Mathematical modeling and testing results for the thermal state of an undamaged multilayer thermal protection of a flight vehicle

Аuthors

Titov D. M.^*, Bon A. F., Ermakov V. Y., Tufan A. ^**

Moscow Aviation Institute (National Research University), 4, Volokolamskoe shosse, Moscow, А-80, GSP-3, 125993, Russia

*e-mail: d.titov@mai.ru
**e-mail: anttufan@gmail.com

Abstract

In the current context of rocket and space technology development, the problem of creating efficient transportation systems for delivering payloads both to and from orbit has acquired particular importance. Colonization of celestial bodies and extraction of minerals on them are becoming key objectives of the 21st century, requiring a range of design solutions aimed at increasing cargo capacity. These solutions must be optimized for both practical and economic efficiency to ensure sustainable development of space programs. 
One of the promising transportation systems capable of effectively addressing these challenges is the reusable aerospace system. This system features horizontal takeoff and landing capabilities, allowing for a smoother acceleration profile and reduced peak dynamic pressure in the lower atmosphere. Additionally, it benefits from enhanced aerodynamic performance due to the use of atmospheric air as an oxidizer for propulsion systems throughout most of the ascent trajectory. 
Despite its numerous advantages, the reusable aerospace system faces a significant technical challenge – ensuring reliable thermal protection. During operation, this system experiences substantial thermal loads arising both during horizontal takeoff and landing, as well as during various stages of the ascent trajectory. 
To address this issue, a new concept of reusable thermal protection coating has been investigated. The concept utilizes composite materials with a ceramic matrix and aerogel to protect critical structural elements of reusable aerospace systems from thermal loads in various operational modes. 
Through numerical simulation of the thermal protection coating at critical points of the reusable aerospace system, using specially developed algorithmic software, it was determined that the temperature range at the considered points of the thermal protection coating reaches values from 935 K in the area of maximum radius rounding more than 1500 K at a rounding radius of 0,07 m. 
Based on the results of numerical simulation, an experimental thermal protection coating sample was manufactured. This sample underwent comprehensive testing on a vacuum plasma facility. Analysis of experimental data allowed comparing the characteristics of the proposed thermal protection coating with the similar material used in the Buran-type reusable aerospace system, known as gravimol. 
The results showed significant advantages of the proposed thermal protection coating in the following parameters: lower coating thickness at comparable heat fluxes compared to carbon-carbon material used in Buran-type systems; lower mass per unit surface area up to heat fluxes of 2,5×106 W/m2. 

Keywords:

Reusable thermal protection coating, reusable aerospace system, aerogel, ceramic matrix, unsteady heat conduction problem, Vacuum plasma facility

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