Small Business Innovation Research/Small Business Tech Transfer
Lightweight Hybrid Ablator Incorporating Aerogel-Filled Open-Cell Foam Structural Insulator, Phase II
Project Introduction
In previous work for NASA and DoD, Ultramet developed lightweight open-cell foam insulators composed of a carbon or ceramic structural foam skeleton filled with a high temperature nanoscale aerogel insulator. Structural integrity and high insulation behavior have been demonstrated when used in combination with a non-ablating, coated carbon/carbon or ceramic matrix composite outer shell. In Phase I, Ultramet demonstrated the initial feasibility of a foam-reinforced hybrid ablator/aerogel insulator thermal protection system (TPS) in which a portion of the thickness (front face) of a low thermal conductivity structural foam was infiltrated with an ablative material and the remainder of the thickness (back face) was filled with the high temperature aerogel insulator. The potential benefit is a reduction in the ablator mass required to reject the aerothermal heat load. The three-dimensionally interconnected foam reinforcement is anticipated to provide increased char retention relative to alternative fiber and honeycomb reinforcements. The vehicle interface temperature will be controlled by the highly insulating aerogel-filled portion of the foam structure. In Phase II, Ultramet will team with Materials Research & Design (MR&D) for continued thermomechanical design optimization, and ARA Ablatives Laboratory for ablator infiltration of Ultramet structural foam. Performance will be evaluated through high heat flux ablation testing and a demonstration of scaleup potential up to 18" diameter.
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Anticipated Benefits
Commercial applications for the proposed advanced TPS include conventional satellite launch system solid rocket motors, nanosatellite launch systems, launch platform protection, and tactical solid rocket motors, internal and external motor case insulation, and nosetips. The proposed foam-reinforced hybrid ablator-insulator may meet NASA requirements for increased TPS heat flux capability and reduced mass. NASA applications include the Orion Crew Exploration Vehicle for which entry velocities ranging from 8 km/s for International Space Station missions to as high as 15 km/s for Moon mission return are anticipated, and planetary sample return missions. Use of ablatives in rocket nozzles has been extensive, and NASA also stands to benefit in that application.
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Primary U.S. Work Locations and Key Partners
| Organizations Performing Work | Role | Type | Location |
|---|---|---|---|
| Ultramet | Lead Organization | Industry | Pacoima, California |
Ames Research Center
(ARC)
|
Supporting Organization | NASA Center | Moffett Field, California |
Primary U.S. Work Locations
-
California
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Organizational Responsibility
Responsible Mission Directorate:
- Space Technology Mission Directorate (STMD)
Lead Organization:
- Ultramet
Responsible Program:
- Small Business Innovation Research/Small Business Tech Transfer
Project Management
Program Director:
Program Manager:
Principal Investigator:
Project Duration
Start: Jun 2010
End: Jun 2012
Technology Maturity (TRL)
| Start: | 5 |
| Current: | 5 |
| Estimated End: | 5 |
Applied Research
Development
Demo & Test
Technology Areas
Primary:
- TX14 Thermal Management Systems
- TX14.2 Thermal Control Components and Systems
- TX14.2.4 Insulation and Interfaces
Target Destinations
Mars, Others Inside the Solar System
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This is a historic project that was completed before the creation of TechPort on October 1, 2012. Available data has been included. This record may contain less data than currently active projects.