progress in manufacturing& characterizingdomestic lyocell ... · opag_feb_2018_pica d_poster...
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ProgressinManufacturing &Characterizing DomesticLyocellPICA(PICA-D)andComparisontoHeritagePICAEthirajVenkatapathy,MaireadStackpooleandMatthewGasch,NASAAmesResearchCenter,MoffettField,CA94035
SteveViolette,FiberMaterialsInc.,Biddeford,ME04005
1.Background– PICAandPICASustainabilityStateoftheArtLowDensityCarbonPhenolicAblators
StardustSRCpostflightwithPICAforebodyheatshield(0.8mmax.diameter)
AcknowledgementsPICAsustainabilityactivitiesarefundedbyNASA’sPlanetaryScience
DivisionoftheScienceMissionDirectorate
NetCasting,BilletFabricationandInfusion
TrimmedpriortoinfusionPost-infusion
Post-gel
Trimmed X-ray(fiberalignmentandFOD/voidcheck
Castunitdensitycouponcutplan
Density(g/cc) FailureStress(psi)
AverageLyocellIPproperties 0.28
246.48
(vs190for rayonPICA)AverageLyocellTTTproperties 0.28
44.03
(vs49.6for rayonPICA)
MechanicalPropertyComparison ThermalPropertyComparison
BilletID SpecimenID
ThermalConductivity(BTU-in/hr-ft2-oF)at100°F at350°F
AverageLyocellTTTproperties 0.939 1.32
AverageRayonTTTproperties 1.22 1.66
• In2016NASAARClearnedthattheheritagerayonutilizedinPICAwasstoppingproduction,leadingtoaflight-qualifiedPICAsustainabilitychallenge
• InFY16/17,NASAARCwasfundedbySMD/PSDtoaddressPICArayonsustainability
• LyocellBasedPICA(PICA-D)wasmanufacturedandlimitedtestingperformedshowingittobeagoodcandidateasapotentialreplacementforheritagerayon
• PhenolicImpregnatedCarbonAblator(PICA)isalowdensity(~0.27g/cm3)ablatorfirstusedastheforebodyheatshieldfortheStardustsamplereturncapsulewhereitwasusedasasinglepieceheatshield
• SinceStardust,PICAwasusedontheMarsScienceLab(MSL)inatiledconfiguration,ontheOSIRIS-REx samplereturncapsuleasasinglepieceandslatedforMars2020asatiledconfiguration
PICAProcessingSteps
RoleofRayon/LyocellinPICA
Manufacturing
RayonorLyocellConversiontocarbon
FiberForm® billetpreform
SinglepiecePICAheatshield(<1.00mmaxdiameter)Nearnetshapepreform
TiledPICAheatshield(>1.00mmaxdiam)
Rawmaterialsustainability
concern
4.ExplorationofLyocellPICA(PICA-D)forFutureMissions
5.PICA-DProjectSchedule
Lyocellisasustainabledomesticsourceofa“rayonalternative”fiberthatcanbeusedinthemanufactureofcarbonFiberForm®,theprecursortoPICA.
• EstablishingPICA-Dasa“dropinreplacement”willallowmissionstodependonanddesignmissionswithPICAwithoutanyrisktypicalofareplacement.
• EstablishingtheextendedcapabilityofPICA-DwillallowSampleReturnMissionswithhigherentryspeedthatwerenotconsideredbefore.
Task1:EstablishPICA-DasaDrop-inreplacementforHeritagePICA
– Developcomprehensivematerialpropertydatabase• Performcomprehensivematerialpropertytesting(rangeoftemperatures)forthermalandmechanicalproperties
– Performcomprehensivearcjettestcampaign• Testatmultipleconditions,includingdifferentmateriallots• Testingtoincludethermalresponse,instrumentedstagnationandwedgeshearcoupons
– DevelopPICA-DThermalResponseModelutilizingarcjettestdataandnewmaterialpropertydatabase
Task2:EstablishtheExpandedCapability(Extensibility)ofPICA-D
– DemonstrateManufacturingandScale-UpofaSinglePieceHeatshieldataScaleof>1.2mDiameter• PerformcomprehensivecharacterizationandevaluationofsinglepieceFiberFormcasting• Characterizefiberalignment,mechanicalpropertiesandnon-destructiveevaluation(NDE)
– EstablishExpandedDesignSpaceofPICA-D• Performarcjettestingandheatflux/pressureconditionsbeyondwhichPICAhaspreviouslybeentestedand/orflown
– PublishallPICA-DDataforcurrentandfuturemissions
InFY18/FY19,NASAAmesisleadinganeffortfundedbySMD-PSDtocharacterizeandextendthecapabilityofPICA-DtoEstablishLyocellPICAas
aDrop-InReplacementforHeritagePICA
2.EstablishmentofPICA-DasaReplacementforHeritagePICA• InFY17,SMD-PSDfundedARCtomanufactureandperformlimitedpropertyand
aerothermalcharacterizationofLyocell-basedPICA– FY17tasksuccessfullycompletedlimitedtestingthatindicatedtheviabilityofPICA-Dasa
potentialreplacementforheritagePICA
MaterialPropertyCharacterization• InFY17,3billetsofPICA-Dweremanufacturedtosupporttesting– LimitedIn-plane(IP)tension,through-thickness(TT)tension,andthroughthicknessthermal
conductivityat100Fand350FwereconductedandcomparedtoheritagerayonPICA
• OveralltheseresultsareinfamilywithproductionrayonPICA– howeveradditionaltestingisneededasonlyafewcouponswereevaluated– Limitedpropertydatahadsubstantialscatter– detailedtestingplannedforFY18/19
3.EstablishmentofPICA-DExpandedCapability• 9billetsofFiberFormweremanufacturedinFY17tooptimizetheprocessusing
Lyocellfibers– BilletsspannedthespecdensityrangeandbilletFiberFormtargetdensitieswereachieved
• Developmentandfabricationof30.8-mnet-shapedFiberFormheatshieldblank(OSIRISREx scale)werealsocompletedinFY17– Densitytargetsinall3netcastblankswereachieved
• Processrefinementsandlessonslearnedhavebeendocumented
• LimitedNonDestructiveEvaluation(NDE)completedontheLyocellnearnetshapeFiberFormunittoevaluatefiberalignmentandcheckforoff-nominalfeatures
• FY18/19workwillexpandontheworkperformedinFY17anddemonstraterepeatabilityaswellasincreasesinglepiecenetcastdimensionsto>1.2-m
ArcJetCharacterization
MaterialAveragecenterline
recession (1550W/cm2
and1.3atm)
Averagecenterlinerecession (400W/cm2
and0.3atm)
Averagecenterlinerecession (220W/cm2
and0.08atm)
LyocellDerivedPICA 4.0mm 6.02mm 3.79mm
RayonDerivedPICA 4.2mm 5.97mm 3.89mm
RayonDerivedPICA LyocellDerivedPICA
Posttest Posttest
Pretest Pretest LyocellDerivedPICARayonDerivedPICA
Examplein-depthTCTrace@1550W/cm2
RecessionComparison
• 3arcjetconditionsweretestedinFY17- NFproposersprovidedguidanceontestconditions- AllconditionswillberepeatedinFY18/19todemonstratedatarepeatability
Foragiventestcondition(sameruntime)initialresultsindicatethatrecessionandin-depthtemperaturebetweenaLyocellderivedPICAand
aheritagerayon-derivedPICAarecomparable
• NASAARCisworkingwithSMD-PSDtoaddressPICArayonsustainabilityconcerns
• InFY16/17,LyocellBasedPICA(PICA-D)wasmanufacturedandlimitedtestingperformedshowingittobeagoodcandidateasapotentialreplacementforheritagerayon
• EstablishingPICA-Dasa“dropinreplacement”willallowmissionstodependonanddesignmissionswithPICAwithoutanyrisktypicalofareplacement.
• EstablishingtheextendedcapabilityofPICA-DwillallowSampleReturnMissionswithhigherentryspeedthatwerenotconsideredbefore.
6.Summary
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