Analytic and experimental evaluation of flowing air test conditions for selected metallics in a shuttle TPS application

A detailed experimental and analytical evaluation was performed to define the response of TD nickel chromium alloy (20 percent chromium) and coated columbium (R512E on CB-752 and VH-109 on WC129Y) to shuttle orbiter reentry heating. Flight conditions important to the response of these thermal protection system (TPS) materials were calculated, and test conditions appropriate to simulation of these flight conditions in flowing air ground test facilities were defined. The response characteristics of these metallics were then evaluated for the flight and representative ground test conditions by analytical techniques employing appropriate thermochemical and thermal response computer codes and by experimental techniques employing an arc heater flowing air test facility and flat face stagnation point and wedge test models. These results were analyzed to define the ground test requirements to obtain valid TPS response characteristics for application to flight. For both material types in the range of conditions appropriate to the shuttle application, the surface thermochemical response resulted in a small rate of change of mass and a negligible energy contribution. The thermal response in terms of surface temperature was controlled by the net heat flux to the surface; this net flux was influenced significantly by the surface catalycity and surface emissivity. The surface catalycity must be accounted for in defining simulation test conditions so that proper heat flux levels to, and therefore surface temperatures of, the test samples are achieved.