83230 91 3 -DOC -TA S -E N -0 0 1
7
th
European Workshop on TPS&HS
Apr. 8-10, 2013
ESA/ESTEC – Noordwijk, The Netherlands
TPS Design, Development and
Verification Approach for IXV Program
Elena Brach Prever, Maria Teresa Signorelli, Flavio Camarri, Angelo Denaro (TAS)
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thEuropean Workshop on TPS&HS
Apr. 8-10, 2013
IXV Program
The Intermediate eXperimental Vehicle
(
IXV) is an atmospheric re-entry
demonstrator, launched by Vega from CSG, conceived to perform a
sub-orbital flight and enter the atmosphere experiencing the typical LEO
re-entry thermal loads, while performing a certain number of experiments
related to TPS, AED, ATD and GNC, and validating engineering approach,
margin policy and tools used to design and develop the demonstrator and
to plan the mission.
Among the various technological challenges of the IXV Project, the
demonstration of the feasibility of using HS for re-entry vehicles and the
acquisition of information on the in-flight behaviour of TPS materials like
ceramic and ablative ones, insulations, attachments and seals are the main
objectives.
This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed to any third party without the prior written permission of Thales Alenia Space -2012, Thales Alenia Space
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thEuropean Workshop on TPS&HS
Apr. 8-10, 2013
IXV Mission Breakdown
The main IXV objective is to verify that the TPS&HS architecture is able to
sustain the environments encountered during the entire mission
1
2
3
4
5
Reference Timeline
1 – Lift off
T = 0 [s]
2 – Separation
T = 966 [s]
3 – Entry gate
T = 3857 [s]
4 – Descent gate
T = 5180 [s]
5 – Splashdown
T = 6061 [s]
120 km entry interface
point
ASCENT
ORBITAL ARC
RE-ENTRY
DESCENT
Separation
Total downrange = ~32800 km
Altitud
e
Re-entry & descent = ~7700 km
Z9A fallout Z23 fallout P80 fallout
25,7 km
max. altitude 412 km
320 km
Downrange
LIBREVILLEMALINDI Mobile
station Recovery ship
AVUM fallout
1
2
3
4
5
Ascent segment
966 [s]
Orbital segment
2891 [s]
Re-entry segment
1323 [s]
Descent segment
881 [s]
[Altitude scale: 10X]
Reference Trajectory 3D view
Ascent segment
966 [s]
Orbital segment
2891 [s]
Re-entry segment
1323 [s]
Descent segment
881 [s]
Nose Heat Fluxes
0 100 200 300 400 500 600 700 800 0 200 400 600 800 1000 1200 time [s] he at fl ux [k W /m 2] N1 N2 N4 N5 N6 NSK4 NSK5 NSK6 N10 N4S N6S NSK6S N10S
This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed to any third party without the prior written permission of Thales Alenia Space -2012, Thales Alenia Space
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thEuropean Workshop on TPS&HS
Apr. 8-10, 2013
TPS Architecture
The TPS&HS S/S consists of the following assemblies
:
Nose Assembly (developed by Herakles)
Windward Assembly (developed by Herakles)
Body Flap Assembly (developed by MT Aerospace)
Leeward, Lateral and Base Assemblies (developed by AVIO)
All the interfaces between different TPS&HS assemblies and between
TPS&HS assemblies and different IXV sub-systems are designed and
developed by Thales Alenia Space
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thEuropean Workshop on TPS&HS
Apr. 8-10, 2013
Nose Assembly
The Nose Assembly HS consists of a Nose Cap made of HKS Sepcarbinox
®
L6
®
CMC material filled with internal insulation (Zircar AB, Pyrogel) held in
place by an Aluminum Nose Dome
The Nose Assembly is linked to an Aluminum Ring that transmits all loads
from the Nose and the Dome via the attachment brackets to the bulkhead
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7
thEuropean Workshop on TPS&HS
Apr. 8-10, 2013
This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed to any third party without the prior written permission of Thales Alenia Space -2012, Thales Alenia Space
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thEuropean Workshop on TPS&HS
Apr. 8-10, 2013
Windward Assembly
The Windward C/SiC Assembly is characterized by the innovative shingle
technology, which is able to dissociate mechanical and thermal insulation
functions
Each shingle is composed of CMC panel with peripheral stiffeners and
internal stiffeners; attachment system, ceramic fiber internal insulation
stack-up (Zircar AB, Aeroguard, Pyrogel) and ceramic fiber seal (Zircar AB
enveloped by Nextel) are placed around the peripheral stiffeners of the
C/SiC panel
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thEuropean Workshop on TPS&HS
Apr. 8-10, 2013
Ablative TPS Assembly
The Ablative TPS consists of different materials, each fulfilling a dedicated
function:
an external insulating material providing the heat absorption and removal by means
of thermo-ablative phenomena:
P50 cork
on the majority of the IXV surface and a
silicone elastomer based material
SV2-A
on antennas
an antistatic paint coating on the external ablative surface, avoiding electrostatic
charge accumulation and providing known thermo-optical properties to the outer
insulator surface, as well as avoiding moisture absorption
an adhesive layer that provides the bonding of the insulating material on IXV cold
structure (EA9394 for P50, siliconic adhesive for SV2-A)
a filler (based on EA9394 and P50 for P50, siliconic for SV2-A) that provides a
continuum insulating mean in correspondence of gaps present between the insulating
material tiles
This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed to any third party without the prior written permission of Thales Alenia Space -2012, Thales Alenia Space
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thEuropean Workshop on TPS&HS
Apr. 8-10, 2013
Body Flap Assembly
The Body Flap Assembly (Keraman
®
), designed to contribute to
aerodynamics and manoeuvrability of IXV, comprises the following main
constituents:
a pair of control surfaces
a rod-like to deflect the flap for flight control
ceramic bearings installed at the attachment points
flexible Nextel-Saffil hinge seals
Hinge TPS forming the TPS interface between the Body Flap and the TPS elements
Electro-Mechanical Actuator (EMA) TPS, that provides the interface with bulkhead,
hinge TPS and flap rod
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thEuropean Workshop on TPS&HS
Apr. 8-10, 2013
This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed to any third party without the prior written permission of Thales Alenia Space -2012, Thales Alenia Space
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thEuropean Workshop on TPS&HS
Apr. 8-10, 2013
TPS Assemblies Interfaces
Each single TPS assembly is designed to properly interface with the vehicle
cold structure, the adjacent TPS assemblies, the launcher adapter, the
in-flight experimentation sensors and the MGSE
Examples of adjacent TPS I/Fs are shown in the following figures
Leeward ablative TPS / Nose Interface
Lateral ablative TPS / Hinge TPS
Ablative
Seal
Hinge TPS seal
Cold structure
Hinge TPS skin
Ablative
Seal
Cold Structure
Nose Skin
This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed to any third party without the prior written permission of Thales Alenia Space -2012, Thales Alenia Space
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thEuropean Workshop on TPS&HS
Apr. 8-10, 2013
Development Tests
Nose and Windward Assembly
CMC samples:
CMC characterization: mechanical tests (tensile, compression, shear), thermal
properties (thermal diffusivity, thermal expansion, specific heat)
CMC oxidation (in VKI Plasmatron)
CMC catalycity (in VKI Plasmatron)
CMC behaviour in sea environment
Insulation:
thermal properties and modal characterization
Attachments:
mechanical strength on nose and shingle attachments
static test on shingle attachments: compressive and shear test on ceramic washers,
tensile test on screws, static/buckling test on complete attachment
fatigue test on shingle attachments
mechanical test on nose attachments
thermal characterization
This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed to any third party without the prior written permission of Thales Alenia Space -2012, Thales Alenia Space
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thEuropean Workshop on TPS&HS
Apr. 8-10, 2013
Development Tests
Nose and Windward Assembly (cont’d)
Singularities:
mechanical strength, dynamic and thermal test on pressure port
Seal:
permeability
venting
sneak-flow
Assembly test:
This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed to any third party without the prior written permission of Thales Alenia Space -2012, Thales Alenia Space
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thEuropean Workshop on TPS&HS
Apr. 8-10, 2013
Development Tests
This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed to any third party without the prior written permission of Thales Alenia Space -2012, Thales Alenia Space
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thEuropean Workshop on TPS&HS
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Development Tests
Ablative TPS – P50
Thermo-physical tests: specific heat, enthalpy of formation (for both virgin
and charred material), thermal conductivity, TGA, mass spectrometry, CTE
Mechanical
characterization:
ultimate
elongation,
Young
modulus,
hardness, density, ultimate pull and shear strength, peeling
Interface bonding shear tests
Humidity tests
Ageing tests
Outgassing tests
Torch tests
Technological tests: full scale application (22 mm)
Thermo-ablative tests (in VKI Plasmatron)
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thEuropean Workshop on TPS&HS
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Development Tests
Body Flaps Assembly
Considering the sufficient high TRL (
≥
5) of the Body Flap reached during
X-38 and EXPERT Programs, no development tests were performed in phase
C2; the same applies to Hinge TPS
For EMA TPS, the increase of the development status by means of ground
tests has been considered unfeasible and therefore the development has
been carried out only by analysis
Catalycity and emissivity tests have been carried out on Keraman
®
samples
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thEuropean Workshop on TPS&HS
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Assembly Qualification Tests
PWT test with singularities in Scirocco
Thermo-mechanical test
Dynamic test
Shock, sine and random tests
[performed]
Manufacturing, integration and verification test (full
scale validation test)
Thermal and thermo-mechanical behaviour verified
through TPS&HS S/S PWT test in Scirocco
Body Flap + EMA TPS dynamic test
[performed]
EMA TPS thermal test
[performed]
Hinge TPS dynamic test
[performed]
This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed to any third party without the prior written permission of Thales Alenia Space -2012, Thales Alenia Space
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thEuropean Workshop on TPS&HS
Apr. 8-10, 2013
Assembly Qualification: Ablative TPS Shock, Sine & Random Tests
This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed to any third party without the prior written permission of Thales Alenia Space -2012, Thales Alenia Space
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thEuropean Workshop on TPS&HS
Apr. 8-10, 2013
Assembly Qualification: Ablative TPS Full Scale Validation Tests
P50 bonding process with vacuum bag already qualified in the frame
of Vega program
Different bonding strategies tested: vacuum bag, bladder, weights,
adhesive tape
Additional tests objectives
SV2-A bonding qualification
mortar cap bonding
unglued area
Bonding strength evaluated by means of pull test
SV2-A
TILE
PARTIALLY
UNGLUED TILE
MORTAR CAP
GLUING TEST
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thEuropean Workshop on TPS&HS
Apr. 8-10, 2013
Assembly Qualification: Body Flap Assembly Dynamic Test
MT-Aerospace performed Body Flap+EMA TPS qualification tests
This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed to any third party without the prior written permission of Thales Alenia Space -2012, Thales Alenia Space
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thEuropean Workshop on TPS&HS
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Design Interface Verification
PWT tests at TPS&HS S/S level are planned in CIRA Scirocco facility to
verify in “hot conditions” the design of the interfaces between the
adjacent TPS assemblies in terms of capability to comply with the
requirements relevant to sneak-flow (overheating) and step&gap
S/S PWT Test
Leeward Ablative
Nose
Windward Assembly
Hinge TPS
This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed to any third party without the prior written permission of Thales Alenia Space -2012, Thales Alenia Space
