Development of Advanced Metallic-Thermal-Protection System Prototype Hardware

Blosser, Max L.; Poteet, Carl C.; Chen, R. R.; Dorsey, John T.; Schmidt, I. H.; Bird, R. Keith; Wurster, Kathryn E.

doi:10.2514/1.9179

Cited by 77 publications

(34 citation statements)

References 8 publications

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“…The analysis focuses on sizing of the fibrous insulation layer and sizing of the honeycomb sandwich on the ARMOR TPS outer surface. Dimensions for other components are based on work reported by Blosser et al 1 Insulation layers are sized by the aerothermal heating and cryogenic conditions experienced in the three environments, whereas the honeycomb sandwich panel on the ARMOR TPS outer surface is sized considering aerodynamic pressure, acoustic pressure, and thermal gradients. Thermal performance is dependent on the structure, and the structural response is dependent on the temperatures in the TPS.…”

Section: Introductionmentioning

confidence: 99%

“…4 Pressure loading is transferred to the box beam picture frame through four corner support brackets. 1 The supports are arranged tangent to a circle about the center of the panel and have low bending stiffness perpendicular to the circle, allowing nearly free in-plane thermal expansion of the sandwich panel while resisting translation and rotation. Bulged, compliant sides, made of thin-gauge metal foil, form the sides of the TPS panel and block the radiative heat transfer path in the panel-to-panel gaps.…”

Section: Introductionmentioning

confidence: 99%

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Preliminary Thermal-Mechanical Sizing of a Metallic Thermal Protection System

Poteet

Abu-Khajeel

Hsu

2004

Journal of Spacecraft and Rockets

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A process is developed to perform thermal and structural analysis and sizing and to perform sensitivity studies on the latest metallic thermal protection system developed at NASA Langley Research Center. The process defined can be used to determine appropriate materials and approximate thicknesses and is the basis for initial thermal protection system weight estimates. Metallic thermal protection systems are a key technology for reducing the cost of reusable launch vehicles, offering the combination of increased durability and competitive weights when compared to other systems. Accurate sizing of metallic thermal protection systems requires combined thermal and structural analysis. Initial sensitivity studies were conducted using transient one-dimensional finite element thermal analysis to determine the influence of various design and analysis parameters on thermal protection system weight. The thermal analysis model was then used in combination with static deflection and failure mode analysis of the thermal protection system sandwich panel outer surface to obtain minimum weight configurations at three vehicle stations on the windward centerline of a representative reusable launch vehicle. The coupled nature of the analysis requires an iterative analysis process, which is described. Findings from the sensitivity analysis are reported, along with preliminary designs at the three vehicle stations considered.Nomenclature d e = honeycomb cell size, ft d g = gas collision diameter, ft H g = gas enthalpy, Btu/lbm H rec = recovery enthalpy, Btu/lbm h = heat transfer coefficient, lbm/ft 2 · s K B = Boltzmann constant, Btu/R k g = gas thermal conductivity, Btu/ft-s-• R k * g = temperature-dependent gas thermal conductivity for air, Btu/ft-s-• R k rad = equivalent conductivity, radiation in honeycomb core, Btu/ft-s-• R L = diagonal length of thermal protection system (TPS) panel, ft L e = enclosure characteristic length, ft L h = honeycomb thickness, ft Pr = Prandtl number p atmospheric = atmospheric pressure at current altitude, lbf/ft 2 p e = pressure in enclosure, lbf/ft 2 p local static = local static-normal aerodynamic pressure, lbf/ft 2 q = integrated heat load, Btu/ft 2 q = heat flux, Btu/ft 2 · s T av = average temperature in rod element, • R T e = temperature in enclosure, • R T surf = TPS surface temperature, • R α = accommodation coefficient γ = specific heat ratio for air p aerodynamic = aerodynamic pressure differential, lbf/ft 2 p rms, acoustic = rms acoustic pressure differential, lbf/ft 2

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Preliminary Thermal-Mechanical Sizing of a Metallic Thermal Protection System

Poteet

Abu-Khajeel

Hsu

2004

Journal of Spacecraft and Rockets

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“…Ni-based superalloy sheets are able to be used for producing metallic thermal protection systems for Reusable Launch Vehicles [2][3][4][5] . Since the profile of the thermal protection system is a hyperboloid, the sheets prepared with traditional techniques in China couldn't meet its modeling and size demands.…”

Section: Introductionmentioning

confidence: 99%

Microstructure Evolution of Electron Beam Physical Vapour Deposited Ni-23.5Cr-2.66Co-1.44Al Superalloy Sheet During Annealing at 600 °C

Zhang

Zhong

et al. 2012

Mat. Res.

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Microstructure evolution of electron beam physical vapour deposited (EB-PVD) Ni-23.5Cr-2.66Co-1.44Al superalloy sheet during annealing at 600 °C was investigated. The results showed that the as-deposited alloy was composed of only γ phase. After annealing at 600 °C, the locations of diffraction peaks were still the same. The (220) diffraction peak of the deposition side increased with annealing time. The sheet on deposited side had a tendency toward forming (220) texture during post-annealing. No obvious texture was observed at as-deposited and annealed sheet at 600 °C in substrate side. The count and size of "voids" decreased with time. The size of grains increased obviously with annealing time. The ultimate tensile strength of EB-PVD Ni-23.5Cr-2.66Co-1.44Al alloy sheet increased from 641 MPa to 829 MPa after annealing at 600 °C for 30 hours.

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“…The metallic TPS used for this study is the Adaptable, Robust, Metallic, Operable Reusable (ARMOR) thermal protection system developed by Langley Research Center. 8 The overall TPS panel has dimensions of 457 x 457 x 89 mm (18 x 18 x 3.5 in.). The major components of ARMOR are: an Inconel 617 honeycomb panel which forms the outer surface of the TPS, a thin-guage titanium box beam frame that defines the edges of the panel's interior surface, four stand-off support brackets that connect the outer honeycomb panel to the inner titanium box beam frame, four compliant bellows-type tubes for bolt access, bulged compliant sides, titanium foil closeout and Saffil™, a loose alumina fibrous insulation.…”

Section: Vehicle and Tpsmentioning

confidence: 99%

Displacements of Metallic Thermal Protection System Panels During Reentry

Daryabeigi

Blosser

Wurster

2006

9th AIAA/ASME Joint Thermophysics and Heat Transfer Conference

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Bowing of metallic thermal protection systems for reentry of a previously proposed single-stage-to-orbit reusable launch vehicle was studied. The outer layer of current metallic thermal protection system concepts typically consists of a honeycomb panel made of a hightemperature nickel alloy. During portions of reentry when the thermal protection system is exposed to rapidly varying heating rates, a significant temperature gradient develops across the honeycomb panel thickness, resulting in bowing of the honeycomb panel. The deformations of the honeycomb panel increase the roughness of the outer mold line of the vehicle, which could possibly result in premature boundary layer transition, resulting in significantly higher downstream heating rates. The aerothermal loads and parameters for three locations on the centerline of the windward side of this vehicle were calculated using an engineering code. The transient temperature distributions through a metallic thermal protection system were obtained using 1-D finite volume thermal analysis, and the resulting displacements of the thermal protection system were calculated. The maximum deflection of the thermal protection system throughout the reentry trajectory was 6.4 mm. The maximum ratio of deflection to boundary layer thickness was 0.032. Based on previously developed distributed roughness correlations, it was concluded that these defections will not result in tripping the hypersonic boundary layer.

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Development of Advanced Metallic-Thermal-Protection System Prototype Hardware

Cited by 77 publications

References 8 publications

Preliminary Thermal-Mechanical Sizing of a Metallic Thermal Protection System

Preliminary Thermal-Mechanical Sizing of a Metallic Thermal Protection System

Microstructure Evolution of Electron Beam Physical Vapour Deposited Ni-23.5Cr-2.66Co-1.44Al Superalloy Sheet During Annealing at 600 °C

Displacements of Metallic Thermal Protection System Panels During Reentry

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