing, making revision to existing models for entry systems more challenging. This work focuses on the following areas of interest to the ablation modeling community: a proper characterization of input probability density functions for material properties, an uncertainty propagation to identify how the uncertainties affect quantities of interest, a sensitivity and uncertainty contributor breakdown, and an analysis of how errors in input characterization contribute to errors in output distributions

Testing of Candidate Rigid Heatshield Materials at LHMEL for the Entry, Descent, and Landing Technology Development Project

The material testing results described in this paper were part of a material development program of vendor-supplied, proposed heat shield materials. The goal of this program was to develop low density, rigid material systems with an appreciable weight savings over phenolic-impregnated carbon ablator (PICA) while improving material response performance. New technologies, such as PICA-like materials in honeycomb or materials with variable density through-the-thickness were tested. The material testing took place at the Wright-Patterson Air Force Base Laser Hardened Materials Laboratory (LHMEL) using a 10.6 micron CO2 laser operating with the test articles immersed in a nitrogen-gas environment at 1 atmosphere pressure. Test measurements included thermocouple readings of in-depth temperatures, pyrometer readings of surface temperatures, weight scale readings of mass loss, and sectioned-sample readings of char depth. Two laser exposures were applied. The first exposure was at an irradiance of 450 W/cm2 for 50 or 60 seconds to simulate an aerocapture maneuver. The second laser exposure was at an irradiance of 115 W/cm2 for 100 seconds to simulate a planetary entry. Results from Rounds 1 and 2 of these screening tests are summarized

Blunt-Body Entry Vehicle Aerothermodynamics: Transition and Turbulence on the CEV and MSL Configurations

Recent, current, and planned NASA missions that employ blunt-body entry vehicles pose aerothermodynamic problems that challenge the state-of-the art of experimental and computational methods. The issues of boundary-layer transition and turbulent heating on the heat shield have become important in the designs of both the Mars Science Laboratory and Crew Exploration Vehicle. While considerable experience in these general areas exists, that experience is mainly derived from simple geometries; e.g. sharp-cones and flat-plates, or from lifting bodies such as the Space Shuttle Orbiter. For blunt-body vehicles, application of existing data, correlations, and comparisons is questionable because an all, or mostly, subsonic flow field is produced behind the bow shock, as compared to the supersonic (or even hypersonic) flow of other configurations. Because of the need for design and validation data for projects such as MSL and CEV, many new experimental studies have been conducted in the last decade to obtain detailed boundary-layer transition and turbulent heating data on this class of vehicle. In this paper, details of several of the test programs are reviewed. The laminar and turbulent data from these various test are shown to correlate in terms of edge-based Stanton and Reynolds number functions. Correlations are developed from the data for transition onset and turbulent heating augmentation as functions of momentum thickness Reynolds number. These correlation can be employed as engineering-level design and analysis tools

Fracture in Phenolic Impregnated Carbon Ablator

The thermal protection materials used for spacecraft heat shields are subjected to various thermal-mechanical loads during an atmospheric entry which can threaten the structural integrity of the system. This paper discusses the development of a novel technique to understand the failure mechanisms inside thermal protection materials. The focus of research is Phenolic Impregnated Carbon Ablator (PICA). It has successfully flown on the Stardust spacecraft and is the TPS material chosen for the Mars Science Laboratory (MSL) and Dragon spacecraft. Although PICA has good thermal properties, structurally, it is a weak material. In order to thoroughly understand failure in PICA, fracture tests were performed on FiberForm* (precursor of PICA), virgin and charred PICA materials. Several samples of these materials were tested to investigate failure mechanisms at a microstructural scale. Stress-strain data were obtained simultaneously to estimate the fracture toughness. It was found that cracks initiated and grew in the FiberForm when a critical stress limit was reached such that the carbon fibers separated from the binder. However, both for virgin and charred PICA, crack initiation and growth occurred in the matrix (phenolic) phase. Both virgin and charred PICA showed greater strength values compared to FiberForm coupons, confirming that the presence of the porous matrix helps in absorbing the fracture energy

Development of a Tool to Recreate the Mars Science Laboratory Aerothermal Environment

The Mars Science Laboratory will enter the Martian atmosphere in 2012 with multiple char depth sensors and in-depth thermocouples in its heatshield. The aerothermal environment experienced by MSL may be computationally recreated using the data from the sensors and a material response program, such as the Fully Implicit Ablation and Thermal (FIAT) response program, through the matching of the char depth and thermocouple predictions of the material response program to the sensor data. A tool, CHanging Inputs from the Environment of FIAT (CHIEF), was developed to iteratively change different environmental conditions such that FIAT predictions match within certain criteria applied to an external data set. The computational environment is changed by iterating on the enthalpy, pressure, or heat transfer coefficient at certain times in the trajectory. CHIEF was initially compared against arc-jet test data from the development of the MSL heatshield and then against simulated sensor data derived from design trajectories for MSL. CHIEF was able to match char depth and in-depth thermocouple temperatures within the bounds placed upon it for these cases. Further refinement of CHIEF to compare multiple time points and assign convergence criteria may improve accuracy

Comparison of MSL RCS Jet Computations With Flow Visualization and Velocimetry

Numerical predictions of the Mars Science Laboratory (MSL) reaction control system (RCS) jets interacting with a Mach 10 hypersonic flow are compared to experimental nitric oxide (NO) planar laser-induced fluorescence (PLIF) data. The steady Reynolds Averaged Navier Stokes (RANS) equations using the Baldwin-Barth one-equation turbulence model were solved using the OVERFLOW code. The experimental PLIF data used for comparison consists of qualitative two-dimensional visualization images, qualitative reconstructed three-dimensional flow structures, and quantitative two-dimensional distributions of streamwise velocity. Through modeling of the PLIF signal equation, computational flow images (CFI) were produced and directly compared to the qualitative PLIF data. Post processing of the experimental and simulation data enabled the jet trajectory to be extracted for a more quantitative comparison. The two-dimensional velocity fields were reconstructed through interpolation of a series of single-component velocity profiles. Each distribution of single-component velocity was obtained using molecular tagging velocimetry (MTV). After validating the numerical model, the numerical solution was further examined to gain insight into hypersonic jet-in-crossflow interaction. Future NO-PLIF experiments are proposed based on this analysis

Assessment of Laminar, Convective Aeroheating Prediction Uncertainties for Mars Entry Vehicles

An assessment of computational uncertainties is presented for numerical methods used by NASA to predict laminar, convective aeroheating environments for Mars entry vehicles. A survey was conducted of existing experimental heat-transfer and shock-shape data for high enthalpy, reacting-gas CO2 flows and five relevant test series were selected for comparison to predictions. Solutions were generated at the experimental test conditions using NASA state-of-the-art computational tools and compared to these data. The comparisons were evaluated to establish predictive uncertainties as a function of total enthalpy and to provide guidance for future experimental testing requirements to help lower these uncertainties

Comparison of Mars Science Laboratory Reaction Control System Jet Computations With Flow Visualization and Velocimetry

Numerical predictions of the Mars Science Laboratory reaction control system jets interacting with a Mach 10 hypersonic flow are compared to experimental nitric oxide planar laser-induced fluorescence data. The steady Reynolds Averaged Navier Stokes equations using the Baldwin-Barth one-equation turbulence model were solved using the OVERFLOW code. The experimental fluorescence data used for comparison consists of qualitative two-dimensional visualization images, qualitative reconstructed three-dimensional flow structures, and quantitative two-dimensional distributions of streamwise velocity. Through modeling of the fluorescence signal equation, computational flow images were produced and directly compared to the qualitative fluorescence data

Assessment of Laminar, Convective Aeroheating Prediction Uncertainties for Mars-Entry Vehicles

An assessment of computational uncertainties is presented for numerical methods used by NASA to predict laminar, convective aeroheating environments for Mars-entry vehicles. A survey was conducted of existing experimental heat transfer and shock-shape data for high-enthalpy reacting-gas CO2 flows, and five relevant test series were selected for comparison with predictions. Solutions were generated at the experimental test conditions using NASA state-of-the-art computational tools and compared with these data. The comparisons were evaluated to establish predictive uncertainties as a function of total enthalpy and to provide guidance for future experimental testing requirements to help lower these uncertainties

Coupled Computation of Fluid and Material Response for Non-Charring Ablative Materials in Hypersonic Flow

Hypersonic vehicles are subjected to high heat loads throughout their flight trajectories, and as a result, some form of thermal protection system (TPS) is required to ensure the vehicle’s survival. Accurate prediction of the behavior of these materials in a hypersonic environment is crucial to the efficient design of a hypersonic flight vehicle. It can be very costly and difficult, however, to experimentally replicate the flow conditions found in many hypersonic regimes, and for this reason it is desirable to be able to simulate the behavior of TPS materials under these flight conditions. This study aims to improve the modeling of the coupled fluid-material response problem for TPS materials in realistic hypersonic flows by coupling a hypersonic CFD code with an axisymmetric material response code