In-Space Repair and Refurbishment of Thermal Protection System Structures for Reusable Launch Vehicles

Advanced repair and refurbishment technologies are critically needed for the thermal protection system of current space transportation systems as well as for future launch and crew return vehicles. There is a history of damage to these systems from impact during ground handling or ice during launch. In addition, there exists the potential for in-orbit damage from micrometeoroid and orbital debris impact as well as different factors (weather, launch acoustics, shearing, etc.) during launch and re-entry. The GRC developed GRABER (Glenn Refractory Adhesive for Bonding and Exterior Repair) material has shown multiuse capability for repair of small cracks and damage in reinforced carbon-carbon (RCC) material. The concept consists of preparing an adhesive paste of desired ceramic with appropriate additives and then applying the paste to the damaged/cracked area of the RCC composites with an adhesive delivery system. The adhesive paste cures at 100-120 C and transforms into a high temperature ceramic during reentry conditions. A number of plasma torch and ArcJet tests were carried out to evaluate the crack repair capability of GRABER materials for Reinforced Carbon-Carbon (RCC) composites. For the large area repair applications, Integrated Systems for Tile and Leading Edge Repair (InSTALER) have been developed and evaluated under various ArcJet testing conditions. In this presentation, performance of the repair materials as applied to RCC is discussed. Additionally, critical in-space repair needs and technical challenges are reviewed.