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National Aeronautics and Space Administration

www.nasa.gov

Op#miza#onandFabrica#onStudiesintheDevelopmentofStructurallyIntegratedThermalProtec#onSystemTechnology

2009 Annual Meeting September 29-October 1, 2009

Mr. Craig Stephens, Element Lead

https://ntrs.nasa.gov/search.jsp?R=20100012826 2020-06-24T03:32:14+00:00Z

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Outline

•  Overviewofnear‐andfar‐termstructurallyintegratedthermalprotec#onsystem(SITPS)efforts–  Processforvehiclelevelairframeanalysisanddesign

–  HypersonicvehicleacreageTPSop9ons•  Insulated,stand‐off,SITPScharacteris9cs•  Comparisonandimplica9onsofthevariousop9ons

–  BackgroundonthecurrentSITPSeffortsunderHYPM&S•  SITPS‐0:Tes9ng•  SITPS‐1:Design,manufacturingandtest•  SITPS‐2:Design•  SITPSAlternateCore:Development

–  Conclusions

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Acknowledgements•  NASAGlenn

–  AnthonyCalominoandDougKiser

•  NASALangley–  DaveBrewer,KamranDaryabeigi,KimBey,andDavidGlass–  KimMar9n(LockheedMar9nCorp)

•  NASADryden–  MaRhewMoholtandLarryHudson

•  MaterialsResearch&Design–  BrianSullivanandKerryHopp

•  ATK‐COIC–  TimEaslerandRichPlunkeR

•  SouthernResearchIns#tute–  JohnKoenigandJacquesCuneo

•  S.D.Miller&AssociatesResearchFounda#on–  SteveMiller

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ProcessforVehicleLevelAirframe

AnalysisandDesign

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HypersonicVehicleAirframeAnalysisandDesignMethodology

•  VehicleFEAmodelincorpora#ngarepresenta#onofboththeairframesubstructureandacreageTPSaredeveloped

–  VehicleacreageTPSismodeled(e.g.buildanequivalentplatemodel)toproduceeffec9ves9ffnessesforuseinvehiclelevelmodel

–  NatureoftheTPS(insulated,stand‐off,orSITPS)dictatesthemodelingoftheloadtransferfrompanel‐to‐panel(PtoP)andpanel‐to‐airframesubstructure(PtoAS)

•  Vehiclegloballoads(aerodynamic,aerothermal,andaerostructural)areappliedtovehicleFEAmodeltoproducenodal{U},{Q},andtemperaturevectorsforen#revehicle

–  Areasofhighdeforma9ons,hightemperatures,highthermalgradientsarecandidateareasforsubmodelinves9ga9on

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HypersonicVehicleAirframeAnalysisandDesignMethodology

•  Foraspecificcri#calregion,submodelsareconstructedandsubjectedtoappropriatetemperatures,loadsanddisplacementboundarycondi#onsfortheseregions

–  Detailed3DFEAsubmodelsofthespecificelements(corrugatedcore,sandwichstructures,etc.)areused

–  StresseswithinindividualelementsaredeterminedandMargin‐of‐Safety(MOS)valuesarecalculated

–  Nega9veMOSand/orhighMOSrequirechangestotheacreagedesignelements

•  Whensubmodeldesignsareobtainedwithallposi#veMOS,updated[A],[B]and[D]matricesofacreageregionsareusedinfullvehiclemodeltoproducenew{U},{Q},andtemperaturevectorsforen#revehicle

–  Submodelsarere‐analyzedwithnew{U}and{Q}tocheckthatallMOSares9llposi9ve

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HypersonicVehicleAcreageTPSOp#ons

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VehicleTrajectoryImpactonTPSNeeds

Re‐EntryVehicles Trans‐AtmosphericVehicles

• Higherpeakhea#ngratesovershorter#meperiods

•  Yieldshighersurfacetemperatures

•  Lowerintegratedheatloads•  Vehiclethermalmanagementsystemstypicallynotrequired

•  Vehiclecoolingprovidedbygroundsupportequipmentsoona^erlanding

•  Mechanical/thermalloadsout‐of‐phase

•  Lowerpeakhea#ngratesoverlonger#meperiods

•  Yieldslowersurfacetemperatures

•  Higherintegratedheatloads•  Vehiclethermalmanagementacri#cal

considera#oninvehicledesignandopera#on

•  Mechanical/thermalloadsin‐phase

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TPSOp#ons–VehicleAcreage*•  InsulatedStructure

–  Insulators(#lesorblankets)areabacheddirectlytothecoldstructuretoformtheoutermoldline(OML)ofthevehicle

•  Insulatorsareforthermalperformanceandtransfersomeaerodynamic(pressureonly)loadstotheinnerstructure,butnothermalloads

•  Iner9alloadsarecarriedbytheinternalvehiclestructure•  Example:SpaceShuRleacreageTPS

*Glass,DavidE.,“CeramicMatrixComposite(CMC)ThermalProtec9onSystems(TPS)andHotStructuresforHypersonicVehicles,”AIAA‐2008‐2682,2008.

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TPSOp#ons–VehicleAcreage*

*Glass,DavidE.,“CeramicMatrixComposite(CMC)ThermalProtec9onSystems(TPS)andHotStructuresforHypersonicVehicles,”AIAA‐2008‐2682,2008.

•  Stand‐offTPS–  TPSsystemis“isolated”soaerodynamic(pressureonly)loadsandnotthermalloadscanbedirectlytransferredtotheinternalvehiclestructure

•  TypicallyconsistofmorepartsbutcanformanOMLofadifferentcontourthantheinternalvehiclestructure

•  Insula9onisrequiredonthepanelinnermoldline(IML)

•  Example:X‐33

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VehicleTrajectoryandTPS

•  VehicleDesignLevel–  Internalsystemsneedtobethermallyprotectedinavolumetricefficientmanner

•  Vehicledesignop9ons–  Applica#onofexternalinsula#on(i.e.insulatedstructure)–  Lessexternalinsula#onbutaddi#onalinternalinsula#onand/orthermal

managementsystems–  Designop9onbecomesinsula9ngattheOMLonlyorinsula9ngatboththeOMLandattheindividualinternalsystems?

–  Isthereanotherop9on?Canyoudevelopamethodforinsula9onapplica9onthatisbothstructurallyandvolumetricallyefficient?

•  ThisgoalisthedriverforNASA’sSITPSdevelopment–  ThedevelopmentofanadvancedTPSthatisbothstructurallyandvolumetrically

efficientusinghigh‐temperatureceramicmatrixcompositeandlight‐weightinsula#onmaterials

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TPSOp#ons–VehicleAcreage*

*Glass,DavidE.,“CeramicMatrixComposite(CMC)ThermalProtec9onSystems(TPS)andHotStructuresforHypersonicVehicles,”AIAA‐2008‐2682,2008.

•  StructurallyIntegratedThermalProtec#onSystems–  “ATPSthathasbothanintegrated(mechanicalandthermal)loadcarryingcapability

andanabilitytosharemechanicalloadswithadjacentTPSstructures”•  SITPSisdesignedtocarrybothaerodynamic(pressure&shear)andiner9alloads

•  Outerandinnerwallscarryairframeloads,withouterwallopera9nghotandtheinnerwallinsulated

•  ForSITPSpanelstobestructurallyefficient,mechanicalloads(i.e.bendingmoments,shear,andtorques)mustoccuracrossadjacentpanels

–  Ifthisdoesnotoccur,allpanelsbehaveas“simplysupported,”thusbehavinglikeastand‐offTPS

•  Poten9alBenefitsofSITPS–  LowerweightTPS,higherstructuralefficiency–  Largerpanelsizespossible,fewerseals,reducedgaps,andlowerpartscount–  MoredurableTPS,lowermaintenance

•  SITPSDesignOp9ons–  Sandwich(e.g.honeycomb,foamfilled,etc.)–  Hat‐s9ffened–  Rib‐s9ffenedshell

•  Example:None(lowTRLtechnology)

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TPSOp#ons–VehicleAcreageComparison

Glasscoa#ng

IndividualAETBShuble#les

StrainIsola#onPad/RTV

AluminumAirframeSubstructure(Skin&S#ffners)

Gapfillerfabric

NoloadSharingFrom#le‐to‐#le

SiC/SiCOML AETBTileWrappedwithSiC/SiCCMC

PMCIML

No#onalSpace

Opera#onsVehicle

SpaceShuble

(nottoscale)

(nottoscale)

Tile#1 Tile#2 Tile#3

CompositeAirframeSubstructure

LoadSharing(Force&Moment)FromPanel‐to‐PanelAero(Pressure

&Shear)andIner#alLoad(Force&Moment)SharingBetweenPanelandAirframe

Aero(Pressure)LoadTransferToAirframe

Panel‐to‐AirframeJoint

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SITPSRoadmap

SITPSTechnology

•  ARMDHypersonicsMaterials&Structures(M&S)Approach–  IncrementallydeveloptherequiredSITPStechnology

–  Con#nuallyintegrateandtestSITPStechnologyasitbecomesavailable–  Documenttechnologyforfutureefforts

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HYPM&SSITPSDevelopmentEffort:SITPS‐0

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SITPS‐0OverviewManufacturingDemonstra#onAr#cle

•  Goal–  Developmanufacturingcapabili9es(ATK‐COIC)

•  SITPS‐0Details–  Panelhasnodetectabledefects–  11.5in.x11.5in.x2.2in.thick(approx.)–  Insula9oncore–AETB16–  OML:S200HPIPSiC/SiC–  IML:M55J/954‐3CyanateEster–  Weight~5.8lbm/t2

•  PaneliscurrentlyatNASALaRCforthermalcharacteriza#ontes#ng

–  Steady‐statemeasurementsof“through‐thickness”effec9vethermalconduc9vity(Keff)

•  OMLCMCside:isothermalcondi9onsfrom250°Fto2000°F•  IMLCEside:mountedtoawatercooledplate•  Pressurevariedfrom0.001Torrto760Torr(10‐6to1atm)

–  Transientmeasurements•  Simulatedre‐entrypressureandsurfacetemperatureprofiles•  Usedtovalidate(1)theKeffdatacollectedand(2)validate

thethermalmodeldevelopedforSITPS‐0

SITPS‐0intheLaRCSteady‐StateThermalTest

Apparatus

SITPS‐0 CMC

PMC

SITPS‐0

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HYPM&SSITPSDevelopmentEffort:SITPS‐1

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SITPS‐1Overview•  Goal

–  Scale‐uptheSITPS‐0manufacturingcapability

–  Fabricateapanelforstructuraltes9ng•  GeneratedatatovalidateamodeloftheSITPS‐1concept

•  Process–  Op9mizetheSITPS‐0Design

•  Reducethepanelareaweight–goalisapproximately3lbm/t2

•  Reducethedispari9esbetweenfailureloadsbetweentheOMLandIMLmaterials

–  Addressmanufacturingissueswithscalinguptheop9mizeddesigntolargerpanelareas

–  DevelopadatabaseofSITPSmaterialstrengthandthermalperformance

•  Results–SITPS‐1PanelDesignBasedonOp#miza#onofSITPS‐0–  ThermalanalysisoftheSITPS‐0performanceforNASAHRRLSre‐entrytrajectory

•  SwitchedfromAETB‐16toAETB‐8tohelpreduceareaweight

•  ModifiedtheIMLtemperatureallowablesfrom400°Fto600°F

•  ModifiedAETB“bar”sizestoreduceareaweight

–  StructuralanalysisoftheOMLandIMLtomodifytheplylayupstoreducethedispari9esbetweenfailureloads

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SITPS‐0Modeling*OriginalThermalAnalysis

•  OriginalSITPS‐0configura#on•  BoundaryCondi#ons

–  Uniformheatfluxcorrespondingtoapar9cularbodypoint

–  Radia9ontospace–  InsulatedsidesandboRom

•  MaterialTemperatureLimitCriteria–  PMCandbondline≤400°F

•  ConcludingRemarks–  TheSITPSconceptwassizedforHRRLS

upperstagere‐entryhea9ng,resul9nginoverallinsula9onthicknessof~3.7,3.25,and3inchesat10,25,and50%ofvehiclelength(respec9vely)

–  Thermal‐stressanalysisofthe3‐inchthickpanelindicatesthattheconceptisviableatthefabricatedpanelscale

*Bey,K.,Butcher,K.,andEasler,T.,“Fabrica9onandThermalAnalysisofaStructurally‐IntegratedThermalProtec9onSystemConcept,”33rdAnnualConferenceonComposites,Materials,andStructures,CocoaBeach,FL,Jan.26‐29,2009.

• BP‐2maximumoutersurfacetemperature~1590°F

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SITPS‐1Op#miza#onThermal/StructuralAnalysis

•  SITPSanalysischanges–  SwitchedfromAETB‐16toAETB‐8tohelpreduceareaweight

–  ModifiedtheIMLtemperatureallowablesfrom400°Fto600°F

–  ModifiedAETB“bar”sizestoreduceareaweight

–  LaminateanalysisresultedintailoringtheOMLandIMLplylayupstoreducethedispari9esbetweenfailureloads

VehicleTouchdown•  “Op#mized”SITPS‐1Design–  4pliesofS200Hastopfacesheet–  2layers(thickerandwider)ofAETB‐8core/insula9on(alterna9ngdirec9ons)

–  4pliesofT650‐35/PIfortheboRomfacesheet

•  Areaweightes#mate=3.1lbm/^2

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SITPS‐1Status•  ATK‐COICtomanufacturelargerpanelforstructuraltes#ng– 20in.widex36in.longx~2.15in.thick– Insula9oncore–AETB8– OML:S200HPIPSiC/SiC– IML:T650‐35WovenPolyimide

•  SITPS‐1panelfabrica#onini#ated–  Numerouspanelfabrica9onissueshavebeenaddressedbytheteam

•  Es9matepanelfabricatedJanuary2010

–  SITPS‐1tobestructurallytestedbySeptember2010•  Currentlyworkingthedesigndetailsofthestructuraltests

–  MaterialdatabasefortheSITPS‐1componentstobecompletedSeptember2010•  MaterialswillbeavailableNovember2009

•  Thermal/structuraltes9ngtobecompletedbySeptember2009andwillbepostedontheHYPM&SCMCWikisite

SITPS‐1

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SITPS‐1Tes#ngAcquisi#onofComplianceCoefficientInforma#on

• CouplingPhenomenaintheSITPS‐1design–  In‐planenormalloadsproducein‐planeshearand

bendingandtwis9ngcurvatures–  Bendingloadsproducein‐planedistor9onsaswell

asbending&twis9ngcurvatures

1 2 3

4 5 6

7 8 9

TransientIR FourPointPressure

Tension PanelShearFourPoint

Tension/ShearCTE FourPointHea#ng

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SITPSStructuralTestPlansFutureEffort

Mul#‐PanelPerformanceTests(Long‐TermGoal)

CurrentEffortSingle‐PanelCharacteriza#onTests

(Near‐TermGoal)

MeasuredA,B,Dcompliancecoefficients

• Quan#fiedeffec#veloadtransfer(PtoPandPtoAS)

•  SITPSoverallperformance

M&SdevelopmentofgenericPtoPandPtoASabachmentop#on(s)

M&SVehicleLevelAnalysis

MDAOAnalysisUsingSITPS

MDAOprovides“visionvehicle”

loads

M&Sdevelopmentofstructuraltestmethodstoevaluatepanelperformance

ImprovedM&SVehicleLevelAnalysis

ImprovedMDAOAnalysisUsingSITPS

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HYPM&SSITPSDevelopmentEffort:SITPS‐2

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SITPS‐2Overview

•  Goal–  SITPS‐2A:Ini9atethedevelopmentofpanelcloseoutsandpanel‐to‐paneljoints–  SITPS‐2B:DevelopmanufacturingcapabilityforcurvedSITPSpanels

•  Process–  SITPS‐2A

•  Formulatepanel‐to‐paneljointconceptsthatallowloadandmomenttransferbetweenpanels

•  Structurallytestthreesub‐elementsofpoten9aljointdesigns•  Downselecttothemostpromisingjointdesignforalargerpaneldevelopmentandtes9ng

–  SITPS‐2B•  Addressmanufacturingissuesassociatedwiththefabrica9onofalarge‐scaleSITPSpanelwithsingle‐direc9oncurvature

•  Results–SITPS‐2–  PlanningforSITPS‐2AandSITPS‐2BtobegininOct2009

•  Ini9atethedesigndiscussionfocusingonthedevelopmentofSITPS‐2Apanel‐to‐panelaRachmentdesignsfor

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HYPM&SSITPSDevelopmentEffort:SITPSAlternateCores

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SITPSAlternateCoreOverview•  Goal

–  Developmentofhigh‐temperaturecoretechnology(i.e.honeycomb)forusewithalternateSITPSdesigns

•  Process–  Iden9fycorematerialsandevaluatethematerialsforpoten9alhoneycombfabrica9on

–  Thermal/structuralevalua9ontes9ngofcandidatehoneycombsub‐elements–  Conductanaly9calstudytoexaminethedifferentcoregeometries(i.e.wallthickness,shape,height,etc.)anditseffectoncorethermal/structuralproper9es

•  GoalistodefinethebestcoregeometryforSITPSapplica9ons

–  Assesswhatmaterial,coregeometries,etc.thatlendthemselvestobescaleduptolargerpanelsandul9matelyvehicleuse

•  Results–SITPSAlternateCores–  CurrentNRAhasbeenre‐directedtofocusonSITPSrequirements

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Conclusions

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Conclusions

•  NASAHYPM&SispursuingthedevelopmentofSITPS– WorkingwithHYPMDAOtoformulatemethodologytoincorporateSITPSintohypersonicvehicledesigntrades

–  SITPS‐0toSITPS‐1(FY10)•  Manufacturingdevelopmentandweightreduc9on(5.8to3.1lbm/t2)

•  Structuraltes9ngtomatureSITPSmodel

–  SITPS‐2(FY11)•  Focusonpanelcloseout,panel‐to‐panelloadtransfer,andpanelcurvature

–  Extendfabrica9ontechnologytoincludealternatecoresandinsula9ons(FY12)

SITPSTechnology