Synthesis of the Gap Heating Analysis of the Hyflex Flight

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The NASDA/NAL HYFLEX vehicle was successfully flown at hypersonic speeds in February 1996. High-quality data were acquired on Thermal Protection System (TPS) heating during the atmospheric re-entry of this representative of a Reusable Launch Vehicle (RLV). The data pointed out large discrepancies between pre-flight predictions and in-flight measurements of the heating within the gaps between TPS tiles. In 1998, ESA started a Technological Research Project (TRP) devoted to the analysis of this issue and aiming at proposing a new methodology to predict the gap heating during atmospheric re-entry. Wind-tunnel tests have been carried out in DLR cold and hot hypersonic facilities (H2K, L3K) around HYFLEX tiles samples in order to characterise both convective and radiative contributions to the gap heating. These experiments have been numerically rebuilt by FGE (cold cases) and ONERA (hot cases), yielding new thermal correlations to be used in the gaps. These correlations have been successfully used by EADS ST to compute the thermal evolution of the samples in the experimental conditions, pointing out the importance of modelling turbulence and physical properties of the material. Eventually, the methodology has been applied to the flight conditions. The overall project results in new recommendations on the gap heating prediction methodology.

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