Additive Insulative Layer for Thermal Protection System

The Heatshield for Extreme Entry Environmental Technology (HEEET) project started as a solution to the difficult entry temperatures and conditions. Its design is robust for the extreme environments that it needs to survive. HEEET Thermal Protection Systems (TPS) is fabricated with two different layers. Recently NASA Ames Research Center (ARC) is exploring other options using this system to produce robust materials that can be scaled to environmental conditions for Mars and low earth orbit (LEO) and other planetary entry. This hybrid manufacturing solution that utilizes the tight weave of the carbon layer and the low fiber volume of the phenolic thermal insulation. The application will use the weaving process established by Bally Ribbon Mills (BRM) and needle punched layer that will be developed with BRM engineering and Thomas Jefferson University (formerly Philadelphia University / Philadelphia Textile) engineering and lab equipment. The BRM team is developing a TPS that can have thermal layers added after the weaving process using needle punching techniques.This effort is based on the work from the original proof of concept. It was proven that in an lab enviroment that a nonwoven webbing made of chopped insulation layer yarn fibers was able to bond to the insulation layer of the HEEET material. Continuing research will prove that the additive layer can be manufactured to increase the thickness while maintaining the fiber volume of the insulation layer of HEEET. This continued work will utilize two different manufacturing techniques for the nonwoven webbing that will be needle punched to the insulation layer, air laid web delivery (Rando)and wet laid web delivery (Southeastern Nonwovens). These two techniques will be explored to scale the thickness of the Additive Insulation Layer(AIL) to 0.5opening options for variable thickness TPS with increased speed to manufacture. The Heatshield for Extreme Entry Environmental Technology (HEEET) project started as a solution to the difficult entry temperatures and conditions. These heavy applications were developed for the Adaptable Deployable Entry Placement Technology (ADEPT) program. NASA Ames Research Center (ARC) is exploring other options using this system to produce robust materials that can be scaled to environmental conditions for Mars and low earth orbit (LEO) and other planetary entry. This hybrid manufacturing solution will utilize the tight weave of the carbon layer and the low fiber volume of the phenolic thermal insulation. It was proven that representative HEEET samples were able to be needle punched on Thomas Jefferson University engineering and lab equipment. BRM will weave a TPS with thermal layers added after the weaving process using needle punching techniques that will mimic the insulation layer using nonwovens. Delivery systems for the web that makes up the nonwoven needle punching layer are being explored at Rando Machine, air laid. The future of this innovation success is dependent on the ability refine the needle punching process to the woven and build the needed thickness while maintaining fiber volume. Identify the manufacturing process needed to produce nonwoven web Source partners that might be able to supply nonwoven utilizing the equipment manufacturers resources. Work on theoretical model for making the density of each layer the same to fabricate a consistent product. Weave representative layer. Fabricate a minimum of 6 samples for each nonwoven condition. Identify the exact source of Needle Punching aspect either at BRM or partnering. Complete needling process on both nonwoven samples. Testing of the physical and mechanical characteristics for Unified Materials. Testing of the woven and nonwoven for physical characteristics. The nonwoven ablative layer will also need a shear or peel strength. Identify the unified materials drawing and specification. This task will include the bond strength of the woven and nonwoven materials. Scaling of the manufacturing process and having preproduction activities identified. Validation plan for the ablative layer bonded to the prototype pieces. Identify fabrication process, FMEA and other manufacturing activities. The investigation of methods to produce the HEEET formed in shape and then have the insulation layer applied.
Benefits: The proposed technology for additive insulation layers on HEEET material offers an innovative perspective on re-entry vehicles system, including the principles of design for manufacturability as key points to reduce mass, delivery time and costs of the final product. This concept will prove itself as a viable thermal protection system (TPS) for entry, descent and landing of future exploration class payload missions such as Mars and other less aggressive entry environments. The proposed development of a nonwoven and HEEET hybrid material concept will pave the way for future development of specific materials for quickly adaptable entry, decent and landing systems with specific need thermal protection systems. This modifiable system will be essential in reducing cost and manufacturing time of thermal protection systems that do not need to withstand extreme conditions.