Exploratory development of a flexible ablative covering for space shuttle application

An applied research program is considered for a preliminary design and development of a flexible ablative covering for the space shuttle vehicle that could be easily replaced and/or refurbished. The program was structured to concentrate resources on the major technical problem areas associated with the flexible ablator concept. These areas included: (1) fabrication of a suitable woven carpet reinforcement, (2) modification of a flexible ablator formulation for filling the woven carpet construction, and (3) testing of the flexible ablator concept. Several approaches were evaluated to obtain a flexible ablator. The final recommended solution was one in which the ablative filler was based on a low-density formulation of the elastomeric shield material series (ESM). The preferred approach is one in which a light-weight fabric backing is bonded to preformed and fully cured ESM, and the composite tufted with Astroquartz fiber to the desired tuft or pile density. Ablation tests performed in a hyperthermal arc facility demonstrated the ablation performance of the concept and overshoot capability of the system.