AEROFAST: DEVELOPMENT OF CORK TPS MATERIAL AND A 3D COMPARATIVE THERMAL/ABLATION ANALYSIS OF AN APOLLO & A BICONIC SLED SHAPE FOR

AN AEROCAPTURE MISSION
G. Pinaud , A.J. van Eekelen* , and J.-M. Bouilly

A STRIUM - SAS, F-33165 St. M edard-en-Jalles, France, E-mail: Gregory.Pinaud@astrium.eads.net, Jean-Marc.Bouilly@astrium.eads.net * S AMTECH s.a., B-4031 Angleur-Li` ege, Belgium, E-mail: Tom.vanEekelen@samtech.com

ABSTRACT An Aerocapture vehicle travelling from Earth to Mars approaches that planet on a hyperbolic interplanetary trajectory. Upon arrival, the vehicle will perform a single atmospheric pass to signicantly reduce its speed, and enters into an orbit around the planet. This manoeuvre uses aerodynamic drag instead of propulsion for orbit insertion, and potentially leads to large mass (fuel) savings as well as reduced ight times (higher arrival speed). However, Aerocapture results in signicant aerodynamic heating, necessitating a Thermal Protection System (TPS), as well as the use of a guidance system to assure that the spacecraft leaves the planetary atmosphere on the correct trajectory. In the frame of the seventh European Community Framework Program (FP7), the AEROFAST (AEROcapture for Future space tranSporTation) research and development project aims at preparing a demonstration of a Martian Aerocapture mission and increasing the Technology Readiness Level (TRL). One of the aims of this paper, is to present the development of an innovative cork based material and the selection process of the different formulations. The material must be able to withstand the severe front shield aerothermal environment. Numerous formulations have been investigated using a parametric combination of cork granule size, resin type/ratio, reinforcement fraction, llers and the mixing and agglomeration processes. A basic (thermo-mechanical) characterization and qualitative analysis allowed for a rst selection of the 4 most promising candidates. These candidates are being tested in the inductive plasma wind-tunnel facilities (COMETE) of ASTRIUM. These tests are performed in a stagnation point conguration, for an aerothermal environment similar to the AEROFAST aerocapture mission. In parallel, a 3D ablation and charring material model has been implemented in the nite element program S AM CEF , and successfully validated during the AEROFAST project. The numerical model consists of three sets of equations, namely the transient heat balance equation, the steady state mass balance equation and the charring equa-

tions. For the charring of the material we use a multispecies Arrhenius model with the species densities as degrees of freedom. The ablation is modelled by a surface imposed and temperature dependent ablation speed, followed by an in volume mesh deformation. Two main probe aerodynamic shapes and concepts have been evaluated, namely an Apollo like shape and a biconic sled with a characteristic diameter of 4 m. A thermo-mechanical comparative analysis of the front-shield has been carried out. The space probes are made of Norcoat-Li` ege (a low density phenolic resin impregnated cork material) which will serve as a baseline solution. The 3D heat load history (convective and radiative), over the front-shield, is based on the maximum energy trajectory extracted from a statistical Monte Carlo GNC study for a CO2 Martian atmosphere. Preliminary experimental plasma tests demonstrate promising enhanced thermal and ablative properties and also the need to improve numerical response model.

1.

INTRODUCTION

Aerocapture is an interesting technology for Solar System exploration that aim at decelerating the spacecraft through a single pass in a planetary atmosphere and consequently at achieving a targeted orbit. This manoeuvre saves a signicant amount of propellant with regard to a more conventional insertion technique. Aerocapture its a multidisciplinary technique involving various eld such as system analysis and integrated vehicle design, aerodynamics, aero-thermal environments, thermal protection systems (TPS), guidance, navigation and control (GN&C), instrumentation; each of them being strongly linked and playing a key role in the success of a challenging mission. Currently, Europe doesnt demonstrate a sufcient Technology Readiness Level (TRL) of aerocapture technology mainly because of its little experience while a TRL 6 is mandatory to envisage aerocapture technology for operational missions. Funded under the 7th Framework Program (FP7) of the European Community, the AEROFAST project has the ambition to remediate to

2 these lacks and is dedicated to increase the TRL level of aero-capture technology up to level 4 through a complete technology for operational missions. mission study of a Martian aero-capture. The main 5 obFunded under the 7th Framework Program (FP7) of the technology missions. jectives of for the operational project th are (see [1]): European Community, the AEROFAST project Funded under the 7 Framework Program (FP7)has of the ambition to remediate to these lacks and project is dedicated to European Community, the AEROFAST has the OBJ1: Dene a project of aero-capture demonstraincrease the TRL level of aero-capture technology up ambition to remediate to these lacks and is dedicated to technology for operational missions. tion to level 4 through a 7th complete mission study a increase the TRL level of aero-capture technology Funded under the Framework Program (FP7) of of up the Martian aero-capture. European Community, the AEROFAST project has the to level 4 through a complete mission study of a OBJ2: Make a signicant progress in space transambition to remediate to project these lacks and is dedicated to The main 5 objectives of the are: Martian aero-capture. portation by increasing the TRL of the planetary relincrease the TRL level of aero-capture technology up OBJ1 : Define a project of aero-capture The main 5 navigation objectives and of the project are: algorithm ative the aerocapture up to to level 4 through a complete mission study of a demonstration. - OBJ1 : Define a project of aero-capture 5 Martian aero-capture. - demonstration. OBJ2 : Make a significant progress in space The main 5 objectives of the project are: OBJ3: Build a to test in real time the transportation bybreadboard increasing the TRL the - OBJ2 : Make significant progress in of space - OBJ1: Define a project of aero-capture pre-aerocapture and aerocapture GNC algorithms planetary relative navigation and the aerocapture transportation by increasing the TRL of the demonstration. algorithm up 5. navigation planetary relative and progress the aerocapture OBJ2 : to Make a significant in protecspace OBJ4: Demonstrate/prototype the - OBJ3 : Build a 5. breadboard to test inthermal real time transportation by increasing the TRL of the the algorithm up to tion system for such a mission pre-aerocapture and aerocapture GNC algorithms, navigation and aerocapture - OBJ3 :planetary Build a relative breadboard to test in the real time the algorithm up to aerocapture 5. - OBJ4 : Dene Demonstrate/prototype the thermal pre-aerocapture and GNC algorithms, OBJ5: on-board instrumentation for aeroOBJ3 : Build a breadboard to testthe in realthermal time the protection system for such a mission capture recovery - OBJ4 : phase Demonstrate/prototype and aerocapture GNC algorithms, - protection OBJ5pre-aerocapture : Define on-board instrumentation for aerosystem for such a mission - OBJ4 : recovery. Demonstrate/prototype the thermal capture phase - The OBJ5 :protection Define instrumentation fordescribaerosystemon for the such a mission 4 by present paper on-board focus objective Thecapture present paper focus on instrumentation the objective for 4 aeroby phase recovery. OBJ5 : Define on-board ing the approach and the preliminary results of the dedescribing the approach and the preliminary results of The present focus on objective by capture recovery. velopment of paper an phase innovative corkthe based thermal 4 protecthe development of an innovative cork based thermal The present paper focus on the objective 4 by describing thecompliant approach with and the the specic preliminary results of tion material mission requireprotection material compliant with the specific mission describing the approach and the preliminary results of the development of an innovative cork based thermal ment. The development of the 3D charring ablation modthe development an innovative cork based thermal requirement. protection material with the specific mission ule (Amaryllis) in compliant theof nite element code S AMCEF was protection material compliant with the 3 specific mission The informatics development of the dimensions also a major breakthrough for the project and the sizing requirement. requirement. thermal and ablation module (AMARYLLIS) in the activities. At the beginning of the project, the choice of The informatics development of the 3 dimensions The informatics development was of the 3 dimensions finite element code (SAMCEF) also a major the aeroshape was open. After a trade off between an thermal and ablation module (AMARYLLIS) in the thermal and ablation module (AMARYLLIS) in the breakthrough for the project and thewas sizing activities. Apollo like shape and a truncated sphero-biconic shape finite element code (SAMCEF) also finite element code (SAMCEF) was alsoa amajor major At the beginning of the project, the choice of the aeroto name but a few, considering various criteria such breakthrough for the project and and the the sizing activities. breakthrough for the project sizing activities. as volume, mass, dynamic stability, lift over drag ratio, inshape was open. After a trade off between Apollo the beginning ofproject, the project, choice of the aeroAt the At beginning of the the the choice ofan the aeronovation, the selection was on favor of the biconic shape. like shape and a truncated sphero-biconic shape to shape was open. After a trade off between an Apollo shape was open. After a trade off between an Apollo Thus, like the a present paper relates also on the heat front name but few, considering various criteria such as shape a truncated sphero-biconic shape to like shape and aand truncated sphero-biconic shape to shield thermal 3D sizing and a design comparison bename but a few, considering various criteria such as volume, mass, dynamic stability, lift over drag ratio, name but a few, considering various criteria such as tween these two latest shapes. volume, mass, dynamic lift of over drag ratio, innovation, the selection wasstability, on favour the biconic volume, mass, dynamic stability, lift over drag ratio, innovation, the selection was on favour of the biconic shape. Thus, the present paper relates also on the heat innovation, the selection waspaper on favour of the shape. Thus, the present relates also onbiconic the heat front shield thermal 3D sizing and a design comparison shape. Thus, the present paper relates also on the heat front shield thermal 3D sizing and a design comparison 2. EXISTING THERMAL PROTECTION between these twoCORK latest shapes. front shield thermal 3D latest sizing and a design comparison between these two shapes. MATERIAL between these two latest shapes. Li` eges-HPK Company (Lavardac, 47230 France) and marketed by ASTRIUM Space Transportation an EADS ASTRIUM has a long experience in the use of Norcoat company. ASTRIUM has a long experience in the use of Lige since 40 years. Indeed, inNorcoat Lige is ASTRIUM has a long the use of Norcoat Norcoat-Li` ege since 40 experience years. Indeed, Norcoat-Li` ege is currently use on ARIANE5 launcher and on M51 Lige since 40 years. Indeed, Norcoat Lige is currently use on ARIANE5 launcher and on M51 French French deterrence force missile. This material has also currently use on ARIANE5 launcher and on M51 deterrence force missile. This material has also been sucbeen used on ARD back Reentry cover French successfully deterrence force missile. This has also cessfully used ARD back cover (Atmospheric ASTRIUM has on a long experience in the usematerial of Norcoat (Atmospheric Reentry Demonstrator) orLige on the front been since successfully used ARD back cover Lige 40or years. Indeed, Norcoat is BEADemonstrator) on the fronton heat shield of the heat shield the BEAGLE2 probeEXPRESS for the European currently useof on ARIANE5 launcher and (Atmospheric Reentry Demonstrator) oron onM51 the front GLE2 probe for the European MARS mission French deterrence force missile. material MARS EXPRESS mission to This MARS. heat shield of the BEAGLE2 probe for has the also European to MARS. been successfully used on ARD back cover MARS EXPRESS mission to MARS.
(Atmospheric Reentry Demonstrator) or on the front heat shield of the BEAGLE2 probe for the European MARS EXPRESS mission to MARS.

Norcoat Lige on ARIANE5 and French deterrence force Figure 1. Norcoat-Li` ge on missile ARIANE5 and French deterNorcoat Lige on e ARIANE5 and French deterrence Norcoat Lige on ARIANE5 French deterrence rence force missile force and missile
force missile

Norcoat Lige on ARD (Atmospheric re-entry Norcoat Lige on ARD (Atmospheric re-entry Demonstrator) back cover. Figure 2. Norcoat-Li` ege on ARD (Atmospheric re-entry Norcoat Lige on ARD (Atmospheric re-entry Demonstrator) back cover. Demonstrator) Demonstrator) back cover. back cover.

Existing cork thermal protection Existing cork thermal protection As objective 4 of AEROFAST project is to demonstrate and prototype a thermal protection material material Existing cork thermal protectionfor an aerocapture mission, the 2 main leaders ofisthe TPS work As objective 4 of AEROFAST project to demonstrate As objective 4 of AEROFAST project is to demonstrate material package and AMORIM) proposed and(ASTRIUM prototype a thermal protectionnaturally for an aerocpature
and prototype a thermal protection for an aerocpature As objective 4 the of AEROFAST project is to demonstrate their top cork product asleaders baseline: respectively Norcoatmission, 2 main of the TPS work package mission, the 2 main leaders of the TPS work package Li` ege for ASTRIUM and TP45-50 AMORIM and prototype a thermal protection for an for aerocpature (ASTRIUM and (AST) AMORIM) naturally proposed their (ASTRIUM and AMORIM) naturally their CORK COMPOSITE (ACC). theproposed material screentop cork product as baseline: respectively Norcoat mission, the 2 main leaders of During the TPS work package top cork product as baseline: respectively Norcoat ing phase ofand the AMORIM) project othernaturally cork composite producers Lige for ASTRIUM (AST) and TP45-50 for (ASTRIUM proposed their Lige for identied ASTRIUM (AST) and TP45-50 for AMORIM CORK COMPOSITE (ACC). During the have been such as Lockheed Martin, NASA, top cork product as baseline: respectively Norcoat AMORIM CORK COMPOSITE (ACC).this During the screening phase of the other ARA,material MSFC to name but a few. However, papercork will Lige for ASTRIUM (AST) andproject TP45-50 for material screening phase of the project other cork composite producers have been identified such as focus only on the cork products family of AST and ACC. AMORIM CORK COMPOSITE (ACC). During but the Lockheed Martin, have NASA,been ARA, identified MSFC to name composite producers such asa material screening phase of will the focus project other cork few. However, this paper on the cork Lockheed Martin, NASA, ARA, MSFC only to name but a composite producers have been identified such as products family of AST and ACC. few. However, this paper will focus only on the cork 2.1. Norcoat-Li` e ge Lockheed Martin, NASA, ARA, MSFC to name but a products family of AST and ACC. Norcoatthis lige few. However, paper will focus only on the cork Norcoat-Li` ege of is AST low density insulators based on cork products family and ACC. Norcoat lige Norcoat liege is low density insulators based on cork granules and phenolic resin as matrix manufactured by granules and phenolic resin as matrix manufactured by Norcoat lige Norcoat liege is low density insulators based on cork
Liges-HPK Company (Lavardac, 47230 France) and marketed by ASTRIUM Space manufactured Transportation by an granules and phenolic resin as matrix Norcoat liege is low density insulators based on cork EADS company. Liges-HPK Company (Lavardac, 47230 France) and granules and phenolic resin as matrix manufactured by marketed by ASTRIUM Space Transportation an Liges-HPK Company (Lavardac, 47230 France) and EADS company. marketed by ASTRIUM Space Transportation an EADS company.

and back cover of Beagle2 probe. Norcoat Lige tiles bonding process front heat shield Figure 3. Norcoat-Li` ge tiles and backecover ofbonding Beagle2process probe. front heat shield and back cover of Beagle2 probe.
Norcoat Lige is produced under the form of flat plat of various Lige thicknesses from 1.5 under to 19 mm. Norcoat is produced the form of flat plat A summary of possible process is described of brief various thicknesses from 1.5 to 19 mm. Norcoat Lige isproduced produced under the form plat Norcoat-Li` ege is under the form of of atflat plat of hereunder: A brief summary of possible process is described various thicknesses from 1.5 to 19 A brief summary of various thicknesses from 1.5 tomm. 19 mm. Cutting hereunder: of process isof described hereunder: A possible brief summary possible process is described Machining - Cutting Hot press forming hereunder: - Bonding Machining - Cuttingunder pressure on the equipment - Possibility Hot press forming Cutting - Machiningof outgassing treatment for space - applications Bonding under pressure on the equipment - Hot press forming - Applicable Possibilityonof outgassing treatment for space developable or not very complex - surfaces Bonding under pressure on the equipment applications

Norcoat Lige tiles bonding process front heat shield Norcoat Lige tiles bonding process front heat shield and back cover of Beagle2 probe.

Possibility on of developable outgassing or treatment space Applicable not veryfor complex applications surfaces Applicable on developable or not very complex surfaces

Lige is also available with planetary protection EXOMARS mission ASTRIUM Simoun arc jet facility assembly constraints being taken into account. enable the qualification of the Norcoat Lige material For NETLANDER, MARS EXPRESS and under CO2 atmosphere. EXOMARS mission ASTRIUM Simoun arc jet facility enable the qualification of the Norcoat Lige material under CO2 atmosphere.

Machining Hot press forming Bonding under pressure on the equipment Possibility of outgassing treatment for space applications Applicable on developable or not very complex sur5: Simoun 9 MW arc jet testfacility facility Figure Figure 5: Simoun arc test Figure 9 5.MW Simoun 9jet MW arc jet test facility faces
Systematic study of the thermal and ablative behaviour

sheets could P50 0,8mm till differ length of 70 c P50 the is pro different rat medi the compre The P medium den The P50 bas

Pro De Tensile El Elongati The Thermal C (15 Specific Sph

Chart 2: M Systematic study ofin the thermal and behaviour is carried out the framework ofablative various programs Char TP material is carried invarious the framework various programs and out under environment of from low temperature TP m 2.2. TP45-50 heating blancket, infra red furnace, to inductive and arc and under various environment from low temperature The P45 and plasma environment leading to a robust on the solid heating jet blancket, infra red furnace, to inductive and arc The P thermochemical and mechanical numerical model. as well as With the cork granules, ACC produces two cork comjet plasma environment leading to a robust This numerical model is currently applied for on th posites especially for the sizing space sector, the P45 and the locations an thermochemical and mechanical numerical model. EXOMARS heat shield activities associated as w Booster P50, different densities and properties. The two for cork with with specific margin policy. This numerical model is currently applied frustum locati composites described are composed with high cork conheat shield sizing Figure Norcoat-Li` ege manufacturing manufacturing process. Figure 4:4. Norcoat Lige process EXOMARS - cat B tent (more than 70 percent in activities weight) andassociated a thermoset - bolt - externa with specific margin policy. binder. The cork raw material is composed of uniformly - f ground cork of the lowest density and cleanness, with There are three material variations: - b There are three material variations: controlled sizes. The binder system accounts for more - Norcoat HPK standard material with no agents - e - Norcoat HPK FI - with fungicide agent (F) and a than 20 percent of the weight and is composed of a therFigure 6: Example of finite element model of front Norcoat HPK - standard no agents confers mosetting phenolic resin with polyol plasticizer, exclufire-proof agent material (I) with which sively used on with these Norcoat materials.Lige The mixing and curing shield selfextinguishing properties. procedures are based on existing methodology and equip Norcoat HPK FI - with fungicide agent (F) and a - re-proof Norcoat agent HPK(I) FIH - with fungicide agent (F); a ment. Blocks of cork are produced by mixing the cork which confers self-extinguishing fire-proof agent (I) which confers and binder, compressing and moulding the slurry, then properties. 2.2 TP45-50 selfextinguishing and a damp-proof agent (H) curing with heat and time. The blocks are then cut acWith the granules, ACCsheets. produces Norcoat HPK FIH - with fungicide agent (F); a recording the requiredcork thickness into exible The two cork which limits water absorption in the material. composites especially for the space sector, the P45 and proof agent (I) which confers self-extinguishing and P45 cork sheets are produced using 10/20 Cork granules a damp-proof agent (H) which limits water absorpobtaining a low density agglomerate. The sheets could the P50, with different densities and properties. The tion properties of the Norcoat Liege HPK FIH, are be delivered in several thicknesses (from 0.8 mm till 125 in the material. The two cork composites described are composed with presented in mm) and with a maximum width and of 700in weight) and high cork content (more thanlength 70 percent 1250 mm, respectively. P50 is produced using 20/40 cork Chart 1 : The properties of the Norcoat-Li` ege HPK FIH, are given thermoset The cork is composed granulesaand differentbinder. ratios of resin and raw cork material along with in Table 1. For planetary exploration mission space grade of uniformly ground cork of the lowest variation of the compression ratios during moulding, ob-density and Property Units Value cleanness, with agglomerated controlled sizes. The The binder system taining a medium density cork sheet. Density kg/m3 470 P50 basic properties are given in Table 2. accounts for more than 20 percent of the weight and is Table 1. Main properties of the Norcoat-Li` ege HPK FIH Tensile Strength MPa composed of a thermosetting phenolic resin with polyol Property Units Value2.5 Elongation %3 plasticizer, exclusively used on these materials. The Density at Break kg/m 470 6 Table 2. Main properties of the P45 ACC cork based TP Tensile Strength Mpa 2.5 Thermal Conductivity materialmixing and curing procedures are based on existing W/mK Elongation at break % 6 0.08 (150C) methodology and Units equipment. Value Blocks of cork are Property Thermal conductivity W/(m.K) 0.08 2.4 3 cork and binder, compressing Specific heat (150C) kJ/kgK produced by mixing the Density kg/m Max 512 (150 ) Tensile Strength Mpa then Min curing 1.72 2.5with heat and and moulding the slurry, Specic heat (150 ) kJ/(kg.K) 2.4 Elongation at break % 13 time. The blocks are then cut according the required Chart 1: Main properties of the Norcoat Liege HPK Thermal conductivity W/(m.K) 0.07 thickness into flexible sheets. FIH Norcoat-Li` ege is also available with planetary protec(150 ) Theheat P45 cork are produced tion assembly constraints being taken into account. For Specic (150 ) sheets kJ/(kg.K) 2.1 using 10/20 Cork granules obtaining a low density agglomerate. The For planetary exploration mission grade Norcoat NETLANDER, MARS EXPRESS andspace EXOMARS mission ASTRIUM Simoun arc jetplanetary facility enable the qualisheets could be delivered in several thicknesses (from Lige is also available with protection cation of the Norcoat-Li` e ge material under CO atmo2 till and a maximum assembly constraints being taken into account. The P450,8mm and P50 are125mm) mainly use forwith thermal protection width and sphere. study of the thermal and ablative be- and length of 700x1250mm, respectively. For Systematic NETLANDER, MARS EXPRESS on the solid rocket booster (SRB) of the space Shuttle as havior is carried out in the framework of various proon theis Delta rochets for these 20/40 various cork locations produced using granules and EXOMARS mission ASTRIUM Simoun arc jet facility well as P50 grams and under various environment from low temperand thermal and mechanical environment: different ratios of resin and cork along with variation of enable the qualification of the Norcoat Lige material ature heating blanket, infra red furnace, to inductive and the compression ratios during moulding, obtaining a under CO2 atmosphere. arc jet plasma environment leading to a robust thermochemical and mechanical numerical model. This numerimedium density agglomerated cork sheet. Booster nose cone cal model is currently applied for EXOMARS heat shield The P50 basic properties are presented in Chart 2:

sizing activities associated with specic margin policy.

frustum bolt catcher

Figure 5: Simoun 9 MW arc jet test facility

Property Density Tensile Strength Elongation at Break Thermal Conductivity (150C) Specific heat (150C)

Units kg/m3 MPa % W/mK kJ/kgK

Value Max 512 Min 1.72 13 0.07 2.1

The P45 and P50 are mainly use for thermal protection on the solid rocket booster (SRB) of the space Shuttle as well as on the Delta rochets for these various locations and thermal and mechanical environment: - Booster nose cone - frustum - bolt catcher - external externalskirt skirt insulation insulation

a predictive swelling phenomena

Because of the more severe environment meet on the frontshield in comparison with the back cover, 2 cork 4 based material families will be developed: - a reinforced material which can withstand stagnation like environment A two step iterative process is adopted in order to select -the best a superlight material for very lowloop, heat basic flux and formulations. During a rst and elmechanical load for mechanical aft side and leeward side. ementary thermal and properties of the new

materials are measured to realize a preliminary selection.

A 2 step iterative process is adopted order to select Based on this pre-selection deeper in analysis are perform the best formulations. During a first loop, basic and (extended thermal properties, plasma test...) The tradeelementary and mechanical properties of the of off criteria thermal are consistent with the targeted properties new materials areand measured to hereunder: realize a preliminary the new material are listed selection. Based on this pre-selection deeper analysis are perform (extended thermal properties, plasma mass loss test) The trade-off criteria are consistent with the targeted thickness properties of the recession new material and are listed hereunder: - mass loss charred recession material integrity - thickness - charred material integrity cracks number, thickness and depth - cracks number, thickness and depth In parallel non ablative (non cork) solutions have been In parallel in non (non off cork) solutions have been introduced theablative global trade in order to balance introduced in the the advantages global tradeand off in order to balance and compare drawbacks of both and compare the advantages and drawbacks of both family family (ablative and non ablative). (ablative and non ablative). Finally, the strategy can be Finally, the strategy can be summarized in the summarized in Fig. 7. following diagram:

P45 SRB theSpace Space Shuttle Shuttle and P50 on Figure 6. P45 onon SRB ofof the the Delta Rockets

Among the 2 well known candidates seen as the state of art for cork based thermal protection material none were optimized for the specic characteristics of a Martian aerocapture mission. Thats why, AEROFAST project is the opportunity to gather the know-how and the experience of the AST and ACC and benet of this synergy to pave the way for the development of an optimized material for such aerocapture mission and more generally to elaborate an innovative and improve family of cork based material.
P50 on Delta Rockets

3.

MATERIAL DEVELOPMENT STRATEGY

Among the 2 well known candidates seen as the state

A of preliminary phase drew the protection baseline of the aerocapart for cork based thermal material none ture project and more aerocapture of phase were optimized for specically the specific the characteristics a thermal and mechanical environment. The AEROFAST TPS requireMartian aerocapture mission. Thats why, ments (see were identied as well the improveproject is [2]) the opportunity to gather the as know-how and ment Consequently within the aerocapture spethe needs. experience of the AST and ACC and benefit of this cic range to of pave maximum heat ux heat load the tarsynergy the way for theand development of an geted new cork basedfor material family properties optimized material such aerocapture missionwould and be: more generally to elaborate an innovative and improve
family of cork based material.

Material development strategystrategy diagramdiagram Figure 7. Material development

an optimized lowest density Material development strategy a better thermal insulation efciency a better resistance to erosion and a lowest fragility of the charred layer the smoothest possible charred wall a predictive swelling phenomena Because of the more severe environment meet on the front-shield in comparison with the back cover, 2 cork based material families will be developed: a reinforced material which can withstand stagnation like environment a superlight material for very low heat ux and mechanical load for aft side and leeward side.

Ablative solution
4. 4.1. ABLATIVE SOLUTION Innovation Road Map

Based on the generally contradictory requirements, some innovation ways were proposed and investigated to improve existing cork ablative material. Fig. 8 presents the different ways explored that lead to the elaboration of more than 25 formulations: In order to improve the cork based material behavior with regard to ablation, reinforcement such as carbon and basalt bers were investigated. The initial amount and length of the bers were set thanks to previous ASTRIUM in-house experience.

- Reaction to fire and cone calorimeter test (ISO Innovation waysproposed for cork based materials some innovation ways were and investigated 5660-1) improve existing cork ablative material. In order toto improve the cork based material - In order to improve the cork based material Hardness The figure belowto presents the different ways explored behaviour with regard ablation, reinforcement behaviour with regard to ablation, reinforcement - Tensil strength that lead to the elaboration of more than 25 5 such as fibres carbon and basalt fibres were investigated. Example such as carbon and basalt were investigated. - Example Elongation of material basiccharacterisations characterisations by TGA of material basic by TGA formulations: amount and fibres length of the fibres were - Compression / recovery The initial amount The andinitial length of the were set thanks to previous ASTRIUM in-house Flexibility set thanks to previous ASTRIUM in-house
experience.

experience. - Fillers like hollow glass, silica spheres, ceramics, carbon and basalt fibres were considered in order Fillers like hollow glass, silica spheres, ceramics, to modify density and thermal behaviour. carbon and basalt fibres were considered in order - 2 main synthetic resins (phenolic and furanic) to modify density and thermal behaviour. were mix to cork granules in various amounts. The mixing operations as blade type, 2 main synthetic resins (phenolic and such furanic) Innovation waysand forspeed cork based materials orientation seemed to play an important were mix to Figure cork granules in various 8. Innovation ways foramounts. cork based materials role to get as most as possible an homogenous The mixing such as type, - Inoperations order to improve the blade cork based material material. Example of material basic characterisations by cone Figure 10. Example of material basic characterizations behaviour with regard to ablation, reinforcement orientation and speed tothe play an important - To seemed improve efficiency of the mixing calorimeter byExample cone calorimeter such as operations, carbon anddifferent basalt fibres were investigated. plasticizers, surfactants and role to get as most as hollow possible an homogenous of material basic characterisations by TGA Fillers like glass, silica spheres, ceramics, lubricants were also tested.of the fibres were The initial amount and length Selection of most promising formulations material. carbon and bers were considered in order on basalt this roadmap, more thanto 25 Example of material basic characterisations by cone setBased thanks to development previous ASTRIUM in-house modify density and thermal behavior. To improve experience. the efficiency of the mixing different formulations were elaborated and are depicted calorimeter Once the most promising formulations being prein the following photographs: operations, different plasticizers, surfactants and 4.2. Selection of the Most Promising Formulations selected, deeper thermochemical analysed were - Fillers like hollow glass, silica spheres, ceramics, 2 main synthetic resins (phenolic and furanic) were performed with special focus on: lubricants were also tested. carbon basalt fibres were considered order mix to and cork granules in various amounts. - in The mix- Selection of most promising formulations - thermal conductivity at room temperature to to modify density andas thermal behaviour. ing operations such blade type, orientation and sed on this development roadmap, more than 25 Once the most promising formulations being pre- se200C - 2speed main synthetic resins (phenolic and seemed to play an important role furanic) to get as lected, deeper thermochemical analyses were performed ferent formulations were elaborated and are depicted Once the most heat promising being pre- specific from -123 formulations to 177C by differential most as possible an homogenous material. were mix to cork granules in various amounts. with special focus on: the following photographs: scanning calorimeter (DSC) - The mixing operations such as blade type, selected, deeper thermochemical analysed were - thermogravimetric analysis with heating rate from orientation To improve the efciency the mixing opera- performed with 100K special focus on: and speed seemedof to play an important 5K to conductivity per minute at room temperature until C tions, different plasticizers, surfactants and lubri thermal at room temperature to 200 role to get as most as possible an homogenous thermal conductivity at room temperature to 1000 C cants were also tested. material. Example of material basic by cone 200C specic heat from -123characterisations to 177 C by differential - To improve the efficiency of the mixing calorimeter scanning calorimeter (DSC) specific heat from -123 to 177C by differential Based on this development roadmap, more than 25 differoperations, different plasticizers, surfactants and scanning calorimeter (DSC) ent formulations were elaborated lubricants were also tested. and are depicted in the thermogravimetric analysis with heating rate from Selection of most promising formulations thermogravimetric analysis with temperature heating rate from Fig. 9. Since it was unrealistic to perform full thermal and Based on this development roadmap, more than 25 5 K to 100 K per minute at room until 5K to 100K per minute at room temperature until different formulations were elaborated and are depicted C Once1000 the most promising formulations being prein the following photographs: 1000 C deeper thermochemical analysed were selected,
performed with special focus on: - thermal conductivity at room temperature to 200CSpecific heat measurements by DSC Since it was unrealistic to perform full thermal and - specific heat from -123 to 177C by differential mechanical characterisations, only basics scanning calorimeter (DSC) measurements have been performed. thermogravimetric analysis with heating rate from These 10: basic, relatively Figure Sample ofquick new cork and formulations before cheap 5K to 100K per minute at room temperature until Figure pre-selection 9. Sample of new cork formulations before preFigure 13: Comparison of thermogravimetric analysis 1000 C at 2 different heating rates selection Since it was unrealistic to perform full thermal and
Sample of new cork formulations before pre-selection
4.3 Plasma test campaign

mechanical characterisations, only basics measurements have been performed. ample of new cork These formulations beforeonly pre-selection mechanical characterizations, basics measurements basic, quick and relatively cheap characterisations in:basic, quick and relatively have been performed.consist These - Low heating consist rate thermogravimetric analysis cheap characterizations nce it was unrealistic to perform fullof: thermal and (TGA) - Thermomechanic analysis (TMA) basics echanical characterisations, only - heating Reactionrate to fire and cone calorimeter test (ISO Low thermogravimetric analysis (TGA) easurements have been performed. 5660-1) ese basic,Sample quick and analysis relatively cheap - Hardness Thermomechanic (TMA) of new cork formulations before pre-selection - Tensil strength - Elongation Reaction to re and cone calorimeter test (ISO Since 5660-1) it- was unrealistic to perform full thermal and Compression / recovery - Flexibility mechanical characterisations, only basics

measurements Hardnesshave been performed. These basic, quick and relatively Tensile strength
Elongation Compression/recovery Flexibility
Figure 11: Example of material basic characterisations by cone calorimeter 4.2 Selection of most promising formulations

cheap

Finally, among the initial set of 25 formulations, the selection process sort out 4 candidates who potentially Specific heat measurements by DSC fulfilled Figure the front heatshield requirements and by DSC 11. Specic heat measurements preliminary criteria, and 3 candidates for the back cover and leeward side environment. A plasma test campaign has been carried out on the 4 more promising front heat shield candidates to asses their thermal and ablative behaviour under realistic 4.3. Plasma Test Campaign aerocapture environment. Specific heat measurements DSC Thus, the ground test thermal environments have by been set on the basis of the simulated flight conditions for Finally, among the initial set of 25 formulations, the sethe sizing trajectory (maximum heat load). lection process sort out 4 candidates potentially fulAertothermal Navier Stokes CFD simulations who as well the Monte front heatshield requirements and preliminary as lled radiative Carlo simulations have been performed by and ONERA (France) to for assess heat flux wall and leeward criteria, 3 candidates the back cover distribution (at maximum A dynamic pressure and at pick has been carside environment. plasma test campaign heatried flux) on on the the selected truncated biconicfront shapeheat in shield canout 4 more promising order to validate and to scale semi-empiric ASTRIUM didates to asses their thermal and ablative behavior uncorrelation.

der realistic aerocapture environment. Thus, the ground test thermal environments have been set on the basis of the simulated ight conditions for the sizing trajectory

Once the most promising formulations being preselected, deeper thermochemical analysed were performed with special focus on: - thermal conductivity at room temperature to 200C

Figure 14: Convective heat flux distribution at pick heat flux and satellite-flow interaction As the biconic aero-shape presents huge variation of

!
!

Figure 12. Comparison of thermogravimetric analysis at 2 different heating rates Figure 14. ASTRIUM plasma test facilities and operating eld (maximum heat load). Aertothermal Navier Stokes CFD simulations as well as radiative Monte Carlo simulations have been performed by ONERA (France) to assess heat ux wall distribution (at maximum dynamic pressure and at pick heat ux) on the selected truncated biconic shape in order to validate and to scale semi-empiric ASTRIUM correlation. As the biconic aero-shape presents huge vari-

Max flu (kW/

Max loa (MJ/ Figure 15: ASTRIUM plasma test facilities and operating field

Ch tes

Tes CO not pla on Th mb at p

Figure 15. plasma test facility at ASTRIUM Figure 16: COMETE COMETE plasma test facility at ASTRIUM

Figure 13. Convective heat ux distribution at pick heat ux and satellite-ow interaction

Finally, the experimental heat flux history is adapted to the ground test facility capability, for which the minimum stabilized heat flux is around 150 kW/m2.

Th dia Ea the

Heat Flux(Tw=300 K): [kW/m ] Heat Flux(Tw=300 K): [kW/m ]

1000 600

Experimental environment Experimental environment

ation of ux along its prole 2 missions were proposed. The proposed values are also consistent with the lower level of ux met on the previous Apollo like shape studied during the project. Among the panel of plasma test facility operated in ASTRIUM, the COMETE (75 kW) inductive torch has been selected. Indeed, in a stagnation point conguration, heat ux from 150 to 3000 kW/m2 can be reach under 30 to 900 mbar AIR pressure. Finally, the experimental heat ux history is adapted to the ground test facility capability, for which the minimum stabilized heat ux is around 150 kW/m2 . In Fig. 16 we compare the ground experimental mission with the ight conditions for the 2 dened missions (Biconic 1, Biconic 2): The heat ux level is selected to enable a proper analysis of key phenomena such as pyrolysis or ablation. The test duration is determined so that heat load is of the same order of magnitude than during ight. The representativity of the ground test campaign in terms of heat ux and energy is shown in Table 3. Tests will be carried out in AIR because operability

! The Figure 17 compare ground experimental mission

1000
2

Biconic stagnation point with flight conditions for the 2 Flight defined missions Apollo Flight stagnation point COMETE Biconic 1 800 (Biconic 1, Biconic 2). COMETE Biconic 2

800 400

B ico nic F lig ht sta gn a tion p oint A p ollo F ligh t sta g n a tio n p oin t C O M E T E B icon ic 1 C O M E T E B icon ic 2

600 200

Fig
200 300 400

400 0

100

Time: [s]

200

Figure 16. Comparison of ight and ground experimental conditions in COMETE facility 0
0 100 200 300

400

T im e : [s]

Figure 17: Comparison of flight and ground experimental conditions in COMETE facility The heat flux level is selected to enable a proper analysis of key phenomena such as pyrolysis or ablation. The test duration is determined so that heat load is of the same order of magnitude than during flight. The representativity of the ground test campaign in

Sin qua per Tes pha for per rou

Truncated Biconic sled Apollo like shape analysis of key phenomena such as pyrolysis or Ground Ground ablation. The test duration is determined so that heat Flight Flight load is of mission the same than 2 during 1 order of magnitude mission

roughness for the lowest level flux mission (Biconic 2):

flight. Truncated Biconic sled Apollo like shape The representativity of the ground test campaign Ground Ground in Flight Flight 1011 of heat 800 330 400 terms flux and energy following mission 1 is shown in the mission 2 chart: Table 3. Representativity assessment of the plasma test Max heat Biconic flux 1011 800sled 330Apollo like 400shape Max heat 2 Truncated Biconic Flight Ground Flight Ground sled Apollo like shape (kW/m load 114 ) 84 92 1 53 mission 2 mision 2 Ground Ground heat (MJ/m ) MaxMax Flight Flight 330 heat ux 1011 800 400 mission84 1 mission 2 load(kW/m114 92 53 2 ) 2 Representativity assessment of the plasma test (MJ/m ) heat load Max 114 84 92 53 Max heat 2 (MJ/m ) Chart 3: Representativity 1011 800 assessment 330of the plasma 400 flux Tests will 2 be carried out in AIR because operability of test (kW/m )

Max heat flux (kW/m2)

After test comparison of surface visual aspect between P50 and TPS3J (carbon fibers reinforced cork based 7 material)
P50 TPS3J

After test comparison of surface visual aspect between P50 and TPS3J (carbon fibers reinforced cork based material)

mbarux. which is thein maximum expected condition COMETE facility CO2 (Martian likeflight atmosphere) is heat at pick heat flux. not yet demonstrated. Previous ASTRIUM comparative The samples will have a cylindrical shape with a plasma test carried out in CO2 and in AIR atmosphere The will have a cylindrical shape with a diamdiameter of samples 50 mm and a useful of 20 mm. The samples willhave have a thickness cylindrical shape with a on Norcoat Lige always shown similar results. eter of 50 mm and a useful thickness of 20 mm. Each Each material piece will be instrumented with one diameter of 50 mm and thickness of 20 mm. The pressure will stay at aa useful constant value around 100 material piece will be instrumented with one thermocouthermocouple on the back face. Each material piece will be instrumented with oneto ple on the back face. Since theses test are not condition devoted mbar which is the maximum expected flight ted to thermocouple on the back face. at pick heat flux. h the m2. The samples will have a cylindrical shape with a diameter of 50 mm and a useful thickness of 20 mm. ission Each material piece will be instrumented with one ssions thermocouple on the back face.

COMETE facility in CO2 (Martian like atmosphere) is heat notMax yet demonstrated. Previous ASTRIUM comparative Tests will be carried out in AIR because operability of of COMETE facility in CO like atmosphere) load 114 84 92 53 isis 2 (Martian plasma test carried out in CO2 and in AIR atmosphere COMETE facility in CO2 (Martian like atmosphere) 2 yet demonstrated. Previous ASTRIUM comparative not (MJ/m ) not yet demonstrated. Previous ASTRIUM on Norcoat Lige have always shown similarcomparative results. plasma test carried out in CO inin AIR atmosphere on 2 and plasma test carried out in CO2 and AIR atmosphere The pressure will stay at a constant value around 100 The Representativity of the plasma test Norcoat-Li` ege have assessment always shown similar results. on Norcoat Lige have expected always shown similar results. mbar which is the maximum flight condition pressure will stay at a constant value around 100 mbar The pressure will stay at a constant value around 100 Tests will be carried out in AIR because operability of at pick heat flux. which is the maximum expected ight condition at pick

Initial profil
Initial and ablated profile on the mission Biconic 2 for Figure 19. Initial and ablated prole on thematerial mission BiNorcoat Liege and TPS3J reinforced
conic 2 for Norcoat-Li` ege and TPS3J reinforced material

profil Non Initial ablative solution

Mainly, twoablated non ablative proposed Initial and profile on solutions the missionwere Biconic 2 for namely CMC and FEI and will be included in the final Norcoat Liege and TPS3J reinforced material trade-off of material, the heat shield sizing and mass Mainly, two non ablative solutions were proposed namely budget realized. CMC being and FEI and will be included in the nal trade-off
5. NON-ABLATIVE SOLUTION

Non ablative solution of material, the heat shield sizing and mass budget being

Figure 18:17. Sample definition and instrumentation Figure Sample denition and instrumentation Since theses test are not devoted to material qualification, only comparative analysis will be material qualication, only comparative analysis will be performed. performed. Tests are currently beingand processed and the Tests are currently being processed the synthesis synthesis phase will start in the coming weeks. The rst phase will start in the coming weeks. The first selected selected formulations tested already show improved performulations tested already show improved formance considering ablation and surfaceand roughness for performance considering ablation surface performance considering ablation and surface the lowest level ux mission (Biconic 2): roughness for forthe thelowest lowestlevel levelflux fluxmission mission(Biconic (Biconic 2): roughness 2).

400

CMC realized. Mainly, non ablative solutions were proposed is The CMCtwo material (Ceramic Matrix Composite) namely CMC and FEI and will be included in the final typically a windward side fibre reinforced ceramic TPS trade-off of material, the heat shield sizing and mass that is made of carbon-reinforced silicon carbide budget being realized. (C/SiC). C/SiC combines the strength and stiffness of 5.1. CMC carbon fibres with a more oxidation resistant matrix. CMC Between the CMC and the substructure an high The CMC material (Ceramic Matrix Composite) is temperature micro-fiber insulation is integrated The CMCamaterial (Ceramic Matrix Composite) is typitypically windward side fibre reinforced ceramic TPS therefore metallic or ceramic stand-offs will be used cally a windward side ber reinforced ceramic TPS that is to that is made of carbon-reinforced silicon carbide fix the CMC tile to the vehicle structure. made of carbon-reinforced silicon carbide (C/SiC). C/SiC (C/SiC). C/SiC combines the strength and stiffness of combines the and stiffness of carbon bers with is All along thestrength piece perimeter, aresistant sealing system carbon fibres with a more oxidation matrix. a more oxidation resistant matrix. Between the CMC and of applied protecting the and gap the to neighbouring panels Between the CMC substructure an high the substructure an high temperature micro-ber insulatemperature micro-fiber insulation the same material or adjacent structures.is integrated tion is integrated therefore metallic or ceramic stand-offs therefore metallic or ceramic stand-offs will be used to This material has been qualified for X38 vehicle: will be used to x the CMC tile to the vehicle structure.
fix along the CMC tile toperimeter, the vehicle All the piece a structure. sealing system is applied All along the piece perimeter, a panels sealingofsystem is protecting the gap to neighbouring the same applied protecting the gap to neighbouring panels of material or adjacent structures. This material has been the same for material or adjacent structures. qualied X38 vehicle: This material has been qualified for X38 vehicle:

proper sis or t heat Sample definition and instrumentation during proper Since theses test are not devoted to material is or gn in t heatqualification, only comparative analysis will be owing duringperformed. Sample P50 P50 definition and instrumentation Tests are currently being processed and TPS3J the synthesis TPS3J gn inphase will start in the test coming The first to selected Since theses are weeks. not devoted material ape 3 hart qualification, only already comparative analysis will be formulations tested show improved nd performed. Figure 19:comparison Aftertest test comparison comparison of surface visual After test of surfaceof visual aspect between Figure 18. After surface visual aspect on 2 Tests are currently being processed and fibers the synthesis aspect between P50 and TPS3J P50 and TPS3J (carbon fibers(carbon reinforced cork based between P50 and TPS3J (carbon bers reinforced cork phase will start the coming weeks. The first selected reinforced corkin based material) based material) material) formulations tested already show improved 00

CMC nose tile and assembling process on X38

Figure 20. CMC nose tile and assembling process on X38 CMC nose tile and assembling process on X38

st

lity of ere) is rative

The aerocapture corridor is bounded by extreme overshoot and under-shoot trajectories. The width of the corridor leads to maximum FPA errors at entry point 8 below +/-1.24deg
5.2. FEI

Con

The product family of FEI types has been established in recent years covering the range of temperatures from 300 C to 1100 C developed and commercialized by ASTRIUM-EADS. The FEI types are made from different organic and inorganic bers components like felts, fabrics and threads. The materials used are NOMEX R , R KEVLAR , PBI, silica, alumina and ABS acwhich is enclosed by an inner and outer ceramic fabric and cording to the required temperature range. In general sewn together by threads. Various coatings are FEIs are quilted blankets composed of and a felt is available to stiffen the other surface to which provide enclosed by an inner and outer fabric and sewn together certain thermo-optical properties. Water repellents can by threads. Various coatings are available to stiffen the be applied to and minimize the hygroscopic behaviour.propother surface to provide certain thermo-optical The FEI blanket is usually glued with an adhesive erties. Water repellents can be applied toRTV minimize the to the substructure of the vehicle. hygroscopic behavior. The FEI blanket is usually glued FEI blanckets have already on ARD back cover with an RTV adhesive to the flown substructure of the vehicle. and blankets were also qualified on X38. on ARD back cover and FEI have already own were also qualied on X38.

Figure 22. Aerocapture trajectory problematic

ion ed

Aero-shape trade-off Aerocapture requires an Aeroshape that provides lift0.3) and sufcient static stability performances. In a addiover-drag (L/D) ratio with the sufficient provision tion, the aeroshape must protect payloads (P/L) from (L/D>0.3) sufficientenvironment static stability performances. the severeand aero-thermal during the aerocapInture, addition, thebe aeroshape mustable protect payloads and shall safely jettison at thethe beginning of the pre-A/C In the frame of environment Aerofast, a trade-off (P/L) from thephase. severe aero-thermal during has been performed two congurations: the aerocapture, and considering shall be safely jettison able at the
Figure 22: Typical FEI blankets Figure 21. Typical FEI Blankets
A blunt body capsule derived from Apollo, ARD concepts A lifting body dealing with bi-conic shape.

posed final mass

Vehicle design

te) is c TPS arbide ess of ix. high grated sed to

em is els of

6. DESIGN 6.1 VEHICLE Aerocapture trajectory The nominal aerocapture trajectory has been computed in order to guaranty a trajectory after aerocapture 6.1. Aerocapture Trajectory compliant wrt the final orbit expected. The feasibility of the aerocapture is mainly driven by the condition at The nominal aerocapture trajectory has been computed in the EIP. order to guaranty a trajectory after aerocapture compliant w.r.t. the nal orbit expected. Theat feasibility of the aeEntry Interface Point (EIP) 120km AGL rocapture is mainly driven by the condition at the EIP. Relative velocity: 6377.6 m/s The aerocapture corridor is bounded by extreme overFlight Path Angle: -10.33 Chart 4: Entry corridor for aerocapture at Mars Table 4. Entry corridor for aerocapture at Mars arrival arrival Entry Interface Points (EIP) at 120 km AGL The aerocapture corridor is bounded Relative velocity 6377.6 m/s by extreme overshoot Flight and under-shoot trajectories. Path Angle -10.33 shoot and under-shoot trajectories. The width of the corridor leads to maximum FPA errors at entry point below 1.24 .

Figure 23. Final aero-shape trade-off.

By considering L/D requirements, payload protection w.r.t. aerothermal heating and layout constraints, the biconic shape has been selected.

6.3.

Aerothermodynamics

6.2.

Aeroshape Trade-off

Aerodynamic, aerothermodynamic and radiative environment on the biconic shape have been assessed for different angle of attack and at key points on the trajectories. Heat uxes histories have been assessed along two worst case aerocapture trajectories identied by Monte Carlo analysis (see [3]): overshoot trajectory corresponding to the maximum heat ux trajectory, with a maximum ux

s on

Aerocapture requires an Aeroshape that provides a liftover-drag (L/D) ratio with sufcient provision (L/D > Figure 23: Aerocapture trajectory problematic

lished from ed by

c and

6.2 Aero-shape trade-off Aerocapture requires an Aeroshape that provides sufficient lift-over-drag (L/D) ratio and sufficient stability performances. In addition, the aeroshape must be safely jettisoned at the beginning of the pre-A/C phase. In the frame of Aerofast, a trade-off has been

9 1064 KW/m2 found at stagnation point. (turbulent regime applied over the whole surface w.r.t. Reynolds criteria, Tw = 300 K). undershoot trajectory corresponding to the maximum energy trajectory. the virgin and the charred state. For this study three types of boundary conditions can be applied to the model. The rst will be an applied pressure P on the outer surface, modelling the aerodynamic pressure. The second type of boundary conditions will be the thermal boundary conditions in the form of an applied ux. T 4 4 (x, t) Tw ) = q (Tw , x, t) + (Tr n (7)

6.4.

Charring Ablation Model and Analysis Code

The materials that we will use (Norcoat-Li` ege) is a so called charring material, i.e. a material that will decompose when subjected to high temperatures. The decomposition of the material will manifest itself by a decrease in material density. In general a material will consist of different constituents, thus degradation of the material can take place over different temperature ranges. To account for this type of behavior, a multi-species Arrhenius denition (as given in [4]) can be used. Here we will only use a single species Arrhenius law due to the material model that is available.
E N = A1 ( c )N e RT v t

In Eq. 7, the applied ux q will depend on the wall temperature the position along the TPS and the time, while the second term models the (re)-radiation with the environment, The third type of boundary condition is the imposed ablation speed, which in this case is a measured quantity. s =s (Tw ) (8) The surface ablation is implemented by a moving ablation surface and a deforming, in volume, mesh as described in [4]. These equations have been implemented in the Finite Element program S AMCEF. One of the main quantities we are interested in this study, and the main justication for performing a 3D analysis (in this case), is the position of the Center of Gravity of the heat shield. The Center of gravity is dened by Eq. 9. xc.o.g. = (x, t)x dV (x, t) dV (9)

(1)

The degradation of the material will result in the production of gaseous products, and these products will diffuse through the material. The steady state gas mass balance equation is used, resulting in Eq. 2. g=0 + .m t (2)

Within the nite element approach used this position will be automatically calculated and is dened in Eq. 10. xc.o.g. =
e

We assume a perfect gas law, and we will introduce Darcys law to relate the pressure of the gas to the gas mass balance, resulting in Eqs. 3-4. g = KP P m KP = (3) 6.5.

(x, t)x dV e (x, t) dV e e

(10)

M g P (4) g RT By introducing the pressure P as a variable, we will be able to dene a 3D gas ow, using a scalar degree of freedom. Thus we do not have to impose a direction of gas mass ow before hand. For the heat balance equation, we look at the following phenomena, time variation of the enthalpy (both solid and gas), heat conduction, and the presence of gas in the pores of the solid. The model is set up with a local thermal equilibrium assumption. This means that the gas and the solid have the same temperature at the point scale. With the assumption of linear variation of the enthalpy, we obtain the heat balance equation of Eq. 5. T g .hg Hp + c = .T m t t v hv c hc v c (5)

Loads and Boundary Conditions

Within the AEROFAST project two aerocapture geometries have been used, namely an Apollo type shape and a biconic shape. The boundary conditions are a convection ux, that is given as a function of wall temperature (Tw ) and time, and an incident radiation ux as a function of time (see Eq. 7). Additionally, for both aerocapture shapes the heat loads are given along the surface (x). The heat ux that is used, is obtained for a maximum heat load trajectory in a CO2 atmosphere. In Fig. 24 we show the cold wall (Tw = 300 K) heat ux and radiation temperature, for both aero-shapes, at the stagnation point. These loads will be used to determine the maximum TPS thickness for both shapes.

And the pyrolysis heat will than be dened by Eq. 6. Hp = hg (6)

6.6.

1D Thickness Calculation

All the material properties (, c) are obtained by interpolation of the temperature dependent properties between

For the 1D thickness calculation we use the geometry as given in Fig. 25. The heat shield consists of a honeycomb support structure to which a cork (Norcoat-Li` ege) material is glued. The honeycomb structure has Carbon Fiber

10
2000 1000 Apollo ux Apollo temperature biconic ux biconic temperature 700 Outer surface Thermocouple Thermocouple Thermocouple Thermocouple 1 2 3 4

Heat ux [kW/m^2]

600 400

Temperature [K]

500

Radiation Temperature [K]

800

600 1500

1000

400

300

200 200 100

500

0 0 200 400 600 800 1000 1200 1400

0 0 200 400 600 800

Time [s]

Time [s]

Figure 24. Cold wall ux and radiation temperature at the stagnation point.

Figure 26. Temperature evolution for the biconic shape at stagnation point load.

Reinforced Plastic outer faces and the honeycomb material itself is made of Aluminium. The thicknesses of all materials are given, except of the cork TPS which has to be determined. In the TPS part, a non-uniform mesh is chosen with a ner distribution close to the loaded surface.

be seen the thermo-couples will loose signal when the ablation surface reaches the thermo-couple position. In Fig. 27 we see the density evolution for the same thermocouples. The density at the outer surface shows that after around 75 seconds the ablation speed is higher than the speed with which the pyrolysis front is moving, resulting in the increase of material density at the outer surface.

400 Outer surface Thermocouple Thermocouple Thermocouple Thermocouple

Density [kg/m^3]

300

1 2 3 4

200

Figure 25. Thermal Protection System plus the support structure.

100

The initial temperature of the structure equals 293.15 K and the pressure at the outer surface is xed to 6.103 N/m2 (maximum local pressure near stagnation point). The value of the pressure will not have a inuence on the result because no blocking of boundary conditions will be modelled and the thermo-physical properties of the supplied model for the Norcoat-Li` ege are pressure independent. To determine the thickness of the of the TPS material we dene a maximum allowable temperature of the support structure that may not be surpassed during the analysis. The maximum allowable temperature for the Glue will be set to 453 K (180 C). The heat loads of Fig. 24 will be applied and on the back-side we assume an adiabatic boundary condition. In Fig. 26 and 27 we will show some results for the highest heat load i.e. for the biconic case. In Fig. 26, we see the temperature evolution, in the 1D test-specimen, for different thermo-couple positions through the thickness. The four thermo-couples are 1 1 placed at respectively 1 8 x, 4 x, 2 x and x. As can

200

400

600

800

Time [s]

Figure 27. Density evolution for the biconic shape at stagnation point load.

In Fig. 28 the maximum support structure temperature is plotted against the TPS thickness x, for both the Apollo and the biconic heat load. It can be seen that the maximum thickness for both aeroshapes is respectively 17 mm for the Apollo shape and 19 mm for the biconic shape.

6.7.

3D TPS Sizing

A total of four different 3D heat shields will be analyses, namely:

11
480
Value*1.E-3 4.314

470

Appolo heat ux Biconic heat ux Maximum allowable

3.883

3.452

460

3.02

Temperature [K]

2.589

450

2.157

1.726

440
1.294 0.863

430

0.431

420

410 15 16 17 18 19 20 21

TPS thickness [mm]

Figure 30. Final ablation deformation.

Figure 28. Maximum support temperature as a function of TPS thickness at stagnation point.

6.7.2.

Bi-conic Shape Heat Shield

Apollo shape heat shield with a constant thickness of 17 mm. A biconic shape with a constant thickness of 19 mm. Two variable thickness heat shields with the thickness distributions given in Table 5. 6.7.1. Apollo Type Heat Shield

The rst biconic analysis that will be performed, is with a constant thickness TPS, where the thickness is obtained for the stagnation point (19 mm). The second and third analysis will be with a variable thickness TPS thickness, in order to reduce mass. The layout and thickness of the support structure will be the same for both the Apollo and all the biconic congurations.
Value*1.E-3 10.65

9.59

8.52

7.46

The Apollo like shape is subjected to the heat ux belonging to the maximum heat load trajectory in a CO2 atmosphere with a constant bank angle of 180 . In Fig. 29 we see the mass evolution and the Center Of Gravity displacement of the complete heat shield (TPS + support structure). The total mass equals 133.5 kg and the mass loss equals 25.6 kg (see Table 6 for a comparison of aeroshapes).

6.39

5.33

4.26

3.2

2.13

1.07

Figure 31. Final ablation deformation.

66 40

C.o.g. displacement [mm]

64 Mass X-displacement Z-displacement 30

62

60

20

58

10

56 0 54 0 200 400 600 800 1000 1200 1400

In Fig. 31 we see the nal ablation deformation for the biconic TPS. The total deformation equals 10.6 mm, which is considerably higher than the 4.3 mm of the Apollo like heat shield. In Fig. 32 we show the mass evolution of all three biconic congurations. The total mass of the constant thickness TPS equals 295.4 kg, which is much higher than the Apollo shape shield and considerably over mass budget. This high mass of the constant thickness TPS prompted the development of a variable thickness TPS. In this case the thickness was calculated, using the same procedure as for the stagnation point, for 10 points around the TPS. These points and given in Fig. 33, and the thickness values are given in Table 5 in the column TPS #1. With the thickness at these points the thickness variation was obtained by linearly interpolating the thickness between the points.

Mass [kg]

Time [s]

Figure 29. Mass and c.o.g shift for the half heat-shield

In Fig. 30 we see the total ablation deformation on the heat shield at the end of the trajectory.

12

140

Constant thickness Variable thickness #1 Variable thickness #2

468

455.1

Mass [kg]

120

442.2

429.2

416.3

403.4

100
390.5 377.5

364.6

80

351.7

338.8 Z

200

400

600

800

Time [s]

Figure 32. Mass evolution for the half heat-shield

Figure 34. Inner temperature at the end of the trajectory (var. thickness TPS #1).

The rst constant thickness TPS resulted in an unacceptable design, due to the fact that the maximum support temperature is not respected, as can be seen in Fig. 34. The problem is that the maximum allowable support temperature is respected at the position of the 10 points, but due to the non-linear variation (over the surface) of the external load not in between these points. This resulted in the development of a second variable thickness TPS (TPS #2 in Table 5), for which the temperature distribution on the inside is given in Fig. 35.

439.8

426.9

413.9

401

388

375.1

362.1

349.1

336.2

323.2

310.3 Z Y

Figure 35. Inner temperature at the end of the trajectory (var. thickness TPS #2).

1.92

Figure 33. Thickness distribution along the heat-shield.

1.9

-0.5

X-coordinate [m]

1.88

-0.55

In Fig. 36 the position of the c.o.g. of the three biconic heat shields are given. The maximum relative (with respect to the shields diameter) c.o.g. displacements are given in Table 6.

1.86

1.84

X constant thickness Z constant thickness X variable thickness #1 Z variable thickness #1 X variable thickness #2 Z variable thickness #2

-0.6

-0.65

6.8.

Results

1.82 0 200 400 600 800

Time [s]

In Table 6 all the results of the four heat shields are summarized. From these four heat shields the variable thickness TPS #1 is not allowable, while the constant thickness biconic heat shield is too heavy. This leaves the Apollo and variable thickness TPS #2 as acceptable solutions. The maximum allowable relative c.o.g. displacement of

Figure 36. C.o.g position for the half heat-shield

Z-coordinate [m]

13

Table 5. Thickness distribution Point number S/D TPS #1 [-] [ ] [ mm ] 1 0.520 0.00 6 2 0.381 0.00 6 3 0.000 180.0 15 4 0.212 180.0 19 1 0.381 180.0 16 6 0.798 180.0 16 7 1.325 180.0 16 8 0.381 90.0 8 9 0.798 90.0 8 10 1.325 90.0 7

TPS #2 [ mm ] 8 8 15 19 19 16 16 10 10 10

Figure 37. Non Ablative TPS heat shield pattern

approximately 2-3 % is reached, but the results here only include the heat shield and not the rest of the entry vehicle. Table 6. Mass and c.o.g data for the heat shield. xc.o.g. zc.o.g. Heat Shield Mass Mass-loss D D [kg] [kg] [%] [%] Apollo 133.5 25.6 -0.083 0.12 Const. thickness 295.4 56.1 -0.88 2.54 Var. thickness #1 201.6 55.8 -1.76 3.20 Var. thickness #2 235.1 55,8 -1.55 2.86

ambition to remediate to the low level of technology maturity in aerocapture by a demonstration of complete mission study of a Martian aero-capture. This paper described the approach and the preliminary promising results of the development of 2 families of innovative cork based thermal protection material compliant with the specic aerocapture mission requirement. The development of the 3D charring ablation module (Amaryllis) in the nite element code SAMCEF, was also successfully validated and applied for the sizing activities of the different selected aero-shape. In the future, the most promising material candidates should be tested under a larger range of thermal environment in order to qualied the materials for an aerocapture mission but also to improve the thermal and ablative numerical model to take into account for example swelling phenomena or ablation scheme.

6.9.

Non Ablative Solution Sizing REFERENCES

Considering both families of non ablative material describe in section 5, a preliminary sizing have been performed. In Table 7 the mass optimized TPS pattern for this aerocapture mission is described. Table 7. Non Ablative TPS heat-shield sizing Surface Thickness Areal weight Mass with 10% zone [mm] [kg/m2 ] margin [kg] 1 2.4 (C/SiC) 6.65 19.4 21 (IFI) 2 2.4 (C/SiC) 6.42 44.1 19 (IFI) 3 2.4 (C/SiC) 6.30 23.7 18 (IFI) 4 2.4 (C/SiC) 5.03 37.0 7 (IFI) 5 2.4 (C/SiC) 4.92 31.6 6 (IFI) 6 6 (F-EI-650) 0.90 10.1

1. T. Salmon, F. Bonnefond, P. Augros, T. Lutz, AEROFAST: Aerocapture For Futur Space Transportation, 3rd international ARA days, Arcachon, May 3rd 2011. 2. Jean-Marc Bouilly Bouilly - AST-SAS, AEROFAST Development of innovative thermal protections, 3rd international ARA days, Arcachon, May 3rd 2011. 3. Philippe Vernis AST-SAS, AEROFAST Aerocapture GNC design and performance, 3rd international ARA days, Arcachon, May 3rd 2011. 4. A.J. van Eekelen, J.-M. Bouilly, S. Hudrisier, J.-M. Dupillier and Y. Aspa. Design and Numerical Modelling of Charring Material Ablators for Re-entry Applications. In 6th European workshop on Thermal Protection Systems and hot structures, April 2009, Stuttgart.

7.

CONCLUSIONS

Funded under the 7th Framework Program (FP7) of the European Community, the AEROFAST project has the