Evaluation of coated columbium alloy heat shields for space shuttle thermal protection system application

A three-phase program to develop and demonstrate the feasibility of a metallic heat shield suitable for use on Space Shuttle Orbiter class vehicles at operating surface temperatures of up to 1590 K (2400 F) is summarized. An orderly progression of configuration studies, material screening tests, and subscale structural tests was performed. Scale-up feasibility was demonstrated in the final phase when a sizable nine-panel array was fabricated and successfully tested. The full-scale tests included cyclic testing at reduced air pressure to 1590 K (2400 F) and up to 158 dB overall sound pressure level. The selected structural configuration and design techniques succesfully eliminated thermal induced failures. The thermal/structural performance of the system was repeatedly demonstrated. Practical and effective field repair methods for coated columbium alloys were demonstrated. Major uncertainties of accessibility, refurbishability, and durability were eliminated.