CMC Nose Skirt Panels for X-38 - Successfully Qualification Tested and Fit-Checked

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Scientific paper

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Scientific paper

The X-38 Nose assembly follows an advanced design concept by considering light-weight C/SiC structures with C/SiC attachments for the Nose Cap and metallic attachments for the Nose Skirt. The design concept of the C/SiC nose assembly contains the advantages of low expansion and stable contour at high temperatures which enabled 3 different companies with different C/SiC materials to combine 4 different C/SiC components to a complete hot structural element. The Nose Cap, fabricated by DLR, can be seen as a separate part of the Nose Assembly due to the special fastening concepts, whereas the Nose Skirt follows a similar design concept for the panels and the metallic fastening concept is identical. The Nose Skirt is divided into the two large side panels, manufactured by Astrium and the small lower part of the skirt, the Chin Panel has been delivered by MAN-Technologie (see figure below). The design of the 3 Skirt panels comprises a light-weight, stringer stiffened concept which compensates the thermal expansion by a system of flexible metallic stand-offs. An optimum in flexibility and stiffness to fulfil all requirements had to be found: strong and stiff enough to carry the thermo-mechanical loads, but flexible enough to realise a fastening concept which does not fail due to thermal expansion. The thermal and vibration qualification tests have been successfully performed with a complete nose assembly full scale qualification model on a nose tip cold structure. These tests provided data with respect to the thermal deflection of the Nose Skirt Panels and the temperature gradients into the cold structure. On a sub-scale model the influences of the steps and gaps between the different panels and to the nose cap were investigated and were found non-critical for the re-entry environmental conditions. The paper gives an overview of the design concept of the newly developed TPS, presents the results of thermal, structural and plasma testing and gives an outlook for further development of the CMC Nose TPS on the CRV with reusable applications and for possible multi-mission application on future RLV's.

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