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In the first mission of the ISS supply ship ATV (Automated Transfer Vehicle) an unexpected power request by the thermal control system was detected, when some thermal blankets were partially detached from the structure. An investigation was carried out, followed by a complete review of the MLI detail design relevant to the venting phenomenon. The process was completed with the qualification of an enhanced MLI design, suitable to resist to all the environmental loads and to provide future ATV modules with the capability to withstand any mission condition with respect to thermal and venting issues. This paper is focused on the thermal development and qualification campaign and on the relevant lessons learnt. NomenclatureATV = Automated Transfer Vehicle CDR = Critical Design Review DAK = Double Aluminized Kapton EADS = European Aeronautic Defence and Space company ICC = Integrated Cargo Carrier JK = Johannes Kepler JV = Jules Verne MDPS = Micrometeoroid and orbital Debris Protection System MPLM = Multi-Purpose Logistics Module MLI = Multi-Layer Insulation OTMM = Overall Thermal Mathematical Model QR = Qualification Review RCF = ReClosable Fastener ST = Space Transportation TAS-I = Thales Alenia Space -Italia
In the first mission of the ISS supply ship ATV (Automated Transfer Vehicle) an unexpected power request by the thermal control system was detected, when some thermal blankets were partially detached from the structure. An investigation was carried out, followed by a complete review of the MLI detail design relevant to the venting phenomenon. The process was completed with the qualification of an enhanced MLI design, suitable to resist to all the environmental loads and to provide future ATV modules with the capability to withstand any mission condition with respect to thermal and venting issues. This paper is focused on the thermal development and qualification campaign and on the relevant lessons learnt. NomenclatureATV = Automated Transfer Vehicle CDR = Critical Design Review DAK = Double Aluminized Kapton EADS = European Aeronautic Defence and Space company ICC = Integrated Cargo Carrier JK = Johannes Kepler JV = Jules Verne MDPS = Micrometeoroid and orbital Debris Protection System MPLM = Multi-Purpose Logistics Module MLI = Multi-Layer Insulation OTMM = Overall Thermal Mathematical Model QR = Qualification Review RCF = ReClosable Fastener ST = Space Transportation TAS-I = Thales Alenia Space -Italia
Multilayer insulation (MLI) components are important parts of spacecraft, in which thin films are the core elements. The film thicknesses are generally small, between 10 and 30 μm, to reduce the weight of the spacecraft. During the launch of a spacecraft, there is a rapid drop in the internal pressure, which causes the internal gas to flow out rapidly through the component. The resulting fluid force may cause film damage and failure, thereby directly affecting the normal operation of the spacecraft. Therefore, the mechanical characteristics of the thin films under rapid decompression conditions were investigated during this study. Considering the effects of the flow field stress distributions on the films during the rapid decompression, a fluid–structure interaction (FSI) model for a component was first constructed. The results show that the stress is largest in the outlet film, which is the part of the overall structure most vulnerable to failure. Furthermore, the effects of the structural parameters of the component on the stresses in the different film layers were analyzed using the orthogonal experimental method. The results show that the film thickness had the largest influence, followed by the film hole diameter, the number of component layers, and finally the staggered hole distance. Finally, a structurally optimized design scheme for the component is proposed based on a parameter range analysis with respect to the maximum film stress. After optimization, the maximum stress of the thin film decreased by 97.6%. This research has practical engineering value for the structural design and optimization of MLI components.
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