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