D O

T S E T
E
L CK E
O
R IEN C
SC

Combustion
Engine
How does it work

Temperature inside the chamber

3000K
Environment and the loads experienced
Pressure Temperature Corrosion
<100MPa 200K-1500K
Manufacturing
Baffles for combustion
stability

High temperature of the

product

High impulse due to com

reaction
Injector plate

Low temperature of fuel

Easier drilling of holes and

combining different parts
Gimbals
Propellant ducts

Withstand low temperatures

Strong and non corrosive

High yield strength
Manufacturing
Gardner Bellows
Stainless steel, Titanium alloys, Inconels
Future Materials and potential problems
Helmholtz resonators replacing baffles to
counter combustion instability
Space Probe

11
 Space Probes
● Space probe is an unpiloted, unmanned device sent to
explore space and gather scientific information.
● Space probe is launched from Earth with a set of
scientific instruments and tools used to study the
atmosphere and composition of space and other planets,
moons, or celestial bodies
● Probes transmit data from space by radio
● Probes will study samples taken from comets, asteroids

12
 Space Probes

Three types
• Interplanetary (fly by celestial body)
• Orbiter (placed on a orbit around celestial body)
• Lander (lands on celestial body and gather information)

13
 Lander
• A lander is a spacecraft which descends toward and comes
to rest on the surface of an astronomical body
• It gathers information about the planet and takes pictures

Phoenix Mars Lander; Credits: NASA 14

 Rover
● A space exploration vehicle designed to move across the
surface of a planet.
● Rovers are created to land on another planet, to find out
information and to take pictures. samples like dust, rocks.

15
Mars Rover Curiosity; Credits: NASA
Landing on Mars

16
 Aeroshell
● Al honeycomb structure sandwiched
between graphite epoxy face sheets
● Outside is phenolic materials filled with
ablator-cork wood, silica glass sphere —
0.5 inch thick layer — dissipates heat
● Temperature of atmosphere is 1447OC

Built by the Lockheed Martin

Astronautics CO. in Denver, CO
Credits: NASA

Aeroshell enters in the Martian

atmosphere, an artistic view

17
 Parachutes
● Deployed at height 30000 feet
from Mars Surface
● Made of lightweight fabrics
polyester and nylon
● 40% Larger than the Lander,
packed with pressure
● Parachute has a triple bridle
Which tethers that connect the
parachute to the backshell
● Triple bridle made of Kevlar, a
high strength material works in Curiosity Rover’s Parachutes system,
-196OC-160OC temperature An artistic concept of Mars Science
Laboratory
range
18
Separation of Lander

● After the Separation of Heat

shield Lander also separates at
20000 feet height from Mars
surface
●  Zylon (Polybenzobisoxazole) a
synthetic polymer having high
tensile strength (5.8 GPa) and
Thermal stability
● Zylon provides the spaces to
deploy the airbags

Credits: NASA 19
 Airbags
• Airbag inflate to protect the lander for a
soft landing over the hard Martian surface
• 24 lobes when fully inflated
• Made from a very durable, synthetic
material called Vectran, an aromatic
polymer fiber, spun from a liquid crystal
polymer

• Vectran is thermal stability at high

temperatures, high strength, low creep,
and good chemical stability. moisture-
resistant. MER Airbags, Credits: NASA

• Polyurethane coating can improve abrasion resistance

and act as a water barrier.
• As it has high resistance to ultraviolet radiation, it can be
used long-term in outdoor environments if inspected
regularly
20
 The Lander Structure
● The lander is a strong, lightweight
structure, consisting of a base and
three sides "petals" in the shape of a
tetrahedron (pyramid-shaped).
● consists of beams and sheets that are
made from a "composite“ such as
fiberglass
● The lander beams are made out of
carbon-based layers of graphite fiber
woven into a fabric.
● The Rover is held inside the lander
with bolts and special nuts that are
released after landing with small
explosives.

Pheonix mars lander, credits: NASA

21
 Rover
● The Mars Exploration Rovers act
as robot geologists while they
are on the surface of Mars.

● Rover has

1. Body
2. Brains
3. Temperature controls
4. Neck and Head
5. Eyes and other "senses
6. Arms
7. Wheels and legs
Mars Rover Spirit, Credits: NASA
8. Energy
9. Communications
22
 Rover : Body
● The rover body is called the warm electronics box(WEB) the outer layer of
rover’s body protects its computer, electronics, and batteries

● The warm electronics box is closed on the top by a triangular piece called the
Rover Equipment Deck (RED). RED makes the rover like a convertible car

● RED allows a place for the

rover mast and cameras to sit out
in the Martian air, taking pictures
and clearly observing the Martian
terrain as it travels.
● The gold-painted, insulated walls
of the rover body also keep heat
in when the night temperatures
on Mars can drop to -96 deg C

Mars Rover Curiosity, an artistic concept; Credits: NASA

23
 Materials used in Rover
● Mainly the composites used in lander
● Following metals are also used in different parts

Metals USES
Titanium Curiosity’s legs
Aluminium Curiosity’s wheel
Bronze Metal-polymer bearings are critical components in
the rover's drill
Lead and Tellurium Curiosity's power supply by a Radioisotope
Thermoelectric Generator that will use PbTe/TAGS
thermocouples produced by Teledyne Energy
Systems
Stainless steel Stainless steel gas generators provided the high-
pressure gas used to propel Curiosity's parachute
from the spacecraft

24
 Rover: Wheel
● Wheel is made from one piece of Aluminum

● The outside of the wheel is covered with a

black coating to provide additional
strength. Smooth surface also minimizes
the threat of the wheels getting caught up
in the deflated airbags

● The “yellow filling" between the spaces in

the spiral flexure is an open-cell foam
called Solimide. It was cut into crescent
shapes and bonded to the wheel. Curiosity’s Wheel; Credits: NASA

● The wheel could pick up rocks and debris and cause a problem. Solid shock
absorber can’t be used. Solimide maintains its flexibility even at very low
temperatures and ideal for Martian atmosphere

25
Damage: Curiosity Wheel

26
 3 Generations of Mars Rover

Sojourner from Mars Pathfinder Project (1997); Spirit from Mars Exploration Project (2004);
Curiosity from Mars Science Laboratory Project (2012); Credits: NASA 27
Space Suits: What to wear
that won’t wear away?
What is a Spacesuit?
• A spacesuit is much more than a set of clothes
astronauts wear on spacewalks. Composed of
numerous tailor-made components, a fully equipped
spacesuit is really a one-person spacecraft.
• It is designed to protect them from the potentially
damaging conditions experienced in space.
• Spacesuits are also known as Extravehicular
Mobility Units (EMUs) to reflect the fact that they
are also used as mobility aides when an astronaut
takes a space walk outside of an orbiting spacecraft.
 Adverse conditions faced
in Space: Need for a spacesuit
• The
• The outer space is mostly vacuum. Absence of consistent pressure means
there is no breathable Oxygen.
• The zero pressure condition faced in Space
• The continuous impact of tiny bits of space-dust, micrometeoroids
• Temperature can vary from -459.4F (~0K) to 250F. This kind of extreme
temperatures must be tolerated.
• The harmful solar and cosmic radiation is also very dangerous for lifeforms.
Materials used in manufacturing a spacesuit:
Numerous raw materials are used for constructing a spacesuit,
• Fabric materials include a variety of different synthetic polymers. The innermost
layer is made up of a Nylon tricot material. Another layer is composed of spandex,
an elastic wearable polymer. There is also a layer of urethane-coated nylon, which
is involved in pressurization. Dacron—a type of polyester—is used for a pressure-
restraining layer. Other synthetic fabrics used include Neoprene that is a type of
sponge rubber, aluminized Mylar, Gortex, Kevlar, and Nomex.
• Fiberglass is the primary material for the hard upper torso segment.
• A polycarbonate material is used for constructing the shell of the helmet.
• Lithium hydroxide is used in making the filter which removes carbon dioxide and
water vapor during a space walk.
• A silver zinc blend comprises the battery that powers the suit. Plastic tubing is
woven into the fabric to transport cooling water throughout the suit.
Different components
of a spacesuit
The spacesuit can be broadly differentiated into
five components,-
• Helmet and communications carrier assembly
(CCA)
• Primary life support subsystem (PLSS)
• Upper torso, including the Hard Upper Torso
(HUT), the arm assembly, the EVA gloves and in-
suit drink bag
• Lower torso assembly
• Liquid cooling and Ventilation garment
The Helmet and CCA:
• The clear plastic bubble of the helmet and the
extravehicular visor assembly is made of
polycarbonate material. The bubble is
covered by the Extravehicular Visor Assembly.
The visor is coated with a thin layer of gold
that filters out the sun's harmful rays. The
visor also protects the spacewalker from
extreme temperatures and small objects that
may hit the spacewalker.
Primary Life Support Subsystem:
•  The unit is covered with 14 protective
cloth layers. The liquid cooling and
ventilation garment makes up the first
three layers. On top of this garment is
the bladder layer, to create the proper
oxygen pressure for the body. The next
layer holds it to the correct shape
around the astronaut's body. The ripstop
liner is the tear-resistant layer. The next
seven layers are Mylar insulation and
make the suit act like a thermos. They
also protect the spacewalker from being
harmed by small, high-speed objects
flying through space. The outer layer is
made of a blend of three fabrics.
Upper torso, Arms and Gloves assembly:
• Hard Upper Torso
The HUT covers the chest and back. It is a vest
made out of fiberglass. The Displays and
Control Module and Primary Life Support
Subsystem attach to this piece.
• EVA Gloves
EVA gloves are made to protect astronauts
from the space environment. They are also
made so spacewalkers can move their fingers
as easily as possible.
• In-Suit Drink Bag
A plastic, water-filled pouch attaches to the
inside of the Hard Upper Torso using Velcro. A
plastic tube with a valve sticks out of the bag.
Lower Torso assembly:
• Lower Torso Assembly
This section is made up of spacesuit pants, boots and the lower
half of the waist closure. A piece called the waist bearing helps
the astronaut move and turn. A metal body-seal closure
connects the lower torso to the hard upper torso.

The lower torso has D-rings to attach tethers.

Liquid Cooling and Ventilation Garment:
• Liquid Cooling and Ventilation
Garment
This underwear keeps spacewalkers
cool. It is made of stretchy spandex
material.
• The chilled water removes extra heat
as it circulates around the
crewmember's entire body. The
vents in the garment draw sweat
away from the astronaut's body.
Sweat is recycled in the water-
cooling system. Oxygen is pulled in
at the wrists and ankles to help with
circulation within the spacesuit.
 
Manufacturing Process:
• Helmet and visor assembly
The helmet is made of polycarbonate material. The helmet and the visor may be constructed using
traditional blow molding method. Pellets of polycarbonate are loaded into a injection-molding
machine. They are melted and forced into a cavity which as the approximate size and shape of the
helmet. When the cavity is opened, the primary piece of the helmet is constructed. A connecting
device is added at the open end so the helmet can be fastened to the hard upper torso. The
ventilation distribution pad is added along with purge valves before the helmet is packaged and
shipped. The visor assembly is similarly fitted with "head lamps" and communication equipment
Manufacturing Process:
• Upper and Lower torso :
The Hard Upper Torso (HUT) is made of fiberglass. The manufacturing
process for glass fibers suitable for reinforcement uses large furnaces to
gradually melt the silica sand, limestone, kaolin clay, fluorspar,
colemanite, dolomite and other minerals to liquid form. Then it is
extruded through bushings, which are bundles of very small orifices.
These filaments are then sized (coated) with a chemical solution. The
individual filaments are now bundled together in large numbers to
provide a roving.
Relevant materials and their corresponding
mechanical properties:
• Upper and Lower torso
• Fiberglass is a lightweight, extremely strong, and
robust material. Although strength properties
are somewhat lower than carbon fiber and it is
less stiff, the material is typically far less brittle,
and the raw materials are much less expensive.
Its bulk strength and weight properties are also
very favorable when compared to metals, and it
can be easily formed using molding processes.
• The plastic matrix may be epoxy, a thermosetting
plastic (most often polyester or vinylester) or
thermoplastic.
Relevant materials and their corresponding
mechanical properties:
• Helmet and Visor Assembly
Polycarbonate is a very durable material.
Although it has high impact-resistance, it
has low scratch-resistance and so a hard
coating is applied. This polymer is highly
transparent to visible light and has better
light transmission characteristics than many
kinds of glass.
The visor is coated with a very thin layer of
gold that absorbs the cosmic radiations.
Relevant materials and their corresponding
mechanical properties:
• Protective layers on the spacesuit
Seven layers of Aluminium Mylar
(metallised film) is put in the outer
portion of the suit. This works as an
insulator layer.
• Metallisation is performed using
a physical vapour deposition
process. The metal is heated and
evaporated under vacuum. This
condenses on the cold polymer
film, which is unwound near the
metal vapour source.
Problems and potential future materials:
• The stiffness experienced by the
spacewalkers makes free
movements extremely difficult.
• This problem is overcome by
using different joints.
• The upper torso, the arms and
legs were strengthened with
reinforced nylon fabric that did
not stretch when inflated.
• But weight of the spacesuits is
still an issue. Each of the present
day spacesuits weigh about 125
Kg.
Thermal
Protection
System
“We have declared that the
thermal protection system [is]
not suspect ”
-Wayne Hale

Shayani Parida
STRUCTURE OF SPACE
SHUTTLE
● The orbiter's structure was made
primarily from Aluminium alloy.

● Aluminium's light weight

(ρ=2698 kg m-3), high strength, easy
availability and easy workability
make it ideal for making structural
elements for space crafts.

45
STRUCTURE OF SPACE
SHUTTLE
But Aluminium has
....

● Low melting point(933.5K)

● High thermal expansion
coefficient
● High thermal conductivity

Thus, Space shuttles need good thermal insulation coating on the

Aluminium frame to protect the interior during the searing 1510°C heat
of atmospheric re entry and bitter cold (-121°C) temperatures of
space.
 METHODS OF THERMAL
PROTECTION
● Ablative heat shields

One way to dissipate this large

amount of thermal
energy is with a heat shield that
works by ablation, that is by parts
of it melting or vaporizing and
breaking off in order to carry the
heat harmlessly away. This
technique was used for re
entering Mercury, Gemini,
and Apollo. 47
ABLATIVE HEAT SHIELDS
● Carbon phenolic is a very
effective ablative
material, but also has
high density which is
undesirable.
● If the heat flux
experienced by an entry
vehicle is insufficient to
cause pyrolysis then the
TPS material's
conductivity could allow
heat flux conduction.
THE SPACE SHUTTLE'S TILES
 Challenges:
The system had to
integrate with other
subsystems. The
Orbiter’s surfaces were
exposed to exceedingly
high temperatures and
needed reusable,
lightweight, low-cost
thermal protection. The
vehicle also required low
vulnerability to orbital
debris and minimal
thermal conductivity
LI-900 TILES
● High-temperature reusable surface
insulation (HRSI)

HRSI tiles provided protection

against temperatures up to
1,260 °C .They covered the
landing gear doors, external
tank umbilical connection
doors, and the rest of the
orbiter's under surfaces.  

50
HSRI TILE
LOW-TEMPERATURE REUSABLE
SURFACE INSULATION (LRSI)
These covered the upper wing
near the leading edge. They
were also used in selected areas
of the forward, mid, and aft
fuselage, vertical tail, and the
OMS/RCS pods. These tiles
protected areas where reentry
temperatures are below 650 °C.
MANUFACTURING PROCESS

Lockheed Missiles and space Company

Manufacturing Process

● The coating used for improving thermal

emissivity is of borosilicate glass , with
silicon carbide to further improve
emissivity . The fact that both Silica and
glass were silicon dioxide ensured low
thermal misfit.
NON-TILE TPS
● Reinforced Carbon-Carbon (RCC)
This material withstood reentry
temperatures up to 1,710 °C
protected the wing leading edges
and nose cap.

● To provide oxidation resistance for

reuse capability, the outer layers of
the RCC were coated with silicon
carbide. The silicon-carbide coating
protected the carbon-carbon from
oxidation
● High density

55
TILES PROFILE
STRAIN INSULATION PAD
● A thin pad of heat resistant nomex
felt fabric cushions each tile against
the aluminum body of the Space
Shuttle orbiter. Called a strain
isolation pad, the fabric allows the
vehicle to flex during the strain of
liftoff, maneuvering, and reentry
without cracking the hard tiles.
TESTING

Thermal stress
Pre flight thermal stress analysis was performed
on the TPS tile under the most severe
temperature gradient during simulated re entry.
The tensile thermal stress induced in TPS tile
was found to be much lower than the tensile
strength of TPS material. The thermal bending of
the TPS tile was not severe enough to cause
tearing of the SIP layer
NASA Technical Memorandum 88276
FATIGUE LOADING
Investigation of the expected lifetime of densified tile TPS under
both sinusoidal loading and random loading simulating flight
conditions indicates that the strain isolation pads are the weakest
components of the TPS under fatigue loading. The felt pads loosen
under repetitive loading.
The RCC was highly resistant to fatigue loading that was
experienced during ascent and entry.

Shuttle Performance: Lessons Learned, Pt. 2; p 1009-1024

COLUMBIA DISASTER

60
COLUMBIA DISASTER

● An apparently
harmless 1kg
piece of foam
debris had blown
a hole in the in
the
“indestructible
RCC” on the left
wing.
61
COLUMBIA DISASTER
● Their flawed
reasoning
combined with
wrong
assumptions in
modelling the
impact (that
predicted the
depth to which
the foam debris
would penetrate
a Thermal
Protection
System tile),
ultimately led
seven astronauts
to pay with their
lives.
10 YEARS HENCE……
● Tougher ceramics
New ceramics are inspired by a material called
nacre, also known as mother-of-pearl.
http://www.livescience.com/44705-breaking-the-mold-nature-inspires-
tougher-ceramics.html

● Workable ceramics
3-D printing techniques are being experimented
to produce ceramics in various shapes.

● Lighter ceramics
A new type of material, made up of nanoscale
struts crisscrossed like the struts of a tiny Eiffel
Tower, is one of the strongest and lightest
substances ever made.
● https://www.technologyreview.com/s/530611/a-super-strong-and-
lightweight-new-material/
 THANK YOU..!!
 Aritrajit Gupta
 Harsha Nallabothula
 Shayani Parida
 Souvik Mandal