Entry Systems Modeling (ESM): Advanced Ablator Development

The long-term goal of the Advanced Ablators task involves the development of novel ablative TPS materials for extremely challenging (e.g. high heat load) proposed future missions. Previous development work on conformal ablators resulted in the Conformal 1 ablator that demonstrated superior integrated heat load capability compared to SoA PICA at comparable bulk density, however, surface recession rates were significantly higher due to excessive loss of poorly interlocked fibers. The degree of interlocking will be improved through the use of commercially available needling capability. Establishing a needled felt capability and the development of polymer resins with improved performance compared to phenolic resin also has the potential to benefit woven ablators capability This task has three objectives:

1. Development of alternative ablative resins with enhanced thermal properties
2. Development of at least two TPS families utilizing advanced resin systems
   1. Low density, <0.5 g/cm³, with 500 W/cm² peak heating capability.
   2. High density, >0.5 g/cm³, with 1000 W/cm² peak heating capability
3. Computational materials modeling to support the material development tasks

The effort will offer ablative TPS material solutions as well as supporting analysis tools for far-term NASA missions in context with relevant heating environment. This involves maturing existing families of resin materials that have demonstrated the potential for improved system performance compared to the current state-of-the-art.

The task will have an experimental element and a modeling element. The efforts under the task will be coordinated with other groups and NASA centers (ARC, GRC, JSC, LaRC).

Experimental element

1. Processing of robust conformable ablative systems through the development of improved methods for interlocking fibrous performs made from carbon, organic systems, and improved char strength polymer impregnation resins.
2. Chemical modification of resin systems to:

•  Increase flexibility of the polymer
•  Tailor density of conformal TPS

The work outlined in this task allows for the fundamental tailoring of TPS properties for a variety of entry environments while also providing appropriate balance between integrated heat load resistance and ablation recession. Specific ablative resins that will be considered include phenolic and polyimide.

Modeling element

Modeling will focus on improving the processing and properties of ablative composites by building chemically accurate models of crosslinked polymer networks, evaluate their mechanical/thermal properties and develop design strategies to improve strength, toughness, etc. of the resin (additives, etc). Establishment of solvent-resin interaction models will aid TPS infiltration and processing for better control of resin morphology and resulting TPS density. The modeling effort includes two primary activities:

1. Construction of chemical models of cross-linked polymer networks and their resulting thermal/mechanical properties.
2. Chemical modeling of solvent-resin interactions

• Successfully modifying resins for improved flexibility without substantially reducing ablative properties.
• Processing TPS with tailored densities with the constraint of maintaining in-family performance for medium and high density systems.
•  Assessing the effects of fiber chemistry, fiber geometry, and resin decomposition as intrinsic parameters of a multi-scale model.

This is early/mid-stage (TRL 4) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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