Thermal & Fluids Analysis Workshop TFAWS 2004 Jet Propulsion Laboratory Pasadena, CA. August 31, 2004 NASA Reentry Material Technology Test and Evaluation Langley 8-ft High Temperature Tunnel Aerothermal Ground Testing Gerald Russell / AMRDEC Joe Raymond & Forrest Strobel/ ITT Jimmy Lee, Susan Spencer, Tony Oneil/NASA MSFC September 2, 2004
Aerothermal Ground Test Objective ♦ 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) 2 2
Ground Testing Will Evaluate: ♦ 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 3 3
Ground Test Candidate Materials 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) ATK Thiokol Carbon-Carbon/CAV 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 4 4
Ground Aerothermal Testing Ground Aerothermal Testing Ground Aerothermal Testing ♦ Simulate aerothermal environments of interest • Shear • Recovery conditions • Pressure NASA Ames Arc Facilities • Test duration (limited compared to Facility flight test time) Selection ♦ Conduct facility assessment for appropriate test validation ♦ Assess external TPS attachment NASA LaRC High Temperature Tunnel (HTT) and seal concept ♦ Collect thermal response data for model validation ♦ Assess flight instrumentation technology AEDC H2, or H3 Arc Heater Large Core (50,70 MW) 5 5
Ground Aerothermal Test Facility Conditions Shock Tunnels 20,000 Operating Limit of Non-Arc Heated Tunnels Hotshots Arc Heated Tunnels 10 15,000 20 8 Equivalent Velocity (1000 ft/sec) Stagnation Temperature, o R Total Enthalpy (1000 Btu/lbm) Sleds 6 15 10,000 4 Shock Tubes 3 Blowdown NSWC Tunnels 10 Hypervelocity 2 Tunnel 9 5,000 Continuous ONERA Tunnel R4CII 1 Limit VKI Longshot 5 Gun Tunnels Ludweig Tubes 0 0 -5 -4 -3 -2 -1 2 3 4 10 10 10 10 10 1 10 10 10 10 Seconds Microseconds Milliseconds Seconds Minutes Hours Flow Duration 6 6
ARC Test Facility Condition Envelopes 300 SHUTTLE SCIROCCO De = 76 in. 200 ALTITUDE SCIROCCO De = 36 in. JSC & AMES MSHWT KFT ARCS LaRC AHSTF 12MW Arc Heater H2 11”x11” Freejet SCRAMJET WITH ASCENT H3 HTR AEDC q = 1000 psf 100 H2 AEDC AEDC ICBM H1 & H3 HR ICBM MAX HEATING 2 4 6 8 10 12 14 16 18 20 22 24 SIMULATED VELOCITY, KFT/S 200 400 600 800 1000 2000 4000 6000 8000 10000 TOTAL ENTHALPY, BTU/LBM 7 7
Facility Comparison Parameter Flight AEDC H2 LaRC 8-ft HTT AMES PTF 5 - 10 5.9 - 7.8 7 5.5 Mach 492-1268 1800 – 2500 785 BTU/lbm max 2000 - 14000 Enthalpy (Temp = 3650 R) (BTU/lbm) 15 - 110 50 5.9 – 39.8 0.5 - 75 Heat Flux (BTU/ft 2 -sec) 0.04 - 0.28 0.12 0.025 - 0.129 0.0005 – 0.05 Edge Pressure (atm) 600 seconds Up to 20 minutes 120 seconds 30 minutes Test Duration Reentry Vehicle Up to 24 inch 8 ft diameter by 12 Test fixture for 14” Test Article Size nozzle exit ft long test section. x 14” flat panels available Full size vehicle can be tested or full scale panel utilizing the HTT panel holder. Pull out condition High enthalpy Matches most High enthalpy low Comments is severe facility. Expanding parameters of pressure. Would flow in test section interest but is not provide a good produces non- limited in test evaluation of the uniform conditions duration sealing concepts. on test panel 8 8
Langley 8-ft HTT Test Section 12 ft ♦ Mach 7 flow provided at 8-ft diameter nozzle exit ♦ Test Section is 12-ft long 8 ft ♦ 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 9 9
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 High Prescription Low Prescription P e H R P e H R Time Panel Angle Panel Angle Time (sec) (deg) (deg) (atm) (BTU/lbm) (atm) (BTU/lbm) 0 0 0.025 786 0 0 0.025 786 5 0 0.025 786 5 0 0.025 786 5 15 0.129 773 5 5 0.037 777 120 15 0.129 773 120 5 0.037 777 10 10
Coldwall Heat Flux and Shear versus Panel Angle for Selected LARC Test Conditions 50 Coldwall Heat Flux (BTU/ft 2 -sec) 40 30 Coldwall Heat Flux 20 10 0 0 5 15 Panel Angle (degrees) 10 9 8 7 Shear (lbf/ft 2 ) 6 Shear 5 4 3 2 1 0 0 5 15 Panel Angle (degrees) 11 11
Predicted Surface Temperatures for 2-inch thick Silica Phenolic for Selected LaRC Test Conditions 5000 20 4500 15 High Prescription Surface Temperature 4000 10 Prescribed Panel Angle (deg) 3500 5 Surface Temperature (F) Low Prescription Surface Temperature 3000 0 2500 -5 High Prescription Panel Angle 2000 -10 1500 -15 1000 -20 Low Prescription Panel Angle 500 -25 0 -30 0 20 40 60 80 100 120 Time (sec) 12 12
Test Panel Configuration 3.5 x 5 ft. test fixture ♦ Three Panels will be tested TPS experiment panels simultaneously ♦ Silica phenolic holders: Rear Panel will be • Constructed of separate panels of interchangeable with silica phenolic that are attached with a CRI interface panel mortis and tenon joints and bonded • 90 degree lay-up relative to heated Interface Design surface Silica phenolic holder LaRC HTT Test Fixture 13 13
Test Fixture Design Verification Thermostructural Analysis • Decomposition Test Fixture Modal Analysis • Thermal Expansion • Modes 1-6 • Initial Natural Frequency = 70 Hz • Redesigned to 130 Hz Expansion Expansion Region Region 0.07 Dmax, test 90 deg 0.06 Dmax, test 20 deg Max. Displacement (in) 0.05 0.04 0.03 3000 Surface, 20-deg layup angle 0.10-in Depth, 20-deg layup angle 0.02 0.25-in Depth, 20-deg layup angle 0.50-in Depth, 20-deg layup angle 2500 1.0-in Depth, 20-deg layup angle 0.01 1.5-in Depth, 20-deg layup angle 2.0-in Depth, 20-deg layup angle Temperature (deg-F) Surface, 90-deg layup angle 0 2000 0.10-in Depth, 90-deg layup angle 0 20 40 60 80 100 120 140 0.25-in Depth, 90-deg layup angle 0.50-in Depth, 90-deg layup angle 1.0-in Depth, 90-deg layup angle 1.5-in Depth, 90-deg layup angle 1500 2.0-in Depth, 90-deg layup angle 1000 500 0 0 100 200 300 400 500 600 700 800 Time (sec) Robust Thermostructural Design 14 14
HTT Test Hardware Configuration with CRI Interface Installed INSULATING TILES (FURNISHED BY LANGLEY) TPS INTERFACE PLATE NEXTEL ROPE SEALS (FURNISHED BY LANGLEY) PS-WF-010782 TPS HOLDER GASKET PS-WF-010785 TPS HOLDER ASSEMBLY PS-WF-010699 INSULATING TILES (FURNISHED BY LANGLEY) CRI INTERFACE PLATE PS-WF-010841 CRI BLANKET (FURNISHED BY MSFC) FRAME CRI GASKET PS-WF-010843 PS-WF-010784 CRI HOLDER PS-WF-010842 PANEL HOLDER STRUCTURE .25” AL PLATE AND (FURNISHED BY LANGLEY) INSULATING TILES (FURNISHED BY LANGLEY) 15 15
Interface Hardware / TPS Experiments • All vendors have received Silica • Fabrication of all interface hardware Phenolic panel holders is complete except for CRI blanket • TPS Samples should begin arriving interface at ITT in August. • Design of CRI interface is complete, • 1 NASA Ames Sample has been fabrication by Millennium Machine is received in-process Fit Checking of TPS Holder CRI Blanket and Interface Hardware 21.9 23.5 16 16
Recommend
More recommend
