A Method of Integrating Aeroheating into Conceptual Reusable Launch Vehicle Design: Evaluation of Advanced Thermal Protection Techniques for Future Reusable Launch Vehicles

A method for integrating Aeroheating analysis into conceptual reusable launch vehicle (RLV) design is presented in this thesis. This process allows for faster turn-around time to converge a RLV design through the advent of designing an optimized thermal protection system (TPS). It consists of the coupling and automation of four computer software packages: MINIVER, TPSX, TCAT, and ADS. MINIVER is an Aeroheating code that produces centerline radiation equilibrium temperatures, convective heating rates, and heat loads over simplified vehicle geometries. These include flat plates and swept cylinders that model wings and leading edges, respectively. TPSX is a NASA Ames material properties database that is available on the World Wide Web. The newly developed Thermal Calculation Analysis Tool (TCAT) uses finite difference methods to carry out a transient in-depth 1-D conduction analysis over the center mold line of the vehicle. This is used along with the Automated Design Synthesis (ADS) code to correctly size the vehicle's thermal protection system (TPS). The numerical optimizer ADS uses algorithms that solve constrained and unconstrained design problems. The resulting outputs for this process are TPS material types, unit thicknesses, and acreage percentages. TCAT was developed for several purposes. First, it provides a means to calculate the transient in-depth conduction seen by the surface of the TPS material that protects a vehicle during ascent and reentry. Along with the in-depth conduction, radiation from the surface of the material is calculated along with the temperatures at the backface and interior parts of the TPS material. Secondly, TCAT contributes added speed and automation to the overall design process. Another motivation in the development of TCAT is optimization. In some vehicles, the TPS accounts for a high percentage of the overall vehicle dry weight. Optimizing the weight of the TPS will thereby lower the percentage of the dry weight accounted for by the TPS. Also, this will lower the cost of the TPS and the overall cost of the vehicle.