Thermal & Fluids Analysis Workshop TFAWS 2004
Jet Propulsion LaboratoryPasadena, CA. August 31, 2004
NASA Reentry Material Technology Test and Evaluation
Langley 8-ft High Temperature TunnelAerothermal Ground Testing
Gerald Russell / AMRDECJoe Raymond & Forrest Strobel/ ITT
Jimmy Lee, Susan Spencer, Tony Oneil/NASA MSFC
September 2, 2004
Aerothermal Ground Test Objective
22
♦Conduct a screening test and evaluation program to identify best candidates for hypersonic/space exploration flight test demonstration
♦Maximize leveraging/collaboration with NASA/DoD programs requiring material aerothermal test data•NASA Aerocapture/Hypersonics•DARPA/Air Force (FALCON/CAV/RESE, SBIRs)•NAVY (HyFLY, SBIRs)•Army (Hypersonic Scramjets, Missiles, SBIRs)
Ground Testing Will Evaluate:
33
♦ Seal & Attachment Technology♦ TPS Thermal Performance♦ Instrumentation♦ Bondline Performance♦ TPS Candidate Technologies:• Metallics• Blankets• Tiles• Ablative/decomposing
♦ Instrumentation Technologies:• Ablation Rate Sensors• Heat Flux Gages• Embedded Thermocouples
Ground Test Candidate Materials
44
TPS Candidate Classification Vendor
CRI Blanket/NASA Boeing
AETB/TUFI Tile/NASA Ames Research Center
20° ply angle 2D C-C with RTV-12 (new MX-4830) Carbon-Carbon/CAV ATK Thiokol
Ceramic Foam CMC Foam/NASA Ames Research Center
SC-20 Ablative/NASA Applied Research Associates
Hyperlite C Ablative/NASA Applied Research Associates
C-SiC CMC/DoD/NASA Physical Sciences Incorporated
MSTPS C-C RTV Ablative/DoD/NASA Aerothermo Technologies
RX2390 Ablative/DoD Mineral Technologies
TMC Metallic/NASA FMW Composites
CeramARC Ceramic/NASA/DoD FMW Composites
Intergral TPS Ablative/DoD Vanguard Composites
20° ply angle 2D C-C with RTV-12 (FiberCote) Carbon-Carbon/CAV ATK Thiokol
20° ply angle 2D C-C with RTV-12 (Lewcott) Carbon-Carbon/CAV ATK Thiokol
Carbon-Carbon Ablative/DoD/NASA Fiber Materials Inc
Carbon Carbon-Silicon Carbide Ablative/DoD/NASA Fiber Materials Inc
HotBlox Ceramic/NASA/DoD Raytheon/American Technical Coatings
Acusil-2 Panel AMRDEC/ITT
Molybdenum Plate Calorimeter Plate AMRDEC/ITT
TC Plugs/ARADS/Heat Flux Gages Instrumentation Data Possible Aerocapture Interest
Ground Aerothermal Testing
55
Ground Aerothermal TestingGround Aerothermal Testing♦Simulate aerothermal
environments of interest•Shear•Recovery conditions•Pressure•Test duration (limited compared to
flight test time)♦Conduct facility assessment for
appropriate test validation♦Assess external TPS attachment
and seal concept♦Collect thermal response data for
model validation♦Assess flight instrumentation
technology
FacilitySelection
AEDC H2, or H3 Arc Heater Large Core (50,70 MW)
NASA LaRC High Temperature Tunnel (HTT)
NASA Ames Arc Facilities
Ground Aerothermal Test Facility Conditions
66
5,000
10,000
15,000
20,000
10 10 10 10 10 1 10 10 1010-5 -4 -3 -2 -1 2 3 4
Seconds
Microseconds Milliseconds Seconds Minutes Hours
5
0
10
15
20
0
1
2
34
6810
Shock TunnelsOperating Limit ofNon-Arc Heated Tunnels
Hotshots Arc Heated Tunnels
Shock Tubes
VKI LongshotGun Tunnels
NSWCHypervelocity
Tunnel 9
Ludweig Tubes
BlowdownTunnels
ContinuousTunnelLimit
ONERAR4CII
Flow Duration
Tota
l Ent
halp
y (1
000
Btu
/lbm
)
Equi
vale
nt V
eloc
ity (1
000
ft/se
c)
Stag
natio
n Te
mpe
ratu
re, o
R
Sleds
ARC Test Facility Condition Envelopes
77
300
2 4 6 8 10 12 14 16 18 20 22 24SIMULATED VELOCITY, KFT/S
AEDCHR
AEDCH1 & H3
SHUTTLE
ICBM
AEDCH2
JSC & AMESARCS
H2WITH
H3 HTR
200 400 600 800 1000 2000 4000 6000 8000 10000TOTAL ENTHALPY, BTU/LBM
ICBM MAXHEATING
SCIROCCODe = 76 in.
SCIROCCODe = 36 in.
LaRC AHSTF12MW Arc Heater11”x11” Freejet
SCRAMJET ASCENT
q = 1000 psf
MSHWT
100
200
AL T
ITU
DE
KFT
Facility Comparison
88
Parameter Flight AEDC H2 LaRC 8-ft HTT AMES PTFMach 5 - 10 5.9 - 7.8 7 5.5
Enthalpy (BTU/lbm)
492-1268 1800 – 2500 785 BTU/lbm max(Temp = 3650 R)
2000 - 14000
Heat Flux (BTU/ft2-sec)
15 - 110 50 5.9 – 39.8 0.5 - 75
Edge Pressure (atm)
0.04 - 0.28 0.12 0.025 - 0.129 0.0005 – 0.05
Test Duration 600 seconds Up to 20 minutes 120 seconds 30 minutes
Test Article Size Reentry Vehicle Up to 24 inch nozzle exit available
8 ft diameter by 12 ft long test section.
Full size vehicle can be tested or full scale panel
utilizing the HTT panel holder.
Test fixture for 14”x 14” flat panels
Comments Pull out condition is severe
High enthalpy facility. Expanding flow in test section produces non-uniform conditions on test panel
Matches most parameters of interest but is limited in test duration
High enthalpy low pressure. Would not provide a good evaluation of the sealing concepts.
99
Langley 8-ft HTT Test Section12 ft
♦ Mach 7 flow provided at 8-ft diameter nozzle exit
♦ Test Section is 12-ft long♦ A 16-ft. I.D. pod intersects the test
section from the bottom, containing a model injection system that can insert the model into the flowfield once steady flow has been achieved
♦ Diffuser system for attaining supersonic flow
♦ A 3.5 ft. x 5 ft. panel test fixture is available
8 ft
1010
Selected Test Conditions:LARC 8-ft HTT Panel
Selected Test Conditions: Peak Facility Operating Conditions at Mach 7, 80-100 kft:• 2000 psia freestream pressure• 3190°F total temperature• 120 second total test time at peak• Vary Panel Angle from 0-degrees at startup to a 5 or 15 degree
angle of incidence (Low and High Test Conditions)
Panel Angle Prescriptions of High and Low Test Conditions
Time (sec)
Panel Angle (deg)
Pe
(atm)HR
(BTU/lbm)Time Panel Angle
(deg)Pe
(atm)HR
(BTU/lbm)0 0 0.025 786 0 0 0.025 7865 0 0.025 786 5 0 0.025 7865 15 0.129 773 5 5 0.037 777
120 15 0.129 773 120 5 0.037 777
High Prescription Low Prescription
1111
Coldwall Heat Flux and Shear versus Panel Angle for Selected LARC Test Conditions
0123456789
10
0 5 15Panel Angle (degrees)
Shea
r (lb
f/ft2 )
Shear
0
10
20
30
40
50
0 5 15Panel Angle (degrees)
Col
dwal
l Hea
t Flu
x (B
TU/ft
2 -sec
)
Coldwall Heat Flux
1212
Predicted Surface Temperatures for 2-inch thick Silica Phenolic for Selected LaRC Test Conditions
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
0 20 40 60 80 100 120Time (sec)
Surf
ace
Tem
pera
ture
(F)
-30
-25
-20
-15
-10
-5
0
5
10
15
20
Pres
crib
ed P
anel
Ang
le (d
eg)
High Prescription SurfaceTemperature
Low Prescription SurfaceTemperature
High Prescription Panel Angle
Low Prescription Panel Angle
Test Panel Configuration
1313
♦ Three Panels will be tested simultaneously
♦ Silica phenolic holders:• Constructed of separate panels of
silica phenolic that are attached with mortis and tenon joints and bonded
• 90 degree lay-up relative to heated surface
3.5 x 5 ft. test fixtureTPS experiment panels
LaRC HTT Test Fixture
Interface Design
Silica phenolic holder
Rear Panel will be interchangeable with a CRI interface panel
Test Fixture Design Verification
1414
0
500
1000
1500
2000
2500
3000
0 100 200 300 400 500 600 700 800
Time (sec)
Tem
pera
ture
(deg
-F)
Surface, 20-deg layup angle0.10-in Depth, 20-deg layup angle0.25-in Depth, 20-deg layup angle0.50-in Depth, 20-deg layup angle1.0-in Depth, 20-deg layup angle1.5-in Depth, 20-deg layup angle2.0-in Depth, 20-deg layup angleSurface, 90-deg layup angle0.10-in Depth, 90-deg layup angle0.25-in Depth, 90-deg layup angle0.50-in Depth, 90-deg layup angle1.0-in Depth, 90-deg layup angle1.5-in Depth, 90-deg layup angle2.0-in Depth, 90-deg layup angle
Thermostructural Analysis• Decomposition• Thermal Expansion
Expansion RegionExpansion Region
Test Fixture Modal Analysis• Modes 1-6• Initial Natural Frequency = 70 Hz• Redesigned to 130 Hz
Robust Thermostructural Design
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0 20 40 60 80 100 120 140
Max
. Dis
plac
emen
t (in
)Dmax, test 90 degDmax, test 20 deg
1515
HTT Test Hardware Configuration with CRI Interface Installed
PANEL HOLDER STRUCTURE(FURNISHED BY LANGLEY)
FRAMEPS-WF-010784
.25” AL PLATE ANDINSULATING TILES(FURNISHED BY LANGLEY)
CRI HOLDERPS-WF-010842
CRI GASKET PS-WF-010843
CRI BLANKET(FURNISHED BY MSFC)
NEXTEL ROPE SEALS(FURNISHED BY LANGLEY)
CRI INTERFACE PLATEPS-WF-010841
INSULATING TILES (FURNISHED BY LANGLEY)
TPS INTERFACE PLATEPS-WF-010782
TPS HOLDER GASKETPS-WF-010785
TPS HOLDER ASSEMBLYPS-WF-010699
INSULATING TILES (FURNISHED BY LANGLEY)
1616
Interface Hardware / TPS Experiments
• All vendors have received Silica Phenolic panel holders • TPS Samples should begin arriving at ITT in August.• 1 NASA Ames Sample has been received
• Fabrication of all interface hardware is complete except for CRI blanket interface• Design of CRI interface is complete, fabrication by Millennium Machine is in-process
23.521.9
Fit Checking of TPS Holder and Interface Hardware
CRI Blanket
Calorimeter Design
1717
0
500
1000
1500
2000
2500
0 50 100 150 200 250 300 350 400 450
Time (sec)
Tem
pera
ture
(o F)
3D1D
♦ A thin skin calorimeter design has been developed for flight
♦ Candidate materials included 17-4PH steel, molybdenum, and oxygen free high conductivity (OFHC) copper
♦ Trade-off studies conducted to select material and thickness
♦ Thin skin criteria (ht/k < 0.1) applied in evaluating the materials
♦ 17-4PH experienced excessive temperatures
♦ OHFC copper needed to be excessive thick (2 inch) to remain at acceptable temperatures
♦ Molybdenum, with a 0.25 inch thickness was selected for the design• Temperature < 1800 ºF• Low thermal expansion
Expansion Gaps
Fiberfrax porivdes seal between Silica Phenolic and Molybdenum
Fasteners secure Molybdenum to Silica phenolic (Fastened at both ends)
Expansion Gaps
Fiberfrax porivdes seal between Silica Phenolic and Molybdenum
Fasteners secure Molybdenum to Silica phenolic (Fastened at both ends)
Pinned joint for thermal expansion
Expansion Gaps
Fiberfrax porivdes seal between Silica Phenolic and Molybdenum
Fasteners secure Molybdenum to Silica phenolic (Fastened at both ends)
Expansion Gaps
Fiberfrax porivdes seal between Silica Phenolic and Molybdenum
Fasteners secure Molybdenum to Silica phenolic (Fastened at both ends)
Pinned joint for thermal expansion
Calorimeter Plate Instrumentation
1818
♦ Calorimeter will be evaluated in HTT test and used to measure the facility heat flux
♦ Instrumentation includes 8 thermocouples and 2 pressure transducers♦ Thermocouples used for redundancy and to quantify three dimensional
conduction effects
xxx
x
x
xx
Thermocouple locations
Pressure ports
xxx
x
x
xx
Thermocouple locations
Pressure ports
X
Pressure Transducers
Molybdenum thin skin calorimeter
Instrumentation Technology Panel
1919
SIPH Holder Assembly
SIPH Test Plate20 Degree Ply
Astrometrics’ Delta-T Sensor
Delta-M’s Thermocouple Plug3 Element
Astrometrics’ QuartzARAD Sensor
Astrometrics’ Thermocouple Plug4 Element
Astrometrics’ Carbon Phenolic ARAD Sensor
Flow
2020
MULTI-ELEMENT SIP QUAD EMBEDDED PLUGTHERMOCOUPLE HAS TPS PLIES IN THE REQUIRED
ORIENTATION FOR TESTING
Instrumentation Test Hardware
Astrometrics Carbon Phenolic ARAD Sensor
AstrometricsSilica Phenolic Thermocouple Plug
Ground Test Candidate Instrumentation/Database
2121
Sublayers/InsulationAttachment Hardware
TPS Material Experiment
TPS Holder
Sublayers/InsulationAttachment Hardware
TPS Material Experiment
TPS Holder
•Vendors will instrument samples to obtain in depth thermal response
•Vendors will provide thermophysical properties
•Measured data and thermophysical properties will assembled in report and database for future material design model development if desired
•Decomposition Kinetics•Density•Thermal Conductivity•Specific Heat•Dimensions (TC locations, Layers)•Emissivity
EmbeddedThermocouples
Preliminary Test Matrix
2222
Test Day Test Condition TPS Candidate Vendor TPS Candidate Vendor TPS Candidate Vendor
1
Calorimeter Plate Prescription, 10
seconds at 0, 5, 10, and 15-deg Calorimeter Plate AMRDEC/ITT Calorimeter Plate AMRDEC/ITT Calorimeter Plate AMRDEC/ITT
2 High AETB/TUFIAmes Research
Center Ceramic FoamAmes Research
Center Calorimeter Plate AMRDEC/ITT
3 High PhenCarb-20Applied Research
Associates SRAM-20Applied Research
Associates SRAM-17Applied Research
Associates
4 High C-SiC Physical Sciences
Incorporated3D C/C-SiC with a SiC-
Rich Seal Coat Fiber Materials Inc2D C/C-SiC with a SiC-
Rich Seal Coat Fiber Materials Inc
5 High MSTPS C-C RTVAerothermo
Technologies Regular HotBlox
Raytheon/American Technical
Coatings HotBlox Light
Raytheon/American Technical
Coatings
6 High
20-deg play angle staple PAN-based 2D C-C with RTV-12 (new MX-4830) ATK Thiokol
20-deg play angle staple PAN-based 2D
C-C with RTV-12 (FiberCote) ATK Thiokol
20-deg play angle Needled PBCF-based 2D C-C with RTV-12
(Lewcott) ATK Thiokol
7 High Calorimeter Plate AMRDEC/ITT
Silica Phenolic Instrumentation
Technology Panel AMRDEC/ITT CeramARC FMW Composites
8 Low RX2390 (1)
Mineral Technologies /
NAWC RX2390 (2)
Mineral Technologies /
NAWC Acusil 2 AMRDEC/ITT
9 Low TMC FMW Composites Intergral TPSVanguard
Composites Calorimeter Plate AMRDEC/ITT
10
Low - CRI Panel aft of TPS Experiment
positions Calorimeter Plate AMRDEC/ITT Calorimeter Plate AMRDEC/ITT Calorimeter Plate AMRDEC/ITT
Position 3Position 1 Position 2Test/Conditions
Summary
2323
♦Ground aerothermal test and evaluation planned for October 2004•Langley Research Center High Temperature Tunnel (HTT)•Variety of candidate material technologies considered to include
projected reusable technology such as blankets, tiles, and metallics as well as a significant number of ablative material technologies supporting NASA and DoD
• Instrumentation candidate technology test and evaluation