Development of Advanced Metallic-Thermal-Protection System Prototype Hardware

A new metallic thermal-protection-system concept has been designed, analyzed, and fabricated. A specific location on a single-stage-to-orbit reusable launch vehicle was selected to develop loads and requirements needed to design prototype panels. The design loads include ascent and entry heating rates, pressures, acoustics, and accelerations. Additional design issues were identified and discussed. An iterative sizing procedure was used to size the thermal protection system panels for thermal and structural loads as part of an integrated wall construction that included the thermal protection system and cryogenic tank structure. The panels were sized to maintain acceptable temperatures on the underlying structure and to operate under the design structural loading. Detailed creep analyses were also performed on critical components of the panels. Four 18-in.-square metallic thermal-protection-system panels were fabricated. A lightweight, thermally compliant support system to connect the thermal protection system to the cryogenic tank structure was designed and fabricated.