Anthony M. Calomino

An Overview of Technology Investments in the NASA Entry Systems Modeling Project

The Entry Systems Modeling Project, within the NASA Game Changing Development Program, is in its third year conducting mid-TRL research in the disciplines of entry aerosciences and entry thermal protection materials. The Project team is working a variety of challenging problems ranging from the delivery of new aerothermal CFD codes, to the development of the first truly new ablation material response model in more than 40 years, to new conformal and truly flexible thermal protection materials, using novel polymer resins and advanced multi-layered concepts, that will revolutionize entry system designs for future NASA missions. This paper briefly summarizes the achievements to date of the ESM project and provides a full bibliography of papers published by the project over its first two years for the interested reader.

Advanced High-Temperature Flexible TPS for Inflatable Aerodynamic Decelerators

Typical entry vehicle aeroshells are limited in size by the launch vehicle shroud. Inflatable aerodynamic decelerators allow larger aeroshell diameters for entry vehicles because they are not constrained to the launch vehicle shroud diameter. During launch, the hypersonic inflatable aerodynamic decelerator (HIAD) is packed in a stowed configuration. Prior to atmospheric entry, the HIAD is deployed to produce a drag device many times larger than the launch shroud diameter. The large surface area of the inflatable aeroshell provides deceleration of high-mass entry vehicles at relatively low ballistic coefficients. Even for these low ballistic coefficients there is still appreciable heating, requiring the HIAD to employ a thermal protection system (TPS). This TPS must be capable of surviving the heat pulse, and the rigors of fabrication handling, high density packing, deployment, and aerodynamic loading. This paper provides a comprehensive overview of flexible TPS tests and results, conducted over the last three years. This paper also includes an overview of each test facility, the general approach for testing flexible TPS, the thermal analysis methodology and results, and a comparison with 8-foot High Temperature Tunnel, Laser-Hardened Materials Evaluation Laboratory, and Panel Test Facility test data. Results are presented for a baseline TPS layup that can withstand a 20 W/cm2 heat flux, silicon carbide (SiC) based TPS layup, and polyimide insulator TPS layup. Recent work has focused on developing material layups expected to survive heat flux loads up to 50 W/cm2 (which is adequate for many potential applications), future work will consider concepts capable of withstanding more than 100 W/cm2 incident radiant heat flux. This paper provides an overview of the experimental setup, material layup configurations, facility conditions, and planned future flexible TPS activities.

Manufacturing challenges and benefits when scaling the HIAD stacked-torus aeroshell to a 15m-class system

Over a decade of work has been conducted in the development of NASAs Hypersonic Inflatable Aerodynamic Decelerator (HIAD) deployable aeroshell technology. This effort has included multiple ground test campaigns and flight tests culminating in the HIAD projects second generation (Gen-2) aeroshell system. The HIAD project team has developed, fabricated, and tested stacked-torus inflatable structures (IS) with flexible thermal protection systems (F-TPS) ranging in diameters from 3-6m, with cone angles of 60 and 70 deg. To meet NASA and commercial near term objectives, the HIAD team must scale the current technology up to 12-15m in diameter. Therefore, the HIAD projects experience in scaling the technology has reached a critical juncture. Growing from a 6m to a 15m-class system will introduce many new structural and logistical challenges to an already complicated manufacturing process. Although the general architecture and key aspects of the HIAD design scale well to larger vehicles, details of the technology will need to be reevaluated and possibly redesigned for use in a 15m-class HIAD system. These include: layout and size of the structural webbing that transfers load throughout the IS, inflatable gas barrier design, torus diameter and braid construction, internal pressure and inflation line routing, adhesives used for coating and bonding, and F-TPS gore design and seam fabrication. The logistics of fabricating and testing the IS and the F-TPS also become more challenging with increased scale. Compared to the 6m aeroshell (the largest HIAD built to date), a 12m aeroshell has four times the cross-sectional area, and a 15m one has over six times the area. This means that fabrication and test procedures will need to be reexamined to account for the sheer size and weight of the aeroshell components. This will affect a variety of steps in the manufacturing process, such as: stacking the tori during assembly, stitching the structural webbing, initial inflation of tori, and stitching of F-TPS gores. Additionally, new approaches and hardware will be required for handling and ground testing of both individual tori and the fully assembled HIADs. There are also noteworthy benefits of scaling up the HIAD aeroshell to a 15m-class system. Two complications in working with handmade textile structures are the non-linearity of the material components and the role of human accuracy during fabrication. Larger, more capable, HIAD structures should see much larger operational loads, potentially bringing the structural response of the material components out of the nonlinear regime and into the preferred linear response range. Also, making the reasonable assumption that the magnitude of fabrication accuracy remains constant as the structures grow, the relative effect of fabrication errors should decrease as a percentage of the textile component size. Combined, these two effects improve the predictive capability and the uniformity of the structural response for a 12-15m HIAD. In this paper, the challenges and associated mitigation plans related to scaling up the HIAD stacked-torus aeroshell to a 15m-class system will be discussed. In addition, the benefits of enlarging the structure will be further explored.

The challenges of integrating instrumentation with inflatable aerodynamic decelerators

New Entry, Decent, and Landing (EDL) technologies are being explored to facilitate the landing of high mass vehicles. Current EDL technologies are limited due to mass and volume constraints dictated by launch vehicle fairings. Therefore, past and present technologies are now being considered to provide a mass and volume efficient solution, including Inflatable Aerodynamic Decelerators (IADs). To better define the instrumentation challenges posed by IAD technology development, a survey was conducted to identify valuable measurements for ground and flight testing of the flexible materials and structures used in their design. From this survey many sensing technologies and systems were explored specific to the stacked torus IAD, resulting in a down-selection to the most viable prospects. The majority of these systems, including wireless data acquisition, were then rapid prototyped and evaluated during component level testing to determine the best integration techniques specific to a 3m and 6m diameter stacked toroid IAD. Each sensing system was then integrated in support of the Hypersonic Inflatable Aerodynamic Decelerator ground test campaign. In this paper these IAD instrumentation systems are described along with their challenges in comparison to traditional rigid aeroshell systems. Requirements resulting from the survey are listed and instrumentation integration techniques and data acquisition are discussed.