Mathematics – Logic
Scientific paper
Jan 2002
adsabs.harvard.edu/cgi-bin/nph-data_query?bibcode=2002iaf..confe.485p&link_type=abstract
IAF abstracts, 34th COSPAR Scientific Assembly, The Second World Space Congress, held 10-19 October, 2002 in Houston, TX, USA.,
Mathematics
Logic
Scientific paper
Ceramic matrix composite (CMC) materials allow design of high-temperature resistant, light and robust structures. CMC materials with silicon-carbide matrix reinforced by carbon fibers (C/SiC) show constant strength and damage-tolerant behavior up to very high temperatures. CMC thermal protection systems and hot structures have been developed in Europe over many years. MAN Technologie developed the necessary technologies to create the technological basis for CMC structures for future, more economical and reusable launch vehicles. Within the German space technology program TETRA (Technologies for Future Space Transportation Systems) body flaps were developed for X-38 by MAN Technologie. Key technologies like high strength oxidation protected CMC materials, manufacturing processes for large and complex structures, advanced high temperature lubricant coating combinations for bearings, joining with ceramic fasteners, metal-to-ceramic interfaces as well as dynamic seals are required for hot structures like control surfaces for re-entry vehicles. Because of the high heat and mechanical loads of a lifting body together with the low mass requirements the body flaps for NASA's X-38 re-entry vehicle V-201were selected to demonstrate as a first flight maturity of a large and complex ceramic structure. The flaps are designed as an all-ceramic, load-carrying hot structure, which needs no heavy metallic primary structure and no additional thermal protection tiles and subsequently offers considerable mass and volume savings. The X-38 body flaps are conceived as a revolutionary step forward. The twin flaps, each with the size of 1.6 m x 1.4 m (5.25 ft x 4.6 ft) and the low weight of 68 kg (150 lb) are all made of C/SiC material to operate up to temperatures of 1800 C (3.270 F) in oxidizing atmosphere while they are deflectable under high mechanical loads up to 50 kN (11.260 lbf) at the same time. The flaps are deflected about the hinge axis on two ceramic bearings and moved by an electromechanical actuator having a third hot bearing. The hinge line gap at the front part of the body flap is closed by a dynamic sealing system to minimize the flow of very hot gases to the leeward side. The paper in hand reports on design, manufacturing and assembly, together with the qualification of the body flaps and their components while the qualification test of the complete flap assembly is brought into focus. Flight readiness was approved by a series of qualification tests representing the full load spectrum of the X- 38 mission. It covered acceptance -, ascend vibration -, thermal transient -, static pressure - and finally descend vibration tests. Special facilities have been developed and manufactured for ground qualification of the flap assembly and the critical subcomponents. The manufacture and qualification of the X-38 body flaps represent a true milestone in the application of CMC. The stringent requirements and constraints, resulting from the assembly of many complex subcompo- nents and vehicle interfaces, require high material quality and precise manufacturing tolerances. Each qualification - and flight hardware element is therefore subjected to rigorous specifications, following detailed manufacturing process procedures with extensive quality control steps, as well as comprehensive documentation of design, analysis, manufacturing, assembly, interface control and vehicle integration. This challenge has been accepted and the objective to utilize MAN Technology's C/SiC as hot, load-carrying structures has reached a promising threshold. Material maturity as well as manufacturing competence is at a level where design and fabrication of CMC components for a operational re-entry vehicle can be proposed. The implementation of lightweight, durable ceramic hot structures is an innovative step forward in new spacecraft design. 1Name of Conference to which abstract is53 rd IAC 2Submission StatusFirst Submission 3TitleAll-Ceramic Body Flap Qualified for Space 4AuthorsPfeiffer, Heinz; Peetz, Kilian.
Peetz K.
Pfeiffer Hendryk
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