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La NASA identifica causa de pérdida de material del escudo térmico de Orion de Artemis I


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El 28 de junio de 2024, la nave espacial Orion de Artemis II es retirada de la Celda de Ensamblaje Final y Pruebas del Sistema (FAST, por sus siglas en inglés) y colocada en la cámara de altitud oeste dentro del Edificio de Operaciones y Revisión del Centro Espacial Kennedy de la NASA en Florida. Dentro de la cámara de altitud, la nave espacial se sometió a una serie de pruebas que simulaban las condiciones de vacío del espacio profundo.
Crédito de la foto: NASA / Rad Sinyak

Read this story in English here.

Tras extensos análisis y pruebas, la NASA ha identificado la causa técnica de la pérdida imprevista de material carbonizado en el escudo térmico de la nave espacial Orion de Artemis I.

Los ingenieros determinaron que, cuando Orion regresaba de su misión sin tripulación alrededor de la Luna, los gases generados dentro del material ablativo exterior del escudo térmico, denominado Avcoat, no pudieron ventilarse y disiparse como estaba previsto. Esto permitió que se acumulara presión y se produjeran grietas, lo que causó que parte del material carbonizado se desprendiera en varios lugares.

“Nuestros primeros vuelos de Artemis son una campaña de prueba, y el vuelo de prueba de Artemis I nos dio la oportunidad de comprobar nuestros sistemas en el entorno del espacio profundo antes de incorporar a la tripulación en futuras misiones”, dijo Amit Kshatriya, administrador asociado adjunto de la Oficina del programa De la Luna a Marte, en la sede de la NASA en Washington. “La investigación sobre el escudo térmico ayudó a garantizar que comprendiéramos completamente la causa y la naturaleza del problema, así como el riesgo que les pedimos a nuestras tripulaciones que asuman cuando emprendan su viaje a la Luna”.

Los hallazgos


Los equipos técnicos adoptaron un enfoque metódico para comprender e identificar el origen del problema de pérdida de material carbonizado, incluyendo el muestreo detallado del escudo térmico de Artemis I, la revisión de las imágenes y los datos de los sensores de la nave espacial, y pruebas y análisis exhaustivos en tierra.

Durante Artemis I, los ingenieros utilizaron la técnica de guiamiento de reentrada atmosférica doble para el regreso de Orion a la Tierra. Esta técnica ofrece más flexibilidad ya que amplía el alcance del vuelo de Orion después del punto de reentrada para llevarlo hasta un lugar de amerizaje en el océano Pacífico. Con esta maniobra, Orion se sumergió en la parte superior de la atmósfera de la Tierra y utilizó la resistencia atmosférica para reducir su velocidad. A continuación, Orion utilizó la sustentación aerodinámica de la cápsula para rebotar y salir de nuevo de la atmósfera, para luego volver a entrar en el descenso final con paracaídas para su amerizaje.

Utilizando los datos de la respuesta del material Avcoat de Artemis I, el equipo de investigación pudo simular el entorno de la trayectoria de entrada de Artemis I —una parte clave para comprender la causa del problema— dentro de la instalación de chorro en arco del Centro de Investigación Ames de la NASA en California. Observaron que, durante el período entre las inmersiones en la atmósfera, las tasas de calentamiento disminuyeron y la energía térmica se acumuló dentro del material Avcoat del escudo térmico. Esto condujo a la acumulación de gases que forman parte del proceso de ablación (desgaste) previsto. Debido a que el Avcoat no tenía “permeabilidad”, la presión interna se acumuló y produjo el agrietamiento y el desprendimiento desigual de la capa exterior.

Los equipos técnicos realizaron extensas pruebas en tierra para simular el fenómeno de rebote en la reentrada antes de la misión Artemis I. Sin embargo, hicieron pruebas a velocidades de calentamiento mucho más altas que las que la nave espacial experimentó durante su vuelo. Las altas velocidades de calentamiento puestas a prueba en tierra permitieron que el material carbonizado permeable se formara y se desgastara como estaba previsto, liberando la presión del gas. El calentamiento menos severo observado durante la reentrada real de Artemis I desaceleró el proceso de formación de material carbonizado, al tiempo que siguió creando gases en esta capa de material. La presión del gas se acumuló hasta el punto de agrietar el Avcoat y liberar partes de la capa carbonizada. Las mejoras recientes en la instalación de chorro en arco han permitido una reproducción más precisa de los entornos de vuelo registrados por Artemis I, de modo que este comportamiento de agrietamiento pudo demostrarse en pruebas en tierra.

Si bien Artemis I no estaba tripulado, los datos del vuelo mostraron que, si la tripulación hubiera estado a bordo, habría estado a salvo. Los datos de la temperatura de los sistemas del módulo de tripulación dentro de la cabina también estaban dentro de los límites y se mantenían estables, con temperaturas alrededor de los 24 grados centígrados (75 grados Fahrenheit). El desempeño del escudo térmico superó las expectativas.

Los ingenieros comprenden tanto el fenómeno material como el entorno con el que interactúan los materiales durante la entrada a la atmósfera. Al cambiar el material o el entorno, pueden predecir cómo responderá la nave espacial. Los equipos de la NASA acordaron por unanimidad que la agencia puede desarrollar un análisis de vuelo aceptable que mantenga a la tripulación segura utilizando el actual escudo térmico de Artemis II con cambios operativos para su entrada en la atmósfera.

El proceso de investigación de la NASA

Poco después de que los ingenieros de la NASA descubrieran las condiciones del escudo térmico de Artemis I, la agencia comenzó un extenso proceso de investigación, el cual contó con un equipo multidisciplinario de expertos en sistemas de protección térmica, aerotermodinámica, pruebas y análisis térmicos, análisis de estrés (fatiga de materiales), pruebas y análisis de materiales, y muchos otros campos técnicos relacionados. El Centro de Ingeniería y Seguridad de la NASA también participó para aportar su experiencia técnica, incluyendo evaluación no destructiva, análisis térmico y estructural, análisis de árbol de fallas y otros métodos de respaldo de las pruebas.

“Nos tomamos muy en serio nuestro proceso de investigación del escudo térmico, con la seguridad de la tripulación como la fuerza impulsora que mueve esta investigación”, dijo Howard Hu, gerente del Programa Orion del Centro Espacial Johnson de la NASA en Houston. “El proceso fue extenso. Le dimos al equipo el tiempo necesario para investigar todas las causas posibles, y trabajaron incansablemente para asegurarse de que entendiéramos el fenómeno y los pasos necesarios para mitigar este problema en futuras misiones”.

El escudo térmico de Artemis I estaba muy cargado de instrumentos para este vuelo, e incluía sensores de presión, extensómetros y termopares a diferentes profundidades del material ablativo. Los datos de estos instrumentos acrecentaron el análisis de muestras físicas, lo que permitió al equipo validar modelos informáticos, crear reconstrucciones de entornos, proporcionar perfiles de temperatura interna y dar información sobre el momento de la pérdida de material carbonizado.

Alrededor de 200 muestras de Avcoat fueron extraídas del escudo térmico de Artemis I en el Centro de Vuelo Espacial Marshall de la NASA en Alabama para su análisis e inspección. El equipo llevó a cabo una evaluación no destructiva para “ver” dentro del escudo térmico.

Uno de los hallazgos más importantes que arrojó el examen de estas muestras fue que algunas superficies en la zona del Avcoat permeable, las cuales habían sido identificadas antes del vuelo, no sufrieron agrietamiento ni pérdida de material carbonizado. Dado que estas superficies eran permeables al comienzo de la entrada en la atmósfera, los gases producidos por la ablación pudieron ventilarse adecuadamente, eliminando la acumulación de la presión, el agrietamiento y la pérdida de material carbonizado.

Los ingenieros hicieron ocho campañas separadas de pruebas térmicas posteriores al vuelo para respaldar el análisis del origen de estas condiciones, y completaron 121 pruebas individuales. Estas pruebas fueron llevadas a cabo en instalaciones en diferentes lugares de Estados Unidos que cuentan con capacidades únicas, entre ellas: la Instalación de Calentamiento Aerodinámico en el Complejo de Chorro en Arco del centro Ames, para poner a prueba perfiles de calentamiento convectivo con diversos gases de prueba; el Laboratorio de Evaluación de Materiales Endurecidos por Láser en la Base de la Fuerza Aérea Patterson-Wright en Ohio, con el fin de poner a prueba perfiles de calentamiento radiativo y proporcionar radiografías en tiempo real; y la Instalación de Calentamiento por Interacción del centro Ames, para poner a prueba perfiles combinados de calentamiento convectivo y radiativo en el aire en bloques completos, esto es, aplicando todas las pruebas en cada bloque de material.

Los expertos en aerotermia también completaron dos campañas de pruebas en el túnel de viento hipersónico del Centro de Investigación Langley de la NASA en Virginia y en las instalaciones de pruebas aerodinámicas del CUBRC en Buffalo, Nueva York, para realizar pruebas con una diversidad de configuraciones de pérdida de material carbonizado, y mejorar y validar los modelos analíticos. También se realizaron pruebas de permeabilidad en el centro Kratos en Alabama, en la Universidad de Kentucky y en el centro Ames para caracterizar aún mejor el volumen elemental y la porosidad del Avcoat. La instalación de pruebas del centro de investigaciones Advanced Light Source, una instalación para usuarios científicos del Departamento de Energía de Estados Unidos en el Laboratorio Nacional Lawrence Berkeley, también fue utilizada por los ingenieros para examinar el comportamiento del calentamiento del Avcoat a nivel microestructural.

En la primavera de 2024, la NASA creó un equipo de revisión independiente que realizó una revisión exhaustiva del proceso de investigación, los hallazgos y los resultados de la agencia. La revisión independiente fue dirigida por Paul Hill, un exdirectivo de la NASA que se desempeñó como director principal de vuelo del transbordador espacial para el programa Return to Flight (Regreso a los vuelos) después del accidente del Columbia, quien también dirigió la Dirección de Operaciones de Misiones de la NASA y es miembro actual del Panel Asesor de Seguridad Aeroespacial de la agencia. La revisión se llevó a cabo durante un período de tres meses a fin de evaluar las condiciones del escudo térmico posteriores al vuelo, los datos del entorno para la entrada a la atmósfera, la respuesta térmica del material ablativo y el avance de las investigaciones de la NASA. El equipo de revisión estuvo de acuerdo con los hallazgos de la NASA sobre la causa técnica del comportamiento físico del escudo térmico.

Avances en el escudo térmico

Al saber que la permeabilidad de Avcoat es un parámetro clave para evitar o minimizar la pérdida de material carbonizado, la NASA tiene la información correcta para garantizar la seguridad de la tripulación y mejorar el desempeño de los futuros escudos térmicos del programa Artemis. A lo largo de su historia, la NASA ha aprendido de cada uno de sus vuelos e incorporado mejoras en el hardware y las operaciones. Los datos recopilados a lo largo del vuelo de prueba de Artemis I han proporcionado a los ingenieros información valiosísima para guiar futuros diseños y refinamientos. Los datos de desempeño del vuelo de retorno lunar y un sólido programa de calificación de pruebas en tierra, mejorado después de la experiencia del vuelo de Artemis I, están respaldando las mejoras en la producción del escudo térmico de Orion. Los futuros escudos térmicos para el regreso de Orion en las misiones de alunizaje de Artemis están en producción para lograr una uniformidad y permeabilidad consistente. El programa de calificación se está completando actualmente, junto con la producción de bloques de Avcoat más permeables, en la Instalación de Ensamblaje Michoud de la NASA en Nueva Orleans.

Para obtener más información sobre las campañas Artemis de la NASA, visita el sitio web (en inglés):

https://www.nasa.gov/artemis

-fin-


Meira Bernstein / Rachel Kraft / María José Viñas
Sede, Washington
202-358-1600
meira.b.bernstein@nasa.gov / rachel.h.kraft@nasa.gov / maria-jose.vinasgarcia@nasa.gov

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      Crews are well underway with parallel preparations for the Artemis II flight, as well as buildup of NASA’s mobile launcher 2 tower for use during the launch of the SLS (Space Launch System) Block 1B rocket, beginning with the Artemis IV mission. This version of NASA’s rocket will use a more powerful upper stage to launch with crew and more cargo on lunar missions. Technicians have begun upper stage umbilical connections testing that will help supply fuel and other commodities to the rocket while at the launch pad.
      In summer 2024, technicians from NASA and contractor Bechtel National, Inc. completed a milestone called jack and set, where the center’s mega-mover, the crawler transporter, repositioned the initial steel base assembly for mobile launcher 2 from temporary construction shoring to its six permanent pedestals near the Kennedy’s Vehicle Assembly Building.   
      Teams at Bechtel National, Inc. use a crane to lift Module 4 into place atop the mobile launcher 2 tower chair at its park site on Jan. 3, 2025, at Kennedy Space Center in Florida. Module 4 is the first of seven modules that will be stacked vertically to make up the almost 400-foot launch tower that will be used beginning with the Artemis IV mission.Betchel National Inc./Allison Sijgers “The NASA Bechtel mobile launcher 2 team is ahead of schedule and gaining momentum by the day,” stated Darrell Foster, ground systems integration manager, NASA’s Exploration Ground Systems Program at NASA Kennedy. “In parallel to all of the progress at our main build site, the remaining tower modules are assembled and outfitted at a second construction site on center.”
      As construction of the mobile launcher 2’s base continues, the assembly operations shift into integration of the modules that will make up the tower. In mid-October 2024, crews completed installation of the chair, named for its resemblance to a giant seat. The chair serves as the interface between the base deck and the vertical modules which are the components that will make up the tower, and stands at 80-feet-tall.
      In December 2024, teams completed the rig and set Module 4 operation where the first of a total of seven 40-foot-tall modules was stacked on top of the chair. Becthel crews rigged the module to a heavy lift crane, raised the module more than 150-feet, and secured the four corners to the tower chair. Once complete, the entire mobile launcher structure will reach a height of nearly 400 feet – approximately the length of four Olympic-sized swimming pools placed end-to-end.
      On the opposite side of the center, test teams at the Launch Equipment Test Facility are testing the new umbilical interfaces, which will be located on mobile launcher 2, that will be needed to support the new SLS Block 1B Exploration Upper Stage. The umbilicals are connecting lines that provide fuel, oxidizer, pneumatic pressure, instrumentation, and electrical connections from the mobile launcher to the upper stage and other elements of SLS and NASA’s Orion spacecraft.
      “All ambient temperature testing has been successfully completed and the team is now beginning cryogenic testing, where liquid nitrogen and liquid hydrogen will flow through the umbilicals to verify acceptable performance,” stated Kevin Jumper, lab manager, NASA Launch Equipment Test Facility at Kennedy. “The Exploration Upper Stage umbilical team has made significant progress on check-out and verification testing of the mobile launcher 2 umbilicals.”
      https://www.nasa.gov/wp-content/uploads/2025/01/eusu-test-3-5b-run-1.mp4 Exploration Upper Stage Umbilical retract testing is underway at the Launch Equipment Test Facility at Kennedy Space Center in Florida on Oct. 22, 2024. The new umbilical interface will be used beginning with the Artemis IV mission. Credit: LASSO Contract LETF Video Group The testing includes extension and retraction of the Exploration Upper Stage umbilical arms that will be installed on mobile launcher 2. The test team remotely triggers the umbilical arms to retract, ensuring the ground and flight umbilical plates separate as expected, simulating the operation that will be performed at lift off.
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