Development of a thermal protection system for the wing of a space shuttle vehicle. Phase 1
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White, D. M.↗
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Prediction and verification of creep behavior in metallic materials and components for the space shuttle thermal protection system
A method of analysis was developed for predicting permanent cyclic creep deflections in stiffened panel structures. This method uses creep equations based on cyclic tensile creep tests and a computer program to predict panel deflections as a function of mission cycle. Four materials were investigated - a titanium alloy (Ti-6Al-4V), a cobalt alloy (L605), and two nickel alloys (Rene'41 and TDNiCr). Steady-state and cyclic creep response data were obtained by testing tensile specimens fabricated from thin gage sheet (0.025 and 0.63 cm nominal). Steady-state and cyclic creep equations were developed which describe creep as a function of time, temperature and load. Tests were also performed on subsize (6.35 x 30.5 cm) rib and corrugation stiffened panels. These tests were used to correlate creep responses between elemental specimens and panels. The panel response was analyzed by use of a specially written computer program.
Davis, J. W.↗
Some considerations of the dynamics of Space Shuttle vehicle thermal protection system
Two types of reusable surface insulation under consideration for Space Shuttle applications have been analyzed for flutter stability. The first consisted of silicone rubber-coated Nomex felt bonded to the skin of the vehicle; the second consisted of silicone tiles with ceramic coating on five faces, bonded to Nomex felt which was then attached to the vehicle skin. The piston theory was used to compute the aerodynamic forces on the basis of simple models on the two systems. Exact solutions were obtained, and the effect of different parameters of the flutter stability boundary was investigated. Possible reasons for the slow convergence of the Galerkin technique for analyzing membrane flutter are suggested, and a consistent set of nondimensional parameters convenient for flutter studies is introduced.
Kuo, C.-C.↗
Aerodynamic heating in gaps of thermal protection system tile arrays in laminar and turbulent boundary layers
An experimental heat-transfer investigation was conducted on two staggered arrays of metallic tiles in laminar and turbulent boundary layers. This investigation was conducted for two purposes. The impingement heating distribution where flow in a longitudinal gap intersects a transverse gap and impinges on a downstream blocking tile was defined. The influence of tile and gap geometries was analyzed to develop empirical relationships for impingement heating in laminar and turbulent boundary layers. Tests were conducted in a high temperature structures tunnel at a nominal Mach number of 7, a nominal total temperature of 1800 K, and free-stream unit Reynolds numbers from 1.0 x 10 million to 4.8 x 10 million per meter. The test results were used to assess the impingement heating effects produced by parameters that include gap width, longitudinal gap length, slope of the tile forward-facing wall, boundary-layer displacement thickness, Reynolds number, and local surface pressure.
Avery, D. E.↗
Aerothermodynamic assessment of corrugated panel thermal protection systems
The results of an analysis of wind-tunnel data for the effect of wave shape on local boundary layer flows and heat transfer are used to assess the feasibility of using corrugated panels on a Single-Stage-To-Orbit (SSTO) vehicle. In the flight assessment, available engineering design procedures are used to compute the inviscid and boundary layer flow for a given flight trajectory. The flight vehicle flow field calculations are then used in conjunction with wind-tunnel corrugated panel heating data correlations to examine the heating penalties associated with using corrugated panels at a number of locations on the vehicle. Severe heating penalties, as a result of the corrugations, were found over large areas of the windward surface. Maximum surface temperature penalties ranged from 100K to 500K and very large structural advantages for the corrugations would be required to override the heating penalties. Computed peak corrugation temperatures were within allowable limits of the equivalent smooth wall material for most leeward and side fuselage locations and corrugated panels will be most likely limited to these locations.
Brandon, H. J.↗
Design and fabrication of a super alloy thermal protection system
A lightweight metallic TPS was designed, and two test articles were fabricated, one from Haynes 188 and one from Rene 41. A baseline TPS concept, selected at the beginning of the program, consisted of a Haynes 25 corrugation-stiffened beaded skin surface panel, a specially designed support system, and an insulation system. By optimizing the structure for the design loads and by chem-milling to remove material not needed, the mass of the baseline surface panel was reduced 25%, and the mass of the support structure was reduced 50%. The insulation system mass was reduced 40% by using two types of insulation, each suited to its temperature range, and by eliminating a foul bag which encapsulated the baseline insulation system. These reductions resulted in an overall 35% reduction in mass of the Haynes 188 panel from the baseline Haynes 25 design. Similar reductions were achieved with the Rene 41 system.
Varisco, A.↗
Design and fabrication of elevon cove thermal protection systems for aerospace vehicles
The design study of a lightweight, effective, reuseable seal for use along the elevon cove of shuttle-type reentry and hypersonic cruise vehicles is presented. The study deals primarily with membrane seals, both metallic and non-metallic. This type of seal spans the cove gap between the wing and elevon, and does not depend on spring tension to maintain contact along a flexing wing span. Technical requirements and criteria were generally derived from the space shuttle and utilized for seal design.
Varisco, A.↗
Thermal protection system repair kit program
The feasibility and conceptual design aspects of repair materials and procedures for in orbit repair of the space shuttle orbiter TPS tiles are investigated. Material studies to investigate cure in place materials are described including catalyst and cure studies, ablation tests and evaluations, and support mixing and applicator design. The feasibility of the repair procedures, the storage of the TPS, dispensing, and cure problems are addressed.
Source record↗
Orbiter thermal pressure drop characteristics for shuttle orbiter thermal protection system components: High density tile, low density tile, densified low density tile, and strain isolation pad
Pressure drop tests were conducted on available samples of low and high density tile, densified low density tile, and strain isolation pads. The results are presented in terms of pressure drop, material thickness and volume flow rate. Although the test apparatus was only capable of a small part of the range of conditions to be encountered in a Shuttle Orbiter flight, the data serve to determine the type of flow characteristics to be expected for each material type tested; the measured quantities also should serve as input for initial venting and flow through analysis.
Lawing, P. L.↗
Producing the high temperature reusable surface insulation for the thermal protection system of the Space Shuttle
The primary insulation system used to protect the space shuttle orbiter on reentry is an externally attached, rigidized, fibrous silica which has been machined into tiles. The tiles constitute the temperature reusable surface insulation system and are used on over 70 percent of the vehicle exterior surface where peak temperatures range from 400 to 1260 C. Cargon-carbon leading edges are used in areas where peak temperatures exceed 1650 C and a felt flexible insulation is used in regions below 400 C. Approximately 32,000 tiles are used in the HRST system and because of vehicle configuration, aerodynamic requirements, and weight considerations no two tiles are alike. Fabrication and quality control procedures are described.
Forgsberg, K.↗
Parametric Analytical Studies for the Nonlinear Dynamic Response of the Tile/Pad Space Shuttle Thermal Protection System
The studies examined for imposed sinusoidal and random motions of the shuttle skin and/or applied tile pressure. Studies are performed using the computer code DYNOTA which takes into account the highly nonlinear stiffening hysteresis and viscous behavior of the pad joining the tile to the shuttle skin. Where available, experimental data are used to confirm the validity of the analysis. Both analytical and experimental studies reveal that the system resonant frequency is very high for low amplitude oscillations but decreases rapidly to a minimum value with increasing amplitude.
Edighoffer, H.↗
Fabrication of titanium multiwall Thermal Protection System (TPS) curved panel
A method is described for fabricating curved T1-6Al-4V multiwall panels having a single radius of curvature of 30.5 cm (12 inches). A panel 30.5 x 30.5 x 1.7 cm (12 x 12 x .688 inch) having 4 dimpled sheets, 5 undimpled sheets, and stepped side closures was designed, fabricated and delivered for evaluation. Tool design for skin and dimpled sheet forming are described as well as layup and liquid interface diffusion bonding.
Blair, W.↗
Extensional, bending and twisting stiffness of Titanium Multiwall Thermal Protection System (TPS)
A test program which determines the extensional, bending and torsional stiffness of various titanium multiwall sandwich configurations is described. It is shown that unlike honeycomb core, the dimpled core is a significant contributor to the stiffness and strength of the sandwich. the extensional stiffness test shows irregularities which are attributed to foil thickness variations and to the difficulty to determine linear values from nonlinear tests.
Meaney, J. E.↗
Assessment of Alternate Thermal Protection Systems for the Space Shuttle Orbiter
Candidate concepts are identified. The impact on the Shuttle Orbiter performance life cycle cost, and risk was assessed and technology advances required to bring the selected TPS to operational readiness are defined. The best system is shown to be a hybrid blend of metallic and carbon-carbon TPS concepts. These alternate concepts offer significant improvements in reusability and are mass competitive with the current ceramic tile reusable surface insulation. Programmatic analysis indicates approximately five years are required to bring the concepts to operational readiness.
Kelly, H. N.↗
Catalytic surface effects on space thermal protection system during Earth entry of flights STS-2 through STS-5
An on going orbiter experiment catalytic surface effects experiment being conducted on the Space Shuttle is discussed. The catalytic surface effects experiment was peformed on four of the five flights of Columbia. Temperature time histories and distributions along the midfuselage and wing of the orbiter were used to determine the surface catalytic efficiency of the baseline high temperature reusable surface insulation. Correlation parameters are shown that allow the comparison of all flight data with predictions from the design and surface emittance decreased as a result of contaminants during the five flights of the Space Shuttle.
Stewart, D. A.↗
Life considerations of the shuttle orbiter densified-tile thermal protection system
The Shuttle orbiter themal protection system (TPS) incorporates ceramic reusable surface insulation tiles bonded to the orbiter substructure through a strain isolation pad. Densification of the bonding surface of the tiles increases the static strength of the tiles. The densification proces does not, however, necessarily lead to an equivalent increase in fatigue strength. Investigation of the expected lifetime of densified tile TPS under both sinusoidal loading and random loading simulating flight conditions indicates that the strain isolation pads are the weakest components of the TPS under fatigue loading. The felt pads loosen under repetitive loading and, in highly loaded regions, could possibly cause excessive step heights between tiles causing burning of the protective insulation between tiles. A method of improving the operational lifetime of the TPS by using a strain isolation pad with increased stiffness is presented as is the consequence of the effect of increased stiffness on the tile inplane strains and transverse stresses.
Cooper, P. A.↗
Steady internal flow and aerodynamic loads analysis of shuttle thermal protection system
An analytical model for calculation of ascent steady state tile loading was developed and validated with wind tunnel data. The analytical model is described and results are given. Results are given for loading due to shocks and skin friction. The analysis included calculation of internal flow (porous media flow and channel flow) to obtain pressures and integration of the pressures to obtain forces and moments on an insulation tile. A heat transfer program was modified by using analogies between heat transfer and fluid flow so that it could be used for internal flow calculation. The type of insulation tile considered was undensified reusable surface insulation (RSI) without gap fillers, and the location studied was the lower surface of the orbiter. Force and moment results are reported for parameter variations on surface pressure distribution, gap sizes, insulation permeability, and tile thickness.
Petley, D. H.↗
Pre-stressed thermal protection systems
A hexagonal protective and high temperature resistant system for the Space Shuttle Orbiter consists of a multiplicity of pockets formed by hexagonally oriented spacer bars secured on the vehicle substructure. A packing of low density insulating batt material 18 in each pocket, and a thin protective panel of laterally resilient advanced carbon-carbon material surmounting the peripherals bars and packing. Each panel has three stepped or offset lips on contiguous edges. At the center of each pocket is a fully insulated stanchion secured to and connecting the substructure and panel for flexing the panel toward the substructure and thereby prestressing the panel and forcing the panel edges firmly against the spacer bars.
Dunn, T. J.↗