fp7/space project hydra hybrid ablative development for re- entry in planetary atmospheric thermal...
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FP7/SPACE PROJECT “HYDRA” Hybrid Ablative Development For Re-Entry In Planetary Atmospheric Thermal Protection
J. Barcena1, S. Florez1, B. Perez1, J-M. Bouilly2, G. Pinaud2, W. P. P. Fischer3, A. de Montbrun4, M. Descomps4, D. Lorrain4, C. Zuber5, W. Rotaermel5 and H. Hald5, P.
Portela6, K. Mergia7, G. Vekinis7, A. Stefan8, C. Ban8, D. Bernard9, V. Leroy9, R. Wernitz10, A. Preci10 and G. Herdrich10
1Tecnalia Research & Innovation, 2Astrium SAS (France), 3Astrium GmbH(Germany), 4 Lièges HPK SA (France), 5DLR (Germany), 6High Performance Structures – HPS (Portugal), 7N.C.S.R "Demokritos"
(Greece), 8INCAS (Romania), 9ICMCB-CNRS (France), 10IRS – University of Stuttgart (Germany
The research leading to these results has received funding from the European Union Seventh Framework Programme (FP7/2007-2013) under grant agreement n° 283797
08-04-2013 / 2OUTLINE
INTRODUCTION AND MOTIVATION
CONCEPT OF THE PROJECT
CONSORTIUM, SCHEDULE AND WPs LOGIC
MISSION REVIEW AND TPS SPECIFICATIONS
MATERIALS STATE OF THE ART AND TRADE-OFF
MATERIALS SELECTION AND PROCUREMENT
BONDING & TPS ASSEMBLY
SIMULATION AND TPS DESIGN
CHARACTERISATION & VERIFICATION PLAN
SUMARY AND MAIN CONCLUSIONS
ACKNOWNLEDMENTS
08-04-2013 / 3
Original approaches based on ablative materials and novel TPS solutions are required for space applications where resistance in extreme oxidative environments and high temperatures are required. The atmospheric entry of space vehicles from high-energy trajectories requires high-performance thermal protection systems that can withstand extreme heat loads.
A new scenario has appeared due to a worldwide change in space mission planning strategies with entry vehicles going back to capsule designs and ablators are re-gaining attention.
Consequently, the development of new, more efficient materials and systems is a must. Such developments, nevertheless, have to be subject to extensive experimental investigations using suitable facilities. In this view, the investigation and development of new materials based on ablative and thermostructural concepts is crucial. A new (hybrid) concept based on the combination of both type of TPS materials is proposed.
The advantage of the ceramic for this function is the low density compared to ablative material and the excellent thermal performance in this heat load range, as well as the stability of the shape of TPS which is an advantage for the aerodynamic of the re-entry vehicle.
Another asset comes from the reliability and safety point of view. The underneath ceramic core offers extra thermal protection in case of the failure or underestimated design of the ablative external protections (see reference of the Galieo’s Probe). An accompanying effect is also the lower contamination during all mission phases and especially during re-entry.
INTRODUCTION AND MOTIVATION
08-04-2013 / 4
The concept of the project is based on the development of a novel hybrid heatshield, based on the integration of an external ablative parts with a CMC thermostructural core. This will be carried out by the integration of dissimilar materials.
The main advantage of a hybrid TPS heat-shield is based on the capability of the ablative layer of the hybrid TPS of bearing higher heat loads than the ceramic layer underneath.
The main challenge is to achieve a sound bonding among the two parts. This will be carried-out by advanced bonding technologies. This will be carried out by the study and development of new adhesives solutions, with improved mechanical and insulating characteristics. The use of advanced high temperature adhesives and hybrid solutions in combination with mechanical attachments will be assessed, as well as other existing hybrid solutions.
Ablative external shield
CMC core
Joining region & InterfaceAblative external shield
CMC core
Joining region & Interface
CMC core
Joining region & Interface
CONCEPT OF THE PROJECT
08-04-2013 / 5CONCEPT OF THE PROJECT
Heatflux
T (sec)
Interfacetemp,
limit 1200 ºC
Timeablative full burn-out
Ablative based re-entry CMC based re-entry
Heatfluxpeak,
From this point of view it will offer improved mechanical properties as well as higher robustness during the entry. Besides, the new moon or interplanetary missions planned cause higher heat loads during earth re-entry than ceramic or metallic TPS can withstand, since these heat loads are characterized by a peak profile the ablator can bear the high heat loads during the peak. For that a comparatively thin layer of ablative material is sufficient. The large integral loads will then be overtaken by the ablative/ceramic interfacial layer.
08-04-2013 / 6
CONSORTIUM MEMBERS LOCATION
1 - TECNALIA (Coordinator)
The core group of HYDRA project is composed of 10 public and private organisations coming from 5 different European countries: France, Greece, Germany, Romania and Spain.
3 – ASTRIUM-F
6 – HPS
7 – DEMOKRITOS
9 – ICMCB4 – HPK
2 – ASTRIUM-G
5 – DLR
10 – IRS
8 – INCAS
CONSORTIUM
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Part.No.Part. Short
NameProfile Relevant expertise for the project Role in the project WPs Involvement
1 TECNALIA Research centreCeramic composite materials design, processing, bonding terisation. Background on disseminations and technology transfer.
Coordination, materials developer, materials joining, centre in charge of dissemination actions.
WP2, WP5, WP8, WP9. Technical coordination in (WP1, WP3, WP4, WP6,
Wp7)
2 ASTRIUM-GEnd user, large company,
large system integrator
CMC material development, design, analysis, manufacturing & flight/ground testing as well as application
Developing, designing, manufacturing and characterization testing of C/SiC CMC's.
WP4, WP8
3 ASTRIUM-F End user, large company
Knowledge of management of atmospheric entry programs. Competence in heatshield thermal protection materials : development, production, characterisation, modelling and analysis
Mission specification, Material developer and producer, heatshield analysis
WP1, WP3, WP6, WP8
4 HPK SME, material supplierCork composite materials (formulations and manufacturing), tooling, bonding, moulding and prototyping
Ablative cork materials and TPS breadboard part supplier.
WP3, WP8
5 DLRResearch centre, space systems manufacturer,
DLR is the German space agency. CMC material development and charactersiation
Developing, designing, manufacturing and characterization testing of C/C-SiC CMC's. Characterisation of hybrid joints.
WP4, WP5, WP6, WP7, WP8
6 HPS SME, technology providerTPS technology provider. Konow-how on
materials selection.Technology advisory. Engineering consulting.
WP2, WP5, WP6, WP7, WP8
7 NCSRD Research centreAblative-ceramic joining. Ceramic composite
materials characterization & coatings.Materials joining and characterization.
WP3, WP4, WP5, WP7, WP8.
8 INCAS Research centre
Composite materials CFRP, C-C composite and partially ceramic matrix design,
processing, thermo-mechanical characterisation and morfostructural
investigation
Characterisation of space materials
WP7, WP8
9 ICMCB Research centreNumerical modeling of coupled phenomenon occurring at local scale, 3D imaging of multi
materialsModelling and characterisation WP6, WP7, WP8
10 IRS UniversityCharacterisation of TPS comments and hot
structures.
Ground re-entry characterisation and validation of the technology sample
WP1, WP7, WP8
CONSORTIUM
08-04-2013 / 8
WP1WP1
Mission Profile & TPS specs
WP2WP2
SoA & Materials Trade-off
WP
8W
P8
Use
, Exp
lota
ition
& D
isse
min
atio
n WP3WP3
Ablative Protection Shield
WP4WP4
Structural Ceramic Core
WP5WP5
Full TPS assembly
WP6WP6
Modeling, Simulation and Design
WP7WP7
Charac., Re-entry test & Validation
WP
9W
P9
Financial M
anagem
ent
RTD
MANAGEMENT
OTHER
WP1WP1
Mission Profile & TPS specs
WP2WP2
SoA & Materials Trade-off
WP
8W
P8
Use
, Exp
lota
ition
& D
isse
min
atio
n WP3WP3
Ablative Protection Shield
WP4WP4
Structural Ceramic Core
WP5WP5
Full TPS assembly
WP6WP6
Modeling, Simulation and Design
WP7WP7
Charac., Re-entry test & Validation
WP
9W
P9
Financial M
anagem
ent
RTD
MANAGEMENT
OTHER
WORKPACKAGE: STUDY LOGIC
08-04-2013 / 9SCHEDULE STATUS
Status at M13
WP No. Feb
ruar
y 20
12
Mar
ch 2
012
Apr
il 20
12
May
201
2
June
201
2
July
201
2
Aug
ust
2012
Sep
tem
ber
2012
Oct
ober
201
2
Nov
embe
r 20
12
Dec
embe
r 20
12
Janu
ary
2013
Feb
ruar
y 20
13
Mar
ch 2
013
Apr
il 20
13
May
201
3
June
201
3
July
201
3
Aug
ust
2013
Sep
tem
ber
2013
Oct
ober
201
3
Nov
embe
r 20
13
Dec
embe
r 20
13
Janu
ary
2014
Feb
ruar
y 20
14
Mar
ch 2
014
Apr
il 20
14
May
201
4
June
201
4
July
201
4
Aug
ust
2014
Sep
tem
ber
2014
Oct
ober
201
4
Nov
embe
r 20
14
Dec
embe
r 20
14
Janu
ary
2015
Feb
ruar
y 20
15
WP1 Mission review, trade-off, selection and TPS specs M1WP1.1 Mission ProfileWP1.2 TPS specificationsWP2 State-of-the-art & Materials trade-off M2WP2.1 State-of-the-artWP2.2 Materials trade-offWP3 Ablative protection shield M3WP3.1 Advanced ablative materials based on resinsWP3.2 Advanced ablative materials based on corkWP3.3 Manufacture of heat-shield partsWP4 Stuctural ceramic core M4WP4.1 Ceramic core development & characterizationWP4.2 Ceramic core concept verification & demonst.WP5 Full protection system assembly M5WP5.1 Definition of bonding processesWP5.2 Ablative/ceramic frames joiningWP5.3 Fabrication of TPS breadboardWP5.4. Testing & characterisation of the jointWP6 Modelling, simulation & TPS design M6WP6.1 Simulation of the oxidationWP6.2 Hybrid thermal modelling of the hybrid conceptWP6.3 TPS final designWP7 Characterisation, re-entry and validation M7WP7.1 Microstructural and Thermo-mechanical chara.WP7.2 Re-entry testingWP7.3 Validation of the envisaged TPS conceptWP8 Use, exploitation and dissemination M8WP8.1 Dissemination activities planWP8.2 Use planWP9 Financial management, coord. and reportingWP9.1 AdministrativeWP9.2 Financial
Year 1 Year 2 Year 3
08-04-2013 / 10MATERIALS TESTING & CHARACTERISATION PLAN
AST-F Manufacture of 10 ASTERM plates
(550 x 550 x 70 mm)
HPK Manufacture of 10 NORCOAT LIEGES
plates(550 x 550 x 70 mm)
AST-G Manufacture of SICARBON samples
1 m2 in different pannels, 5mm
DLR Manufacture of C-C/SiC samples
1 m2 in different pannels, 5mm
TECNALIA•Materials machining•Basic Thermal & Mechanical Characterisation•Gluing & Joining• Materials & Breadboard store
ICMCB - Thermal Characterisation:Only ablators Laser Flash (RT - 1100)Linear Dilatometry (RT-1600 ºC).(No. samples & Dimension TBD)
INCAS – Thermo-mechanical:Compression & Flexural (RT)Thermal shock QST2 (RT-1500 ºC)Microstructural study< 75 samples & 30 x 50 x 10 mm
NCRSD Neutron Tomography20 samples, Ø 40 x 40 mm aprox (special assembly). Before and after PWT
NCRSD Additional testing & surface treatments (K. Mergia)Ablative-ablative interfaces (G. Veknis)
DLRThermo-mechanical at INDUTHERM facility (RT-2000ºC)X-Ray tomography45 sa mples - 60x 60 x 60
IRSPlasma Wind Tunnel. 20 samples, Ø 39.8 x 40 mm aprox (special assembly)Emissivity (few samples are possible)
MANUFACTUREWP3 & WP4
ASSEMBLYWP5
CHARACTERISATION WP7
HPK“in-situ” Cork Composite manufacture on top of a
CMC plate
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Mission review and trade-off (by Astrium SAS): analysis of the current mission and European roadmaps for planetary re-entry
MISSION REVIEW AND TPS SPECIFICATIONS
08-04-2013 / 12
Final selection based on Earth re-entry: CSTS (from Low lunar orbit) and CTV/ARV (from ISS)
CSTS (Credit Astrium GmbH)CTV/ ARV (Credit Astrium SAS)
MISSION REVIEW AND TPS SPECIFICATIONS
08-04-2013 / 13MISSION REVIEW AND TPS SPECIFICATIONS
CTV/ARV (CREW TRANSFER VEHICLE / ADVANCED RE-ENTRY VEHICLE)
Control Points Heatflux evolution
Local stagnation pressure Heat-flux vs. Local stagnation pressure
08-04-2013 / 14MISSION REVIEW AND TPS SPECIFICATIONS
Control Points Heatflux evolution
Local stagnation pressure Heat-flux vs. Local stagnation pressure
CSTS (CREW SPACE TRANSPORTATION SYSTEM)
08-04-2013 / 15MISSION REVIEW AND TPS SPECIFICATIONS
Set of requirements defined with regards to the following criteria:
08-04-2013 / 16MATERIALS STATE OF THE ART AND TRADE-OFF
State of the art considering:
Analysis of previous “hybrid” concepts: SEPCORE® (ablator on top), SPA (CMC on top), HybridTPS (Porous ceramic infiltrated). Review of ablative materials at worldwide level with emphasis on European supplier. Locate the project partners in this state-of-the-art
Trade-off Consider relevant ablative TPS materials at worldwide level. Elaborate a TPS material selection matrix -> Trade-off criteria Establish a materials ranking Locate project partner in the ranking Tailor this selection matrix to mission definition from WP1
SEPCORE® (Herakles) SPA (Astrium GmbH)
08-04-2013 / 17MATERIALS SELECTION & PROCUREMENT
Two types of phenolic ablator envisaged for the project:
Cork based materials: NORCOAT FI (backshield) Graphite based materials: ASTERM (frontshield)
NORCOAT
(HPK Liéges)
ASTERM
(Astrium SAS)
08-04-2013 / 18
Two manufacturers CMC (Cf/SiC) envisaged for the project:
C/C-SiC (from DLR stuttgart). SICARBON© (EADS)
C/C-SiC
(DLR)
(EADS)
MATERIALS SELECTION & PROCUREMENT
08-04-2013 / 19
Selection of materials combination
FRONT SHIELD
Hybrid TPS selected
ASTERM+
SICARBON
Ablative external shield
CMC core
Joint at 100-150 ºCAblative external shield
CMC core
Joint at 100-150 ºC
CMC core
Joint at 100-150 ºC
EADS DLR + HPK
BACK SHIELD
NORCOAT+
C/C-SiC
BONDING & TPS ASSEMBLY
08-04-2013 / 20BONDING & TPS ASSEMBLY
Selection of adhesive:
Inorganic based adhesive for the ablator/ceramic joint Organic adhesive for the ablator/ablator interface Criteria of selection:
o Performance at the different phases (launching, ascent, re-entry)o Nature of the inorganic filler (alumina, silica, graphite, etc..)o Wettability with the surfaceso Curing temperatureo Ablator/ceramic interface temperature (aided by modeling)o Thermal properties (CTE, Thermal conductivity)
First stage of the re-entry
Ablative external shield
CMC core
Joint at 100-150 ºCAblative external shield
CMC core
Joint at 100-150 ºC
CMC core
Joint at 100-150 ºCJoint at 1500 ºC?Charred Ablator
CMC core
Second stage of the re-entry
08-04-2013 / 21SIMULATION & TPS DESIGN
Simulation at different levels:
Local thermo-chemical modelo At the micro/nano rangeo Aided by 3D model technologies by the use of a nano-tomographic system (ICMCB)
1D Thermal ablation model (Astrium SAS) -> Assessment of ablator thickness and interfacial temperature -> Lecture by G. Pinaud. Thermal analysis (2D model) -> Materials properties as input
TPS Design
Tile breadboard:o Foreseen dimensions of 100 mm x 100 mm (planar)o Including ablator/ablator joints and ablator/ceramic bonding.
Further mass saving calculation wrt a whole capsule vehicle (i.e. CTV/ARV)
Local model on ablators 1D model (thickness vs. interface temperature and recession)
08-04-2013 / 22CHARACTERISATION & VERIFICATION PLAN
Characterization of materials and bonded structures:
ASTERM ablator. Full characterization of thermal and mechanical propertieso Emissivity, coefficient of thermal expansion, specific heat, thermal diffusivity and
conductivityo Tensile, compressive and flexural strength (including cryogenic temperatures)
Adhesive:o First screening based on bonding results and shear strength testo Second screening based on thermal shock (QST-2 at INCAS) and cyclic test at
INDUTHERM (DLR Stuttgart)o Final selection based on the performance and the plasma wind tunnel (correlation with
WP1 specifications). Final test of the breadboard at the PWT (IRS, Stuttgart). Comparison of perfirmace vs. requirements.
Shear test at NCSR “Demokritos”Thermal schock furnace at INCAS
08-04-2013 / 23CHARACTERISATION & VERIFICATION PLAN
Cyclic test at INDUTHERM (DLR Stuttgart)
08-04-2013 / 24CHARACTERISATION & VERIFICATION PLAN
Final test of the breadboard at the PWT (IRS Stuttgart):
08-04-2013 / 25CHARACTERISATION & VERIFICATION PLAN
Final test of the breadboard at the PWT (IRS Stuttgart):
o Facility PWK2 for CTV/ARV conditionso Facility PWK1 for CSTS, using either RD5 or RD7 as plasma source for 5.7 MW/m2 condition
08-04-2013 / 26MAIN CONCLUSIONS AND FUTURE WORK
HYDRA is a new TPS concept that combines a low density ablator and a underneath hot substructure.
Main advantages are:1) Mass reduction as compared with a solution based on a single ablator solution, while 2) Increase the temperature limits as compared with a re-usable system
The project is running for one third of the total duration, the mission is selected, the requirements complied and the characterisation/verification plan is ready.
The materials trade-off is almost finished and the materials are have been just procured to the partners. The simulation phase and bonding study has been initiated.
Future effort will include the selection of the adhesive based on a complete screening study (2 nd year) and the execution of the verification plan (3 rd Year) including characterisation under Plama Wind Tunnel conditions.
A mass saving analysis will be carried-out with regards to a full shield concept.
08-04-2013 / 27ACKNOWLEDGMENTS
European Space Agency (M. Bottacini and B. Jeusset)
European Commission
Research Executive Agency (C. Ampatzis)
EADS-Innovation Works (C. Wilhelmi).
NCSRD (K. Triantou).
IRS (T. Marynowski)
ASTRIUM SAS (Y. Aspa)
08-04-2013 / 28
For more details visit the Project webpage: www.hydra-space.eu
WEB PAGE
08-04-2013 / 29
END OF PRESENTATION
Many thanks for your attention