Thermo-Chemical and Mechanical Coupled Analysis of Swelling Char

Thermo-chemical and mechanical coupled
analysis of swelling charring and ablative

materials for re-entry application
G. PINAUD
ASTRIUM SPACE TRANSPORTATION, F-33165 St. Médard-en-Jalles, France
5th Ablation Workshop, Feb. 28th – Mar. 1st 2012, Lexington, Kentucky
Outline
Astrium
Norcoat Liege
OUTLINE Phenomena overview

and model
Experimental validation
Numerical simulation
Astrium Conclusion
Norcoat Liege
Phenomena overview
Aerothermodynamics
Conductive heat transfer
Pyrolysis
Ablation
Swelling
Conclusions & perspectives
G. Pinaud - 5th Ablation Workshop, Feb. 28th – Mar. 1st 2012, Lexington, Kentucky -2
Astrium
Norcoat Liege
Astrium:
Astrium part of EADS, a global Phenomena overview
and model
leader in aerospace and defence Numerical simulation
Conclusion
Astrium Space
Transportation
The European
prime contractor
for civil and RE-ENTRY SYSTEM
military space
&
transportation
and manned TECHNOLOGY DEPARTMENT
space activities
Thermal protection
systems for
interplanetary probes
ISS servicing
Interplanetary
exploration
Astrium
A material: Norcoat Liege Norcoat Liege

Phenomena overview
and model
Harvest of cork bark Beagle2 Heat-shield
From tree "Quercus suber"
to
space
Stockpiling Back cover of ARD
drying of bark
Grinding
in granules
NL molding
Mixing- Curing
NL sheets
Phenolic Resin Additives

Astrium
PHENOMENA OVERVIEW & MODEL Norcoat Liege

Phenomena overview
and model
Conclusion
Close up view on a side cut of the heat shield
Astrium

Phenomena overview
and model:
Side view
Conclusion
Boundary layer
Free stream flow
Thermal protection
material
Aero-shell
Astrium
Phenomena overview
and model:
Aerothermodynamic
Conclusion
Computation of the viscous boundary

layer heat transfer: Boundary layer
Radiation
Öconvective heat flux Free stream flow

Surface shear Convection
Ö shock radiation
Ö wall shear stress
Ö equilibrium and non equilibrium
air chemistry
Mutual Radiation
Internal Convection
Astrium
Phenomena overview
and model:
Conductive heat
transfer
Conclusion
Computation of the conductive heat

transfer in the material: Boundary layer
Ö standard Fourier's law

Ö material state (density) default
linear dependency
Heat conduction
λ = λ v − α [λ v − λ c ]
ρv − ρ
α =
ρv − ρ c
Astrium
Phenomena overview
and model:
Under heating, organic material Pyrolysis (1/2)

compounds start to degrade: Numerical simulation
Ö kinetics of the pyrolysis approached Conclusion
by multiple Arrhenius law

χ&i = Ai (ρv ) [ρv − ρc ] (1− χi )
Ei
1− Ni Ni −1 Ni −
RT
e Boundary layer
Decomposition
ρ (t ) Δρi
= 1. − ∑ χi gas blowing
ρv i =1, Narrh ρ v
Charred
Decomposition
100
90
Pyrolysis
80
70
MASS LOSS: [%]
60
50 Virgin
40
30
T G A : 5 K / m in
2 A rrh e n iu s la w s : 5 K /m in
20 T G A 2 0 K /s
2 A rrh e n iu s la w 2 0 K /s
T G A : 5 0 K /s
10 2 A rrh e n iu s la w 5 0 K /s
0
T E M P E R A T U R E : [K ]
Ö momentum conservation of the

gaseous products follows Darcy's law m& g
= − K P∇ P
for porous media ( and perfect gas
law)
Astrium
Phenomena overview
and model:
Pyrolysis (2/2)
Enthalpy of pyrolysis gas supposed Experimental validation

at thermal and chemical equilibrium Conclusion
with charred material
Ö Extrapolation at low
e
m
gi
re
temperature to keep constant
m
riu
endothermal heat of pyrolysis
b
ili
qu
e
al
ic
ΔH pyro(T , P) = H gaz (T , P) − H NL (T )
me
Ch
ρV H NL (T ) − ρC H NL (T ) Extrapolation
ΔH pyro(T , P) = H gaz (T , P) − V C
at constant ΔHpyro
ρV − ρC
Using quasi-steady state

assumption for pyrolysis gas
advective heat term
∂ ρ g H gaz (T , P )
<< ∇ ( m& g H gaz (T , P ))
∂t
G. Pinaud - 5th Ablation Workshop, Feb. 28th – Mar. 1st 2012, Lexington, Kentucky - 10
Astrium
Phenomena overview
and model:
Surface material is removed by: Ablation

Ö heterogeneous chemical reactions Numerical simulation
Conclusion
(oxydation with temperature
dependent rate)
m& c = fc (Tw ) Boundary layer
Ablation Original surface

Ö Heat of ablation taken into account
Charred Heatshield surface
ΔHc = ΔHc (Tw )

Ö mechanical spalation under shear
Virgin
stress
m& m = f m (Tw ,τ w )
Astrium
Phenomena overview
and model:
Volume expansion generated by: Swell (1/3 )

Ö in-depth structural and chemical Numerical simulation
Conclusion
decomposition initiated by heat
transfer
Ö internal pyrolysis gas product Boundary layer
pressure in cork cell

Heatshield surface
Charred
Prismatic cork cells membranes are Original surface
made of 2 main molecules: Swelling
Suberin
Lignin Virgin
responsible for flexbility and rigidity

Temperature increase
triggers mass
exchange between the
2 structural molecules
Ö cells wall become
more brittle
Astrium
Phenomena overview
and model:
At higher temperature: Swell (2/3 )

Öcell membrane thickness becomes Numerical simulation
Conclusion
thinner (mass loss)
Ö membranes start to stretch
1500
Ö membranes break-off
Considering:
Volume phenomenon 2000
Thermo-chemically decomposition
linked mechanical expansion
non-elastic expansion 2500
Ö choice of an Arrhenius kind law for

the strain rate evolution:
Temperature °C
∂ t ε s ∝ (ρ v ) [ρ v − ρ c ] (1 − χ s )
Es
1− N s N s −1 Ns −
RT
e
Astrium
Phenomena overview
and model:
Swelling numerically treated by a staggered Swell (3/3)

coupling scheme involving : Numerical simulation
Conclusion
Amaryllis for the thermal and
ablative response
Mecano for the mechanical
response
Supervisor as the interface and the
synchronisation of the chore modules
Need to implement A.L.E (arbitrary

Lagrangian Eulerian ) solution in Mecano to
take into account for the mesh deformation ⎧ τ ij , j + f i = 0
⎪ ∂P
(due to ablation) sent by Amaryllis ⎪⎪ f i = and τ ij = C ijkl (T , ρ )ε kl
T,ρ,χ i,P,X exchange at every time step and ⎨ ∂x i
⎪ ε ij = ε ij tot − αδ ij Δ T − F (T , P , ρ , χ i )
are used to solve for the stress and strain ⎪
⎪⎩ Eulerian + Lagrangian
Astrium
EXPERIMENTAL VALIDATION Norcoat Liege

Phenomena overview
Observation of swelling under various

and model:
environment Conclusion
Radiative furnace
Flat plate configuration
Max cold wall heat flux: ~500 kw/m2
Duration : ~ 80 s
Inner face thermocouple
Inductive plasma torch: Comete

Stagnation point configuration
Max cold wall heat flux 800 kW/m2
Internal thermocouple
Arcjet plasma: Simoun

Air/CO2 atmosphere
Max cold wall heat flux 1.8 MW/m2
Duration: ~60 s
Thermocouple plugs
Laser recession
Astrium

Phenomena overview
Radiative furnace
and model:
Conclusion
Perspective view of the specimen during exposure to
radiative heat flux
50
Measures
40
WALL DISPLACEMENT: [%]

30
20
Post-test direct
measurements
10
T=0 s T=22 s T=74 s T=100 s 0 100 200

TIME: [s]
300 400 500
Swell timeline
Specimen sheet after test
Final thickness
Initial thickness
Specimen sheet before test

Astrium

Phenomena overview
Comete inductive plasma torch

and model:
~800 kW/m2 Numerical simulation
Heat flux
Conclusion
Post-test direct
axial
measurements
T=0 s T=45 s T=150 s
20
Measures
15

10
Expansion
0
Recession
Specimen Specimen
-5
before test after test -10

0 50 100 150 200 250 300 350 400 450 500
TIME: [s]
Comparison of surface
scanned geometry Ö Strong lagged swelling effect on thickness
before/after test
Astrium

Phenomena overview
Simoun arc-jet plasma test

and model:
Conclusion
Cross section:
Charred, pyrolysis and
virgin layer
Specimen before test Specimen after test

10
Plasma shut down
0
M e a sure s La se r A
M e a sure s La se r B
-1 0
-2 0
Recession Top view of the sample

-3 0
at thermocouple plug
r
se
-4 0
location
La
on
ati
tur
-5 0
Sa
-6 0
Ö Due to high convective exchange coefficient,
-7 0 Expansion recession is dominating expansion
0 50 100 150 200
T IM E : [s]
Laser tracked surface motion

Astrium
NUMERICAL SIMULATION Norcoat Liege

Phenomena overview
and model:
Surface kinetic rebuilding including Experimental validation

Surface chemical recession Conclusion
Surface mechanical recession

Volume swelling
0.0025 0.0035 0.002
Plasma shut down

0.003
0 MeasuresLaserA
0.002 0.0025 MeasuresLaserB
WALL DISPLACEMENT: [m]
Simulation

0.002 -0.002
0.0015
0.0015
0.001 -0.004
0.0005
0.001 -0.006
Measures 0 Measures
ser
Simulation
n La
Simulation -0.0005
ratio
-0.008
0.0005
Satu
-0.001
-0.01
-0.0015
0
-0.002
0 100 200 300 400 0 50 100 150 200 250 300 350 400 450 500 -0.012
TIME:[s] TIME:[s] 0 50 100 150 200
TIME:[s]
Ö Optimization of the ablation law, and the swelling

Arrhenius law parameters to fit the surface motion,
density gradient and thermal thermocouple history
Astrium
CONCLUSION Norcoat Liege

Phenomena overview
and model:
New development in Amaryllis and Mecano were Experimental validation

successfully applied to model the behavior of a cork Conclusion
based Thermal Protection Material including:

conductive heat transfer
chemical decomposition (pyrolysis) kinetics and energy
chemical and mechanical ablation
thermally-generated volume swelling
For cork based material, ablation and swelling

cannot be dissociated in model rebuilding. Lagged
effects of swelling must be considered for checking
the reliability of post-test direct measurements
Samcef modules enable full coupling between

thermal, thermo-chemical and mechanical response
Ö various industrial issues when coupled thermal and mechanical
loads play an important rule could be treated
Astrium
CONCLUSION & FUTURE Norcoat Liege

Phenomena overview
and model:
Future model will focus on 2D orthotropic swelling Conclusion
material properties
f ie ld Den
pe rature sity
fi
Tem eld
Design a specific instrumentation for in-depth

characterization of swelling phenomena

Thermo-Chemical and Mechanical Coupled Analysis of Swelling Char

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Thermo-Chemical and Mechanical Coupled Analysis of Swelling Char

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Thermo-chemical and mechanical coupled

analysis of swelling charring and ablative

OUTLINE Phenomena overview

A material: Norcoat Liege Norcoat Liege

Stockpiling Back cover of ARD

Phenolic Resin Additives

PHENOMENA OVERVIEW & MODEL Norcoat Liege

Close up view on a side cut of the heat shield

PHENOMENA OVERVIEW & MODEL Norcoat Liege

Free stream flow

 Computation of the viscous boundary

Öconvective heat flux Free stream flow

 Computation of the conductive heat

Ö standard Fourier's law

 Under heating, organic material Pyrolysis (1/2)

Ö kinetics of the pyrolysis approached Conclusion

by multiple Arrhenius law

Ö momentum conservation of the

 Enthalpy of pyrolysis gas supposed Experimental validation

with charred material

Using quasi-steady state

 Surface material is removed by: Ablation

Ablation Original surface

ΔHc = ΔHc (Tw )

 Volume expansion generated by: Swell (1/3 )

pressure in cork cell

made of 2 main molecules: Swelling

responsible for flexbility and rigidity

 At higher temperature: Swell (2/3 )

Ö choice of an Arrhenius kind law for

 Swelling numerically treated by a staggered Swell (3/3)

 Need to implement A.L.E (arbitrary

EXPERIMENTAL VALIDATION Norcoat Liege

 Observation of swelling under various

Inductive plasma torch: Comete

Arcjet plasma: Simoun

EXPERIMENTAL VALIDATION Norcoat Liege

WALL DISPLACEMENT: [%]

T=0 s T=22 s T=74 s T=100 s 0 100 200

Specimen sheet after test

Specimen sheet before test

EXPERIMENTAL VALIDATION Norcoat Liege

 Comete inductive plasma torch

WALL DISPLACEMENT: [%]

before test after test -10

EXPERIMENTAL VALIDATION Norcoat Liege

 Simoun arc-jet plasma test

Specimen before test Specimen after test

Recession Top view of the sample

Laser tracked surface motion

NUMERICAL SIMULATION Norcoat Liege

 Surface kinetic rebuilding including Experimental validation

 Surface mechanical recession

Plasma shut down

WALL DISPLACEMENT: [m]

WALL DISPLACEMENT: [m]

Ö Optimization of the ablation law, and the swelling

CONCLUSION Norcoat Liege

 New development in Amaryllis and Mecano were Experimental validation

based Thermal Protection Material including:

 For cork based material, ablation and swelling

 Samcef modules enable full coupling between

CONCLUSION & FUTURE Norcoat Liege

Computation of the viscous boundary

Computation of the conductive heat

Under heating, organic material Pyrolysis (1/2)

Enthalpy of pyrolysis gas supposed Experimental validation

Surface material is removed by: Ablation

Volume expansion generated by: Swell (1/3 )

At higher temperature: Swell (2/3 )

Swelling numerically treated by a staggered Swell (3/3)

Need to implement A.L.E (arbitrary

Observation of swelling under various

Comete inductive plasma torch

Simoun arc-jet plasma test

Surface kinetic rebuilding including Experimental validation

Surface mechanical recession

New development in Amaryllis and Mecano were Experimental validation

For cork based material, ablation and swelling

Samcef modules enable full coupling between

Design a specific instrumentation for in-depth