Chart 1 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles > HELSMAC 7-8th April 2016

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1 Chart 1 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles > HELSMAC 7-8th April 2016 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles Dietmar Koch Thomas Reimer, Marius Kütemeyer, Hannah Böhrk Institute of Structures and Design, Stuttgart DLR German Aerospace Center

2 Chart 2 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles > HELSMAC 7-8th April 2016 Classification Attempt of TPS Systems Stardust FOTON-M2 ORION ARD EXPERT

3 Chart 3 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles > HELSMAC 7-8th April 2016 Classification Attempt of TPS Systems X-33 SHEFEX II Space Shuttle X-37B

4 Chart 4 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles > HELSMAC 7-8th April 2016 Classification Attempt of TPS Systems Deployable systems for long term missions (Mars) and heavy masses Contour changing systems LDSD = Low Density Supersonic Decelerator (NASA, Test 2014) IRDT = Inflatable Re-entry Demonstrator (ESA/Astrium, several tests 2000, 2002, 2005) LDSD IRDT

5 Chart 5 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles > HELSMAC 7-8th April 2016 Topics Ceramic Matrix Composites as thermal protection materials Ultra High Temperature Ceramic Matrix Composites High thermal conductive composites Applications Conclusions and Outlook

6 Chart 6 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles > HELSMAC 7-8th April 2016 Apollo The reason for blunt body re-entry shapes Amount of heat generated in re-entry depends on the vehicle shape Heat load increases with decreasing nose curvature radius The minimum radius is limited by available materials Shuttle nose factor qq = aa RR nn ρρ ρρ ssss Nose radius SHEFEX II Actual velocity normalised with orbital velocity = speed term 0,5 UU UU cccc 3,15 Actual density normalised with sea level density = altitude term

7 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles > HELSMAC 7-8th April 2016 Vision of Hypersonic Cruise Spaceliner SHEFEX III Twin cone Body/wing more efficient Source: NASA, X43 more flexible Shefex II From: Gasch et al., Handbook of Ceramic Composites, 2005, pp

8 Chart 8 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles > HELSMAC 7-8th April 2016 Vision of Hypersonic Cruise ZrB 2 (3400 C) HfB 2 (3400 C) HfC (3900 C) TaC (3800 C) From: Gasch et al., Handbook of Ceramic Composites, 2005, pp

9 Chart 9 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles > HELSMAC 7-8th April 2016 Ultra High Temperature stable CMC UHTCMC UHTC Low fracture toughness UHTCMC keep promising properties enhance fracture toughness by fiber reinforcement

10 Chart 10 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles > HELSMAC 7-8th April 2016 Processing of UHTCMC Manufacturing of porous fiber preform Reactive Melt Infiltration RMI via capillary forces reduced processing temperature without mechanical pressure good formation of ZrB2 in between fiber bundles to achieve low porosity UHTCMC Exothermal Reaction B+Zr ZrB 2 Melt

11 Chart 11 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles > HELSMAC 7-8th April 2016 Development Stages Processing of monolithic ZrB2 by RMI Use of thermo softening plastic (TP), Polycarbosilane (PCS), Depleted phenolic (PFA) Fiber reinforced ZrB2 by RMI Slurry Infiltration of Boron in SiC fiber with adapted porosity C fiber coating as protection against Zr melt ZrB2 SiC(f)/ZrB2+ZrC C f-tib2 /ZrB 2 -ZrC

12 Chart 12 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles > HELSMAC 7-8th April 2016 C f-tib2 /ZrB 2 -ZrC C f-tib2 -ZrB2-ZrC Carbon fiber with TiB 2 coating withstand Zr melt infiltration Phase C f TiB2 ZrB2 ZrC Residual melt UHTC Porosity Vol%

13 Chart 13 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles > HELSMAC 7-8th April 2016 Applications

14 Chart 14 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles > HELSMAC 7-8th April 2016 EXPERT TPS CMC Nose by DLR CMC material provides for clean flight environment Platform for 4 experiments Technology demonstration for complex CMC structures with joints

15 Chart 15 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles > HELSMAC 7-8th April 2016 SHEFEX Sharp Edge Flight Experiment Optimised aerodynamics in hypersonic regime with low drag and increased lift Mission flexibility due to greatly increased crossrange Low angle of attack and defined shock position for reduced black-out times Cost reduction for TPS elements due to facetted shape with flat panels Classic way to go: high angle of attack SHEFEX I Optimised way: low angle of attack

16 Chart 16 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles > HELSMAC 7-8th April 2016 Segmented CMC TPS for SHEFEX II CMC panels on CMC load introductions Lightweight dedicated insulation Focus on serial production aspects

17 Chart 17 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles > HELSMAC 7-8th April 2016 SHEFEX II Successful Flight Testing Launch 22 June 2012, Andoya, Norway Trajectory deviation < 1% Flight manoeuvers successful High quality experimental data Mach 10 resp. 2.8 km/s top velocity

18 Chart 18 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles > HELSMAC 7-8th April 2016 Conclusions Various TPS are available for specific applications New vehicle designs (sharp edges, hypersonic cruisers) need improved TPS Current activities focus on UHTC and UHTCMC based TPS for even higher thermal loading and long term use Outlook Development of highly efficient ablator systems with low density

19 Chart 19 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles > HELSMAC 7-8th April 2016 Thank you or your attention

20 Chart 20 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles > HELSMAC 7-8th April 2016 High Temperature Stable Fibre Reinforced Composites for Thermal Protection of Spacecraft Vehicles Dietmar Koch Thomas Reimer, Marius Kütemeyer, Hannah Böhrk Institute of Structures and Design, Stuttgart DLR German Aerospace Center