Development of Wireless Subsurface Microsensors for Health Monitoring of Thermal Protection Systems

Low cost access to space is a primary goal for both NASA and the U.S. aerospace industry. Integrated subsystem health diagnostics is an area where major improvements have been identified for potential implementation into the design of new reusable launch vehicles (RLVS) in order to reduce life cycle costs, increase safety margins and improve mission reliability. A number of efforts are underway to use existing and emerging technologies to establish new methods for vehicle health monitoring on operational vehicles as well as X-vehicles. This paper summarizes a joint effort between several NASA centers and industry partners to develop rapid wireless diagnostic tools for failure management and long-term TPS performance monitoring of thermal protection systems (TPS) on future RLVS. An embedded wireless microsensor suite is being designed to allow rapid subsurface TPS health monitoring and damage assessment. This sensor suite will consist of both passive overlimit sensors and sensors for continuous parameter monitoring in flight. The on-board diagnostic system can be used to radio in maintenance requirements before landing and the data could also be used to assist in design validation for X-vehicles. For a 3rd generation vehicle, wireless diagnostics should be at a stage of technical development that will allow use for intelligent feedback systems for guidance and navigation control applications and can also serve as feedback for TPS that can intelligently adapt to its environment.