Advanced ceramic matrix composites for TPS

Recent advances in ceramic matrix composite (CMC) technology provide considerable opportunity for application to future aircraft thermal protection system (TPS), providing materials with higher temperature capability, lower weight, and higher strength and stiffness than traditional materials. The Thermal Protection Material Branch at NASA Ames Research Center has been making significant progress in the development, characterization, and entry simulation (arc-jet) testing of new CMC's. This protection gives a general overview of the Ames Thermal Protection Materials Branch research activities, followed by more detailed descriptions of recent advances in very-high temperature Zr and Hf based ceramics, high temperature, high strength SiC matrix composites, and some activities in polymer precursors and ceramic coating processing. The presentation closes with a brief comparison of maximum heat flux capabilities of advanced TPS materials

A Perspective on the Design and Development of the SpaceX Dragon Spacecraft Heatshield

In December, 2010, Space Exploration Technologies (SpaceX) successfully orbited, re-entered and recovered their Dragon spacecraft, on an almost “picture perfect” first full mission. Earlier in 2009, SpaceX, announced the passing of a significant technical milestone with the successful arc jet testing of a their new high performance heat shield material, called PICA-X, which provided the primary (forebody) thermal protection for Dragon. In 2008 and 2009, Dr. Rasky worked closely with SpaceX on the Dragon heatshield design and also developing the ability to manufacture PICA-X. The “X” stands for the SpaceX-developed variants that have several improved properties and greater ease of manufacture than the original PICA used on Stardust. Dr. Rasky will discuss and describe a number of his perspectives and observations from his experience working with SpaceX, including some of the stark contrasts from his 20 years working at NASA

Thermal protection materials at NASA Ames Research Center

The topics addressed are: (1) Space Exploration Initiative (SEI); (2) Aeroassist Flight Experiment (AFE); (3) Mars Environmental Survey (MESUR); (4) National Aero-space Plan (NASP); (5) Pegasus and Pegasus/SWERVE Hypersonic Testing; and (6) Personnel Launch System TPS evaluation

Entry Systems Panel deliberations

The Entry Systems Panel was chaired by Don Rummler, LaRC and Dan Rasky, ARC. As requested, each panel participant prior to the workshop prepared and delivered presentations to: (1) identify technology needs; (2) assess current programs; (3) identify technology gaps; and (4) identify highest payoff areas R&D. Participants presented background on the entry systems R&D efforts and operations experiences for the Space Shuttle Orbiter. These participants represented NASA Centers involved in research (Ames Research Center), development (Johnson Space Center) and operations (Kennedy Space Center) and the Shuttle Orbiter prime contractor. The presentations lead to the discovery of several lessons learned

Fibrous-Ceramic/Aerogel Composite Insulating Tiles

Fibrous-ceramic/aerogel composite tiles have been invented to afford combinations of thermal-insulation and mechanical properties superior to those attainable by making tiles of fibrous ceramics alone or aerogels alone. These lightweight tiles can be tailored to a variety of applications that range from insulating cryogenic tanks to protecting spacecraft against re-entry heating. The advantages and disadvantages of fibrous ceramics and aerogels can be summarized as follows: Tiles made of ceramic fibers are known for mechanical strength, toughness, and machinability. Fibrous ceramic tiles are highly effective as thermal insulators in a vacuum. However, undesirably, the porosity of these materials makes them permeable by gases, so that in the presence of air or other gases, convection and gas-phase conduction contribute to the effective thermal conductivity of the tiles. Other disadvantages of the porosity and permeability of fibrous ceramic tiles arise because gases (e.g., water vapor or cryogenic gases) can condense in pores. This condensation contributes to weight, and in the case of cryogenic systems, the heat of condensation undesirably adds to the heat flowing to the objects that one seeks to keep cold. Moreover, there is a risk of explosion associated with vaporization of previously condensed gas upon reheating. Aerogels offer low permeability, low density, and low thermal conductivity, but are mechanically fragile. The basic idea of the present invention is to exploit the best features of fibrous ceramic tiles and aerogels. In a composite tile according to the invention, the fibrous ceramic serves as a matrix that mechanically supports the aerogel, while the aerogel serves as a low-conductivity, low-permeability filling that closes what would otherwise be the open pores of the fibrous ceramic. Because the aerogel eliminates or at least suppresses permeation by gas, gas-phase conduction, and convection, the thermal conductivity of such a composite even at normal atmospheric pressure is not much greater than that of the fibrous ceramic alone in a vacuum

Building a Robust Commercial Microgravity Economy in Earth's Orbit: Economic Readiness Considerations

The reduced gravity environment of space provides a unique opportunity to further our understanding of various materials phenomena involving the molten, fluidic and gaseous states as well as life science applications where, contrary to earlier beliefs, microgravity induces changes in single cells and simple organisms; not only in large organisms with a complex overall response to gravity (or lack thereof). The potential breadth of commercial opportunities in microgravity thus spans over many verticals of the private sector with applications ranging from fiber optics, high-resolution crystals, microencapsulation, 3D organs to perfume and color dyes. Overall, products manufactured in microgravity hold the promise to have key properties surpassing their best terrestrial counterparts. Commercialization, also known as taking a new technology to market, is a journey in itself where the business, economic, market and technological components must align to generate a successful outcome. A business perspective is very different than technology maturation. In order for a technology to be ready for commercialization, it must not only be mature, but it must also have a compelling business case, and the means to scale up production must be identified and practical. Creating a robust economy in Earths orbit (Fig 1) is especially challenging because of the complexity (high risks, lack of standardization) involved in predicting future growth. This complexity can easily overwhelm the fact that many of the products have an attractive touch of space which aids with branding and marketing.This paper reviews the types of added value that can be extracted from space, with an emphasis on the microgravity environment. In addition, lessons learned from past commercialization efforts will be reviewed. While past efforts have yielded some point successes, they have as a whole failed to precipitate a sustainable LEO based marke

Hybrid Flexible and Rigid Ceramic Insulation

A method is provided for closing out the edges of a flexible ceramic insulation member including inner and outer mold line covering layers. A rigid, segmented, ceramic frame is placed round the edges of the insulation member and exposed edges of the inner and outer mold line covering layers are affixed to the ceramic frame. In one embodiment wherein the covering layers comprise fabrics, the outer fabric is bonded to the top surface and to grooved portion of the side surface of the frame. In another embodiment wherein the outer cover layer comprises a metallic foil, clips on the edges of the frame are used to engage foil extensions. The ceramic frame is coated with a high emittance densifier coating

Economic Readiness Level Considerations for a Robust LEO Economy

The reduced gravity environment of space provides a unique opportunity to further our understanding of various materials phenomena involving the molten, fluidic and gaseous states as well as life science applications where, contrary to earlier beliefs, microgravity induces changes in single cells and simple organisms; not only in large organisms with a complex overall response to gravity (or lack thereof). The potential breadth of commercial opportunities in microgravity thus spans over many verticals of the private sector with applications ranging from fiber optics, high-resolution crystals, microencapsulation, 3D organs to perfume and color dyes. Overall, products manufactured in microgravity hold the promise to have key properties surpassing their best terrestrial counterparts. Commercialization, also known as taking a new technology to market, is a journey in itself where the business, economic, market and technological components must align to generate a successful outcome. A business perspective is very different than technology maturation, which can be measured with the usual Technology Readiness Level (TRL) approach. In order for a technology to be ready for commercialization, it must not only be mature (high TRL), but it must also have a compelling business case, and the means to scale up production must be identified and practical. Creating a sustainable economy in an emerging market such as microgravity is especially challenging because of the complexity (high risks, lack of standardization) involved in predicting future growth. This complexity can easily overwhelm the fact that many of the products have an attractive touch of space which aids with branding and marketing.This paper builds upon the concept of the verticals of microgravity, capturing not only new lines of investigations but also promising killer apps originating from microgravity to discuss and define the notion of Economic Readiness Level (ERL). To advance in ERL, the technology itself may not necessarily need to mature at all, but the understanding of its economic potential does. Building upon ERL, a model that ultimately leads to the creation of pathways for infusion of private capital and a sustainable commercial microgravity LEO-Earth economy will be discussed

Entry Systems Panel

As general findings, lessons learned from shuttle are: (1) bridge established between development center (JSC) Research Centers (ARC, LARC), and industry (RI, LMSC, Corning, Mansville, 3M LTV, Union Carbide, Hexcel) for shuttle TPS; (2) not all test results adequately analyzed or in hindsight, completely encompassing all failure modes; (3) gap heating effects from ground facilities not totally indicative of flight experience; (4) need to design with operations in mind (not just to cost) example: moisture intrusion of GR/EP, many other examples; (5) RSI- developed as point design for maneuvering entry vehicle of high L/D; and (6) RSI - 15 years from invention to use on flight hardware

Building an Economical and Sustainable Lunar Infrastructure to Enable Lunar Industrialization

A new concept study was initiated to examine the architecture needed to gradually develop an economical, evolvable and sustainable lunar infrastructure using a public/private partnerships approach. This approach would establish partnership agreements between NASA and industry teams to develop a lunar infrastructure system that would be mutually beneficial. This approach would also require NASA and its industry partners to share costs in the development phase and then transfer operation of these infrastructure services back to its industry owners in the execution phase. These infrastructure services may include but are not limited to the following: lunar cargo transportation, power stations, communication towers and satellites, autonomous rover operations, landing pads and resource extraction operations. The public/private partnerships approach used in this study leveraged best practices from NASA's Commercial Orbital Transportation Services (COTS) program which introduced an innovative and economical approach for partnering with industry to develop commercial cargo services to the International Space Station. This program was planned together with the ISS Commercial Resupply Services (CRS) contracts which was responsible for initiating commercial cargo delivery services to the ISS for the first time. The public/private partnerships approach undertaken in the COTS program proved to be very successful in dramatically reducing development costs for these ISS cargo delivery services as well as substantially reducing operational costs. To continue on this successful path towards installing economical infrastructure services for LEO and beyond, this new study, named Lunar COTS (Commercial Operations and Transport Services), was conducted to examine extending the NASA COTS model to cis-lunar space and the lunar surface. The goals of the Lunar COTS concept are to: 1) develop and demonstrate affordable and commercial cis-lunar and surface capabilities, such as lunar cargo delivery and surface power generation, in partnership with industry; 2) incentivize industry to establish economical and sustainable lunar infrastructure services to support NASA missions and initiate lunar commerce; and 3) encourage creation of new space markets for economic growth and benefit. A phased-development approach was also studied to allow for incremental development and demonstration of capabilities needed to build a lunar infrastructure. This paper will describe the Lunar COTS concept goals, objectives and approach for building an economical and sustainable lunar infrastructure. It will also describe the technical challenges and advantages of developing and operating each infrastructure element. It will also describe the potential benefits and progress that can be accomplished in the initial phase of this Lunar COTS approach. Finally, the paper will also look forward to the potential of a robust lunar industrialization environment and its potential effect on the next 50 years of space exploration