Static and aerothermal tests of a superalloy honeycomb prepackaged thermal protection system

A reusable metallic thermal protection system has been developed for vehicles with maximum surface temperatures of up to 2000 F. An array of two 12- by 12-in. panels was subjected to radiant heating tests that simulated Space Shuttle entry temperature and pressure histories. Results indicate that this thermal protection system, with a mass of 2.201 lbm/ft(exp 2), can successfully prevent typical aluminum primary structure of an entry vehicle like the Space Shuttle from exceeding temperatures greater than 350 F at a location on the vehicle where the maximum surface temperature is 1900 F. A flat array of 20 panels was exposed to aerothermal flow conditions, at a Mach number of 6.75. The panels were installed in a worst-case orientation with the gaps between panels parallel to the flow. Results from the aerothermal tests indicated that convective heating occurred from hot gas flow in the gaps between the panels. Proposed design changes to prevent gap heating occurred from hot gas flow in the gaps between the panels. Proposed design changes to prevent gap heating include orienting panels so that gaps are not parallel to the flow and using a packaged, compressible gap-filler material between panels to block hot gas flow in the gaps.