Carbon Nanotube-enhanced Carbon-phenolic Ablator Material

Phenolic impregnated carbon ablator (PICA) is a thermal protection system (TPS) material developed at NASA Ames Research Center in the mid-90 s for Discovery missions. It was used on the Stardust return capsule heat shield which successfully executed the highest speed Earth entry to date on January 15, 2006. PICA is a porous fibrous carbon insulation infiltrated with phenolic resin, and is an excellent ablator that is effective for heating rates up to 1000 W/sq cm. It is one of several candidate TPS materials for the next generation of crewed spacecraft for Lunar and Mars missions. We will describe an ongoing research effort at NASA to improve mechanical properties of the phenolic matrix with carbon nanotubes. The aim is two-fold: to increase overall TPS strength during reentry and to improve Micrometeoroid/Orbital Debris (MMOD) protection in space. The former requires at least a good dispersion of nanotubes in phenolic, while the latter also requires covalent bonding between them to couple and transfer impact energy effectively from matrix to nanotubes. We will discuss the required chemical functionalization of nanotubes, processing issues and test results.