Thermostructural Evaluation of Joggle Region on the Shuttle Orbiter's Wing Leading Edge

An investigation was initiated to determine the cause of coating spallation occurring on the Shuttle Orbiter's wing leading edge panels in the slip-side joggle region. The coating spallation events were observed, post flight, on differing panels on different missions. As part of the investigation, the high re-entry heating occurring on the joggles was considered here as a possible cause. Thus, a thermostructural evaluation was conducted to determine the detailed state-of-stress in the joggle region during re-entry and the feasibility of a laboratory test on a local joggle specimen to replicate this state-of-stress. A detailed three-dimensional finite element model of a panel slip-side joggle region was developed. Parametric and sensitivity studies revealed significant stresses occur in the joggle during peak heating. A critical interlaminar normal stress concentration was predicted in the substrate at the coating interface and was confined to the curved joggle region. Specifically, the high interlaminar normal stress is identified to be the cause for the occurrence of failure in the form of local subsurface material separation occurring in the slip-side joggle. The predicted critical stresses are coincident with material separations that had been observed with microscopy in joggle specimens obtained from flight panels.