High Temperature Inflation Hoses and Ports for Next Generation Inflatable Heat Shields

NASA Langley Research Center (LaRC) led the successful flight test of a 6-meter diameter HIAD in November 2022 under the project called the Low earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) project. This demonstration has led to new opportunities with commercial partners that require further scale-up of the deployable aeroshell technology. For example, NASA LaRC is developing a 10-meter diameter HIAD that is being considered for use by United Launch Alliance (ULA). Scaling the inflatable heat shield from LOFTID’s 6-meter to a 10-meter class and beyond will require solving manufacturing, design, and procurement challenges for several materials, components, and systems. The Inflatable Structure (IS) system of NASA’s 10m HIAD will benefit from larger hoses and ports than are currently available to inflate the heat shield. The hoses are located on the back side of the inflatable heat shield, somewhat protected from the front side heat pulse, yet must survive radiation from plasma trails and heat conduction through the heat shield during the ~5 min heat pulse. The hoses are expected to near peak external temperatures of 400C during reentry while the inside will need to resist hot gases from a gas-generator inflation system with gas temperatures up to 200C. JBE is proposing to demonstrate the design and manufacturing of a 1 inch and 2 inch diameter class hoses and ports, that can survive the requirements of an inflatable heat shield aeroshell component including packing and deployment, inflation load, max aerodynamic load, and the forementioned temperatures. The SOTA LOFTID hoses limit the inflation time of the inflatable heat shield. In PHI, JBE will focus on demonstrating the use of novel materials and manufacturing techniques to develop a 1 inch diameter class hose and port. In PHII, JBE will build upon the lessons learned in PHI, develop a 2 inch diameter class hose and port and validate the performance of both classes with thermo-mechanical testing.

Deployable decelerator technology will increase mission capabilities for Mars, Venus and beyond. HIAD is considered a key technology for human rated Mars Entry Descent and Landing (EDL). A HIAD will enable delivery of an estimated 20 metric tons of payload required to support human exploration of Mars. Methods to reuse spacecraft hardware, which would significantly lower the cost of launching payloads to LEO and beyond, are currently being developed by many companies including ULA, SpaceX, Blue Origin, Rocket Lab, and Relativity. In EDL areas where the hardware is flying at hypersonic velocities, a HIAD could be a key decelerator technology. This Phase I effort could provide more design options and expand the mission capability for these companies. • ULA has announced that they will use a HIAD as part of their Sensible, Modular, and Autonomous Return Technology (SMART) for their upcoming Vulcan rocket. ULA claims that the SMART booster reusability initiative will reduce their booster cost by 65%, sustainably collapsing the cost of up-mass capability making ULA more competitive within the commercial sector. This initiative is targeted to begin operation in 2026. • Blue Origin is developing their New Glenn rocket for “operational reusability” but they have not yet publicly indicated reusing their 2nd stage. An inflatable aerodynamic decelerator is a technology that may enable reusability of the second stage. • Rocket Lab has announced reusability plans for their Neutron Rocket. Rocket Lab is also developing missions to Venus and Mars which both have atmospheres.

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