Dynamic and Static High Temperature Resistant Ceramic Seals for X- 38 re-Entry Vehicle

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Scientific paper

In a highly successful partnership, NAS A, ESA, DLR (German Space Agency) and European industry are building the X-38, V201 re-entry spacecraft, the prototype of the International Space Station's Crew Return Vehicle (CRV). This vehicle would serve both as an ambulance for medical emergencies and as an evacuation vehicle for the Space Station. The development of essential systems and technologies for a reusable re-entry vehicle is a first for Europe, and sharing the development of an advanced re-entry spacecraft with foreign partners is a first for NASA. NASA, in addition to its subsystem responsibilities, is performing overall X-38 vehicle system engineering and integration, will launch V201 on the Space Shuttle, deliver flight data for post-flight analysis and assessment and is responsible for development and manufacture of structural vehicle components and thermal protection (TPS) tiles. The major European objective for cooperation with NASA on X-38 was to establish a clear path through which key technologies needed for future space transportation systems could be developed and validated at affordable cost and with controlled risk. Europe has taken the responsibility to design and manufacture hot control surfaces like metallic rudders and ceramic matrix composites (CMC) body flaps, thermal protection systems such as CMC leading edges, the CMC nose cap and -skirt, insulation, landing gears and elements of the V201 primary structure. Especially hot control surfaces require extremely high temperature resistant seals to limit hot gas ingestion and transfer of heat to underlying low-temperature structures to prevent overheating of these structures and possible loss of the vehicle. Complex seal interfaces, which have to fulfill various, tight mission- and vehicle-related requirements exist between the moveable ceramic body flaps and the bottom surface of the vehicle, between the rudder and fin structure and the ceramic leading edge panel and TPS tiles. While NASA concentrated on the development, qualification and manufacture of dynamic seals in the rudder area, the responsibility of MAN Technologie focused on the development, lay-out, qualification and flight hardware manufacture of static and dynamic seals in ceramic hot structures' associated gaps and interfaces, dealing with re-entry temperatures up to 1600°C. This paper presents results for temperature and mechanical stability, flow, scrub (up to 1000 cycles) and of arc jet tests under representative low boundary conditions and plasma step/gap tests, conducted during the development and qualification phases of these different kind of ceramic seals. Room temperature seal compression tests were performed at low compression levels to determine load versus linear compression, preload, contact area, stiffness and resiliency characteristics under low load conditions. Flow tests with thermally aged seals were conducted at ambient temperature to examine leakage at low compression levels and in as-manufactured conditions. Seal scrub tests were performed to examine durability and wear resistance and to recommend surface treatments required to maximize seal wear life. Results of arc jet/plasma tests under simulated re-entry conditions (pressure, temperature) verified seal temperature stability and function under representative assembly and interface conditions. Each of these specifically developed seals fulfilled the requirements and is qualified for flight on X-38, V201.

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