Design and fabrication of a super alloy thermal protection system

A lightweight metallic TPS was designed, and two test articles were fabricated, one from Haynes 188 and one from Rene 41. A baseline TPS concept, selected at the beginning of the program, consisted of a Haynes 25 corrugation-stiffened beaded skin surface panel, a specially designed support system, and an insulation system. By optimizing the structure for the design loads and by chem-milling to remove material not needed, the mass of the baseline surface panel was reduced 25%, and the mass of the support structure was reduced 50%. The insulation system mass was reduced 40% by using two types of insulation, each suited to its temperature range, and by eliminating a foul bag which encapsulated the baseline insulation system. These reductions resulted in an overall 35% reduction in mass of the Haynes 188 panel from the baseline Haynes 25 design. Similar reductions were achieved with the Rene 41 system.