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David Stewart, Ceramic Engineer/Research Scientist


What I do

I have written over 85 papers on a wide variety of technical subjects including the effects of surface catalysis on heating to advance heat shields, shock tunnel performance, blunt body heating and characterization and thermal conductivity modeling of rigid fibrous insulations. The papers were related to Apollo, Viking, Planetary Atmospheric Entry Test (PAET), Space Shuttle, Aeroassist Flight Experiment (AFE), X-30 National Aerospace Plane (NASP), MEUSER, Hypersonic Flight Experiment (HYFLITE), and Access-to-Space programs such as X-37. These have been published by NASA, American Ceramic Society, and in AIAA Journals and Proceedings. They have been referenced world wide in Journals and technical articles.

I currently hold three U.S. patents, and as a co-inventor, I have submitted a patent disclosure for a new family of High Efficiency Tantalum-based Ceramic (HETC) formulations and a Toughened Uni-piece Fibrous Reinforced Oxidation-Resistant Composite (TUFROC) that is the backbone in the development of a light-weight ceramic leading edge thermal protection system (TPS). Currently, I am a co-principal investigator for the technology transfer of TUFROC TPS from NASA Ames Research Center to industry for application on the X-37 wing leading edge. This technology extends the upper use temperature of a fibrous ceramic TPS to temperatures above 3000 °F.

My career path

I graduated from San Jose State University in electrical engineering, and joined NASA in April 1959. I conducted pioneering research on optimizing the performance of a combustion-driven shock tunnel, and the arc-jet facilities. I was instrumental in the construction of the first shock-driven CO2 gas dynamic laser in the U.S.A. For the past 35 years I have worked in the Thermal Protection Materials Branch where I have conducted extensive studies on TPS materials. These studies include code development for TPS thermal response, the effect of surface catalysis on heating, and arc-jet stream calibration using Laser-Induced Fluorescence technology.

I conducted the early screening and characterization studies on fibrous insulation and reinforced Carbon Carbon (RCC) thermal protection systems for the Space Shuttle. I was awarded the Exceptional Service Medal (1981) for my work on the development of the Space Shuttle TPS.

I was the first investigator to experimentally demonstrate the effect of surface catalysis on the heating rate distribution over a flight vehicle (OEX Space Shuttle 1982) during Earth entry. Also, I was the principal investigator for the Catalytic Surface Effects Experiments for the AFE, and X-33 programs. In support of Access-to-Space, Bantam, and X-33 programs, I have completed surface catalysis and characterization studies on over thirty different thermal protection systems. These include coated and non-coated metals, carbon, and ceramic systems. I received the exceptional Technology Achievement Award (2003) for advanced work in surface catalysis and TPS material development.

A typical day

In any given day, I am on the phone, involved in meetings, conducting research, putting out fires

What I like about my job

It is so unusual, and always a challenge. In 50 years, I find that if I keep my ears open, I can always learn something: whether it is from a technical person, an engineer, or a secretary. When I first came in as a contractor, I was providing a service; now as a civil servant, I have been able to become more involved in research, whether it be with the shock tunnel (as in my early years) or in developing new materials. One of the reasons I haven't retired is that I would miss the challenge: this is a once in a lifetime opportunity.

Advice for a student

I would say the same thing I say to my grandchildren: you have to keep your mind open, like what you are doing, and go for it. Do what you like, not what someone else thinks you should be doing: you will be working for at least 30 years and you need to make the most of life. Do not get hung up on the little things.