Further Investigations of Control Surface Seals for the X-38 Re-Entry Vehicle

NASA is currently developing the X-38 vehicle that will be used to demonstrate the technologies required for a potential crew return vehicle (CRV) for the International Space Station. This vehicle would serve both as an ambulance for medical emergencies and as an evacuation vehicle for the Space Station. Control surfaces on the X-38 (body flaps and rudder/fin assemblies) require high temperature seals to limit hot gas ingestion and transfer of heat to underlying low-temperature structures to prevent over-temperature of these structures and possible loss of the vehicle. NASAs Johnson Space Center (JSC) and Glenn Research Center (GRC) are working together to develop and evaluate seals for these control surfaces. This paper presents results for compression. flow, scrub, and arc jet tests conducted on the baseline X-38 rudder/fin seal design. Room temperature seal compression tests were performed at low compression levels to determine load versus linear compression, preload. contact area, stiffness. and resiliency characteristics under low load conditions. For all compression levels that were tested, unit loads and contact pressures for the seals were below the 5 lb/in. and 10 psi limits required to limit the loads on the adjoining Shuttle thermal tiles that the seals will contact. Flow rates through an unloaded (i.e. 0% compression) double arrangement were twice those of a double seal compressed to the 20% design compression level. The seals survived an ambient temperature 1000 cycle scrub test over relatively rough Shuttle tile surfaces. The seals were able to disengage and re-engage the edges of the rub surface tiles while being scrubbed over them. Arc jet tests were performed to experimentally determine anticipated seal temperatures for representative flow boundary conditions (pressures and temperatures) under simulated vehicle re-entry conditions. Installation of a single seat in the gap of the test fixture caused a large temperature drop (1710 F) across the seal location as compared to an open gap condition (140 F) confirming the need for seals in the rudder/fin gap location. The seal acted as an effective thermal barrier limiting heat convection through the seal gap and minimizing temperature increases downstream of the seal during maximum heating conditions.