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All sourcesNASA NTRSDOE OSTI
NASA NTRS2000

TPS Materials and Costs for Future Reusable Launch Vehicles

There is considerable interest in developing new reusable launch vehicles (RLVs) for reducing the cost of transporting payload to and from orbit. This work reviews thirteen candidate thermal protection system (TPS) options currently available for RLVs. It is useful to begin with the current Shuttle TPS layout as a reference. The nose cap and wing leading edge , which reach the highest temperatures, are made of reinforced carbon-carbon (RCC) that is protected from oxidation by an external coating (about 0.020" thick) of silicon-carbide. Most of the windward surface is 9 lb/cubic ft ceramic tiles (LI-900) with a thin (about 0.012") coating of Reaction Cured Glass (RCG). The leeward side of the vehicle is covered largely by AFRSI, a quilted ceramic blanket, and FRSI, a polyamide felt. These four materials can be considered first generation reusable TPS. Since the time of the Shuttle design, considerable progress has been made advancing TPS technologies in terms of thermal performance, robustness, and cost. For each of the major systems, a second generation ceramic TPS has been developed, tested, and characterized. Metallic-based systems have also been developed. For applications requiring RCC in the past, advanced carbon-carbon (ACC) is now available. This material has better mechanical properties, somewhat higher temperature capability to 2900F and greatly increased oxidation resistance. New carbon fiber reinforced silicon-carbide matrix composites (C/SiCs) have shown additional improvement in properties over ACC with use temperatures to 3000F and above. For rigid tiles, NASA Ames has made two significant advancements. The first is a tile substrate called Alumina Enhanced Thermal Barrier, or AETB, that incorporates alumina fibers for improved dimensional stability at high temperatures, to 2600F and above. This material can be made to densities as low as 8 lb/cubic ft. The second is a coating preparation called Toughened Uni-piece Fibrous Insulation, or TUFT, that penetrates about 0.1 in. into the tile substrate. The resulting composite, with a functionally gradient density near the surface, provides orders of magnitude increased damage resistance compared with RCG coated LI-900, with only a small weight increase. The TPS that combines these two developments is called AETB-8/TUFI and has been adopted for high damage areas on the Shuttles. Two notable developments have occur-red in flexible ceramic blanket technology. The first is aluminoborosilicate-based fibers with use temperatures of 2200F and above," in comparison to quartz and silica fiber used in AFRSI which have multi-use temperature limits of 1200 to 1400F. Blankets incorporating these new high temperature fibers are referred to as AFRSI-HT. The second is an integral weaving techniques that produces a fluted core blanket with a smoother surface and greater resistance to aero-acoustic noise, to levels as high as 170 dB. This Ames innovation is called Tailorable Advanced Blanket Insulation, or TABI. Finally, for felt-based TPS, Boeing is developing Polybenzimidazole Blanket Insulation, or PBI, with a multi-use temperature limit of 1000F and above, in contrast to Shuttle FRSI which has a multi-use temperature limit of about 700F. 1.6 NASA Langley and BF Goodrich (formerly Rohr Corp.) have led the development of metallic-based TPS. This activity uses essentially three approaches: metallic tiles which encase a fibrous ceramic batting in a box fabricated largely from metallic honeycombs, typically Nickel based alloys; metallic honeycomb sheets, made of Nickel-based alloys, incorporating a fibrous back-side insulation encapsulated in a metallic foil bag, providing reduced weight; and metallic multi-wall, which is comprised of dimpled Titanium metal sheets, which are stacked and then diffusion bonded at contact points to form the TPS. The Nickel-based systems can be used up to temperatures of about 1800F, and the Titanium system to about 100F. These thirteen TPS materials have pros and cons to their usage in terms of temperature capability, weight, initial cost, and maintenance. Carbon-carbon and C/SiC systems have the highest temperature capability but are relatively expensive and heavy, requiring significant time, expertise, and costly facilities and tools for design and fabrication. Second generation ceramic tiles are relatively light, durable, simple to fabricate and easy to install; however, waterproofing is a concern. Blankets and felts are light, simple, inexpensive, and easy to install over curved vehicle surfaces, but durability and waterproofing are concerns. Metallics are robust and appear to have eliminated waterproofing, but they tend to be heavy and relatively expensive, requiring costly facilities and tools. If thin metal sheets are used to reduce weights, then issues arise from possible metal fatigue and corrosion caused by thermal cycling, pressure oscillations, and environmental exposure. For application to future RLVs, system analyses show that a significant component of the vehicle life cycle cost is from the TPS; however, it is difficult to quantify and to compare the potential savings of advanced systems without performing full vehicle designs using each of the different options. Because this entails a considerable effort and also tends to submerge TPS cost impacts under unrelated vehicle design assumptions, there is a clear need for a simpler quantitative method to evaluate the cost impact of different TPS options. To this end, this work introduces a TPS life-cycle cost parameter which is easily computed and applicable to generic RLVs.

Rasky, Dan J.↗
NASA NTRS2005

Quick Access Rocket Exhaust Rig Testing of Coated GRCop-84 Sheets Used to Aid Coating Selection for Reusable Launch Vehicles

The design of the next generation of reusable launch vehicles calls for using GRCop-84 copper alloy liners based on a composition1 invented at the NASA Glenn Research Center: Cu-8(at.%)Cr-4%Nb. Many of the properties of this alloy have been shown to be far superior to those of other conventional copper alloys, such as NARloy-Z. Despite this considerable advantage, it is expected that GRCop-84 will suffer from some type of environmental degradation depending on the type of rocket fuel utilized. In a liquid hydrogen (LH2), liquid oxygen (LO2) booster engine, copper alloys undergo repeated cycles of oxidation of the copper matrix and subsequent reduction of the copper oxide, a process termed "blanching". Blanching results in increased surface roughness and poor heat-transfer capabilities, local hot spots, decreased engine performance, and premature failure of the liner material. This environmental degradation coupled with the effects of thermomechanical stresses, creep, and high thermal gradients can distort the cooling channel severely, ultimately leading to its failure.

Raj, Sai V.↗
NASA NTRS2000

How X-37 Technology Demonstration Supports Reusable Launch Vehicles

This presentation discusses, in viewgraph form, how X-37 Technology Demonstration Supports Reusable Launch Vehicles. The topics include: 1) X-37 Program Objectives; 2) X-37 Description; 3) X-37 Vehicle Characteristics; 4) X-37 Expands the Testbed Envelope to Orbital Capability; 5) Overview of X-37 Flight Test Program; 6) Thirty-Nine Technologies and Experiments are Being Demonstrated on the X-37; 7) X-37 Airframe/Structures Technologies; 8) X-37 Mechanical, Propulsion, and Thermal System Technologies and Experiments; 9) X-37 GN&C Technologies; 10) X-37 Avionics, Power, and Software Technologies and Experiments; and 11) X-37 Technologies and Experiments Support Reusable Launch Vehicle Needs.

Manley, David J.↗
NASA NTRS1996

DSMC Grid Methodologies for Computing Low-Density, Hypersonic Flows About Reusable Launch Vehicles

Two different grid methodologies are studied for application to DSMC simulations about reusable launch vehicles. One method uses an unstructured, tetrahedral grid while the other uses a structured, variable-resolution Cartesian grid. The relative merits of each method are discussed in terms of accuracy, computational efficiency, and overall ease of use. Both methods are applied to the computation of a low-density, hypersonic flow about a winged single-stage-to-orbit reusable launch vehicle concept at conditions corresponding to an altitude of 120 km. Both methods are shown to give comparable results for both surface and flowfield quantities as well as for the overall aerodynamic behavior. For the conditions simulated, the flowfield about the vehicle is very rarefied but the DSMC simulations show significant departure from free-molecular predictions for the surface friction and heat transfer as well as certain aerodynamic quantities.

Wilmoth, Richard G.↗
NASA NTRS2000

Reusable Launch Vehicle Control In Multiple Time Scale Sliding Modes

A reusable launch vehicle control problem during ascent is addressed via multiple-time scaled continuous sliding mode control. The proposed sliding mode controller utilizes a two-loop structure and provides robust, de-coupled tracking of both orientation angle command profiles and angular rate command profiles in the presence of bounded external disturbances and plant uncertainties. Sliding mode control causes the angular rate and orientation angle tracking error dynamics to be constrained to linear, de-coupled, homogeneous, and vector valued differential equations with desired eigenvalues placement. Overall stability of a two-loop control system is addressed. An optimal control allocation algorithm is designed that allocates torque commands into end-effector deflection commands, which are executed by the actuators. The dual-time scale sliding mode controller was designed for the X-33 technology demonstration sub-orbital launch vehicle in the launch mode. Simulation results show that the designed controller provides robust, accurate, de-coupled tracking of the orientation angle command profiles in presence of external disturbances and vehicle inertia uncertainties. This is a significant advancement in performance over that achieved with linear, gain scheduled control systems currently being used for launch vehicles.

Shtessel, Yuri↗
NASA NTRS2001

Evaluation of Advanced Thermal Protection Techniques for Future Reusable Launch Vehicles

A method for integrating Aeroheating analysis into conceptual reusable launch vehicle RLV design is presented in this thesis. This process allows for faster turn-around time to converge a RLV design through the advent of designing an optimized thermal protection system (TPS). It consists of the coupling and automation of four computer software packages: MINIVER, TPSX, TCAT and ADS. MINIVER is an Aeroheating code that produces centerline radiation equilibrium temperatures, convective heating rates, and heat loads over simplified vehicle geometries. These include flat plates and swept cylinders that model wings and leading edges, respectively. TPSX is a NASA Ames material properties database that is available on the World Wide Web. The newly developed Thermal Calculation Analysis Tool (TCAT) uses finite difference methods to carry out a transient in-depth I-D conduction analysis over the center mold line of the vehicle. This is used along with the Automated Design Synthesis (ADS) code to correctly size the vehicle's thermal protection system JPS). The numerical optimizer ADS uses algorithms that solve constrained and unconstrained design problems. The resulting outputs for this process are TPS material types, unit thicknesses, and acreage percentages. TCAT was developed for several purposes. First, it provides a means to calculate the transient in-depth conduction seen by the surface of the TPS material that protects a vehicle during ascent and reentry. Along with the in-depth conduction, radiation from the surface of the material is calculated along with the temperatures at the backface and interior parts of the TPS material. Secondly, TCAT contributes added speed and automation to the overall design process. Another motivation in the development of TCAT is optimization.

Olds, John R.↗
NASA NTRS1999

Reusable Launch Vehicle Control in Multiple Time Scale Sliding Modes

A reusable launch vehicle control problem during ascent is addressed via multiple-time scaled continuous sliding mode control. The proposed sliding mode controller utilizes a two-loop structure and provides robust, de-coupled tracking of both orientation angle command profiles and angular rate command profiles in the presence of bounded external disturbances and plant uncertainties. Sliding mode control causes the angular rate and orientation angle tracking error dynamics to be constrained to linear, de-coupled, homogeneous, and vector valued differential equations with desired eigenvalues placement. The dual-time scale sliding mode controller was designed for the X-33 technology demonstration sub-orbital launch vehicle in the launch mode. 6DOF simulation results show that the designed controller provides robust, accurate, de-coupled tracking of the orientation angle command profiles in presence of external disturbances and vehicle inertia uncertainties. It creates possibility to operate the X-33 vehicle in an aircraft-like mode with reduced pre-launch adjustment of the control system.

Shtessel, Yuri↗
NASA NTRS2005

The Importance of Detailed Component Simulations in the Feedsystem Development for a Two-Stage-to Orbit Reusable Launch Vehicle

To meet the requirements for the 2nd Generation Reusable Launch Vehicle (RLV), a unique propulsion feed system concept was identified using crossfeed between the booster and orbiter stages that could reduce the Two-Stage-to-Orbit (TSTO) vehicle weight and development cost by approximately 25%. A Main Propulsion System (MPS) crossfeed water demonstration test program was configured to address all the activities required to reduce the risks for the MPS crossfeed system. A transient, one-dimensional system simulation was developed for the subscale crossfeed water flow tests. To ensure accurate representation of the crossfeed valve's dynamics in the system model, a high-fidelity, three-dimensional, computational fluid-dynamics (CFD) model was employed. The results from the CFD model were used to specify the valve's flow characteristics in the system simulation. This yielded a crossfeed system model that was anchored to the specific valve hardware and achieved good agreement with the measured test data. These results allowed the transient models to be correlated and validated and used for full scale mission predictions. The full scale model simulations indicate crossfeed is ' viable with the system pressure disturbances at the crossfeed transition being less than experienced by the propulsion system during engine start and shutdown transients.

Mazurkivich, Pete↗
NASA NTRS1998

Macroeconomic Benefits of Low-Cost Reusable Launch Vehicles

The National Aeronautics and Space Administration (NASA) initiated its Reusable Launch Vehicle (RLV) Technology Program to provide information on the technical and commercial feasibility of single-stage to orbit (SSTO), fully-reusable launchers. Because RLVs would not depend on expendable hardware to achieve orbit, they could take better advantage of economies of scale than expendable launch vehicles (ELVs) that discard costly hardware on ascent. The X-33 experimental vehicle, a sub-orbital, 60%-scale prototype of Lockheed Martin's VentureStar SSTO RLV concept, is being built by Skunk Works for a 1999 first flight. If RLVs achieve prices to low-earth orbit of less than $1000 US per pound, they could hold promise for eliciting an elastic response from the launch services market. As opposed to the capture of existing market, this elastic market would represent new space-based industry businesses. These new opportunities would be created from the next tier of business concepts, such as space manufacturing and satellite servicing, that cannot earn a profit at today's launch prices but could when enabled by lower launch costs. New business creation contributes benefits to the US Government (USG) and the US economy through increases in tax revenues and employment. Assumptions about the costs and revenues of these new ventures, based on existing space-based and aeronautics sector businesses, can be used to estimate the macroeconomic benefits provided by new businesses. This paper examines these benefits and the flight prices and rates that may be required to enable these new space industries.

Shaw, Eric J.↗
NASA NTRS1998

Optimization of Turbine Blade Design for Reusable Launch Vehicles

To facilitate design optimization of turbine blade shape for reusable launching vehicles, appropriate techniques need to be developed to process and estimate the characteristics of the design variables and the response of the output with respect to the variations of the design variables. The purpose of this report is to offer insight into developing appropriate techniques for supporting such design and optimization needs. Neural network and polynomial-based techniques are applied to process aerodynamic data obtained from computational simulations for flows around a two-dimensional airfoil and a generic three- dimensional wing/blade. For the two-dimensional airfoil, a two-layered radial-basis network is designed and trained. The performances of two different design functions for radial-basis networks, one based on the accuracy requirement, whereas the other one based on the limit on the network size. While the number of neurons needed to satisfactorily reproduce the information depends on the size of the data, the neural network technique is shown to be more accurate for large data set (up to 765 simulations have been used) than the polynomial-based response surface method. For the three-dimensional wing/blade case, smaller aerodynamic data sets (between 9 to 25 simulations) are considered, and both the neural network and the polynomial-based response surface techniques improve their performance as the data size increases. It is found while the relative performance of two different network types, a radial-basis network and a back-propagation network, depends on the number of input data, the number of iterations required for radial-basis network is less than that for the back-propagation network.

Shyy, Wei↗
NASA NTRS2004

Aeroheating Design Issues for Reusable Launch Vehicles: A Perspective

An overview of basic aeroheating design issues for Reusable Launch Vehicles (RLV), which addresses the application of hypersonic ground-based testing, and computational fluid dynamic (CFD) and engineering codes, is presented. Challenges inherent to the prediction of aeroheating environments required for the successful design of the RLV Thermal Protection System (TPS) are discussed in conjunction with the importance of employing appropriate experimental/computational tools. The impact of the information garnered by using these tools in the resulting analyses, ultimately enhancing the RLV TPS design is illustrated. A wide range of topics is presented in this overview; e.g. the impact of flow physics issues such as boundary-layer transition, including effects of distributed and discrete roughness, shockshock interactions, and flow separation/reattachment. Also, the benefit of integrating experimental and computational studies to gain an improved understanding of flow phenomena is illustrated. From computational studies, the effect of low-density conditions and of uncertainties in material surface properties on the computed heating rates are highlighted as well as the significant role of CFD in improving the Outer Mold Line (OML) definition to reduce aeroheating while maintaining aerodynamic performance. Appropriate selection of the TPS design trajectories and trajectory shaping to mitigate aeroheating levels and loads are discussed. Lastly, an illustration of an aeroheating design process is presented whereby data from hypersonic wind-tunnel tests are integrated with predictions from CFD codes and engineering methods to provide heating environments along an entry trajectory as required for TPS design.

Zoby, E. Vincent↗
NASA NTRS2004

Aeroheating Design Issues for Reusable Launch Vehicles: A Perspective

An overview of basic aeroheating design issues for Reusable Launch Vehicles (RLV), which addresses the application of hypersonic ground-based testing, and computational fluid dynamic (CFD) and engineering codes, is presented. Challenges inherent to the prediction of aeroheating environments required for the successful design of the RLV Thermal Protection System (TPS) are discussed in conjunction with the importance of employing appropriate experimental/computational tools. The impact of the information garnered by using these tools in the resulting analyses, ultimately enhancing the RLV TPS design is illustrated. A wide range of topics is presented in this overview; e.g. the impact of flow physics issues such as boundary-layer transition, including effects of distributed and discrete roughness, shock-shock interactions, and flow separation/reattachment. Also, the benefit of integrating experimental and computational studies to gain an improved understanding of flow phenomena is illustrated. From computational studies, the effect of low-density conditions and of uncertainties in material surface properties on the computed heating rates a r e highlighted as well as the significant role of CFD in improving the Outer Mold Line (OML) definition to reduce aeroheating while maintaining aerodynamic performance. Appropriate selection of the TPS design trajectories and trajectory shaping to mitigate aeroheating levels and loads are discussed. Lastly, an illustration of an aeroheating design process is presented whereby data from hypersonic wind-tunnel tests are integrated with predictions from CFD codes and engineering methods to provide heating environments along an entry trajectory as required for TPS design.

Zoby, E. Vincent↗
NASA NTRS2005

Simulation and Analyses of Stage Separation Two-Stage Reusable Launch Vehicles

NASA has initiated the development of methodologies, techniques and tools needed for analysis and simulation of stage separation of next generation reusable launch vehicles. As a part of this activity, ConSep simulation tool is being developed which is a MATLAB-based front-and-back-end to the commercially available ADAMS(registered Trademark) solver, an industry standard package for solving multi-body dynamic problems. This paper discusses the application of ConSep to the simulation and analysis of staging maneuvers of two-stage-to-orbit (TSTO) Bimese reusable launch vehicles, one staging at Mach 3 and the other at Mach 6. The proximity and isolated aerodynamic database were assembled using the data from wind tunnel tests conducted at NASA Langley Research Center. The effects of parametric variations in mass, inertia, flight path angle, altitude from their nominal values at staging were evaluated. Monte Carlo runs were performed for Mach 3 staging to evaluate the sensitivity to uncertainties in aerodynamic coefficients.

Pamadi, Bandu N.↗
NASA NTRS2007

Simulation and Analyses of Stage Separation of Two-Stage Reusable Launch Vehicles

NASA has initiated the development of methodologies, techniques and tools needed for analysis and simulation of stage separation of next generation reusable launch vehicles. As a part of this activity, ConSep simulation tool is being developed which is a MATLAB-based front-and-back-end to the commercially available ADAMS(Registerd TradeMark) solver, an industry standard package for solving multi-body dynamic problems. This paper discusses the application of ConSep to the simulation and analysis of staging maneuvers of two-stage-to-orbit (TSTO) Bimese reusable launch vehicles, one staging at Mach 3 and the other at Mach 6. The proximity and isolated aerodynamic database were assembled using the data from wind tunnel tests conducted at NASA Langley Research Center. The effects of parametric variations in mass, inertia, flight path angle, altitude from their nominal values at staging were evaluated. Monte Carlo runs were performed for Mach 3 staging to evaluate the sensitivity to uncertainties in aerodynamic coefficients.

Pamadi, Bandu N.↗
NASA NTRS1996

Development of a Pressure Box to Evaluate Reusable-Launch-Vehicle Cryogenic-Tank Panels

A cryogenic pressure-box test machine has been designed and is being developed to test full-scale reusable launch vehicle cryogenic-tank panels. This machine is equipped with an internal pressurization system, a cryogenic cooling system, and a heating system to simulate the mechanical and thermal loading conditions that are representative of a reusable launch vehicle mission profile. The cryogenic cooling system uses liquid helium and liquid nitrogen to simulate liquid hydrogen and liquid oxygen tank internal temperatures. A quartz lamp heating system is used for heating the external surface of the test panels to simulate cryogenic-tank external surface temperatures during re-entry of the launch vehicle. The pressurization system uses gaseous helium and is designed to be controlled independently of the cooling system. The tensile loads in the axial direction of the test panel are simulated by means of hydraulic actuators and a load control system. The hoop loads in the test panel are reacted by load-calibrated turnbuckles attached to the skin and frame elements of the test panel. The load distribution in the skin and frames can be adjusted to correspond to the tank structure by using these turnbuckles. The seal between the test panel and the cryogenic pressure box is made from a reinforced Teflon material which can withstand pressures greater than 52 psig at cryogenic temperatures. Analytical results and tests on prototype test components indicate that most of the cryogenic-tank loading conditions that occur in flight can be simulated in the cryogenic pressure-box test machine.

Ambur, Damodar R.↗
NASA NTRS1995

Reusable launch vehicle development research

NASA has generated a program approach for a SSTO reusable launch vehicle technology (RLV) development which includes a follow-on to the Ballistic Missile Defense Organization's (BMDO) successful DC-X program, the DC-XA (Advanced). Also, a separate sub-scale flight demonstrator, designated the X-33, will be built and flight tested along with numerous ground based technologies programs. For this to be a successful effort, a balance between technical, schedule, and budgetary risks must be attained. The adoption of BMDO's 'fast track' management practices will be a key element in the eventual success of NASA's effort.

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