The FEI-TPS on the Upper Surface of the X-38

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Scientific paper

The X-38 is being developed by NASA-JSC as a technology demonstrator of a future Crew Rescue Vehicle. The size of the vehicle is limited to fit into the cargo bay of the shuttle. Due to its small size and shuttle-like trajectory all surfaces will receive comparably high heat rates leading to high surface temperatures. Temperatures on the nose are calculated to reach 1750°C, which is significantly higher than on the shuttle. Due to the lifting body shape, large areas of the central fuselage will be exposed to flow of hot gases around the vehicle. Here temperatures of the upper surface are calculated to reach up to 1000°C and the application of a high temperature blanket thermal protection system (TPS) becomes mandatory. Consecutively, the temperature level of the upper surface and the base area will be significantly high. Unlike on the shuttle, where large areas of the surface are covered by flexible reusable surface insulation (FRSI), locations with temperatures below 400°C will be scarce on the X-38. During development of the European shuttle HERMES the Flexible External Insulation (FEI) was developed for the upper surface TPS. This development was continued by ESA and DLR funded programs and currently a product family is available for temperatures ranging from 450°C to 1100°C for re-usable application. For a single re- entry under ultimate conditions temperatures may reach up to 1400°C. Under funding of DLR and ESA, the FEI assembly is one of the European contributions to the X-38. Three subassemblies have been chosen: the FEI-450, FEI-650 and FEI- 1000, capable of limit temperatures of 450°C, 650°C and 1000°C, respectively. The FEI-650 and FEI-1000 were already developed in the HERMES program. The FEI- 450 was developed in the German TETRA program. The qualification for X-38 application was performed for temperatures up to 510°C for the FEI-450 and up to 1130°C for the FEI-1000. Acoustic noise loads of up to 160dB have been endured, far beyond what X-38 will ever experience. The paper presents the design of the flexible blanket TPS in a joint effort by NASA-JSC and Astrium. The design process at NASA had to consider aerothermal loads and constraints of the structure and parachute subsystems. It provided the configuration of the FEI assembly and the requirements design of the FEI blankets. Astrium first designed the concept and lay-out of the FEI-assembly. Proceeding from NASA furnished model files, the design to manufacturing of the FEI-blankets was established. In addition, Astrium qualified the FEI for X-38 application. The FEI design is constrained by the aeroshell concept that distinguishes acreage panels, carrier panels and close-out areas, with dedicated blankets for each. Close out areas cover the locations of the parafoil system and create an uneven surface requiring vaulted blankets. The total of these requirements leads to an assembly of a large number of blankets, several of which have a complex shape.

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