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J-M BOUILLY , A. PISSELOUP - EADS Astrium - Saint-Médard-en-Jalles, France

RASTAS SPEAR : Ra diation- S hapes- T hermal Protection Investig a tion s for High Spe ed Ea rth R e-entry. 3rd International ARA Days - Arcachon, France 2011, May 2-4 - Session TPS-3. J-M BOUILLY , A. PISSELOUP - EADS Astrium - Saint-Médard-en-Jalles, France

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J-M BOUILLY , A. PISSELOUP - EADS Astrium - Saint-Médard-en-Jalles, France

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  1. RASTAS SPEAR :Radiation-Shapes-Thermal Protection Investigations for High Speed Earth Re-entry 3rd International ARA Days - Arcachon, France 2011, May 2-4 - Session TPS-3 J-M BOUILLY, A. PISSELOUP - EADS Astrium - Saint-Médard-en-Jalles, France O. CHAZOT - Von Karman Institute, Rhode-St-Genese, Belgium G. VEKINIS - Institute of Materials Science, NCSR "Demokritos", Greece A. BOURGOING - EADS Astrium Space Transportation, Les Mureaux, France B. CHANETZ - ONERA, Meudon, France O. SLADEK - Kybertec, s.r.o., Chrudim, Czec Rep. The research leading to these results has received funding from the European Union Seventh Framework Programme (FP7/2007-2013) under grant agreement n° 241992

  2. Overview • Introduction • Objectives • Overview of technical activities • Review of System Requirements • Ground Facilities Improvement • Key Technologies for High Speed Entry • Ablation – flight mechanics coupling assessment • Gas-surface interactions modeling • Next Steps / Conclusion 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3

  3. In the frame of EC FP7 second call Activity 9.2 – strengthening of space foundations / research to support space science exploration SPA.2009.2.1.01 Space Exploration Duration Sep 2010 - Sep 2012 Status : Team composed of 10 partners Astrium is the coordinator Budget total : 2.3 M€ including 1.6 M€ EU grant More on www.rastas-spear.eu Introduction 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3 3

  4. IoA MSU CNRS KYBERTEC LANDING GEAR DEPARTMENT ONERA VKI AST-F CFS DEMOKRITOS CIRA 10 partners from 8 European countries 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3

  5. General Objective • Sample Return Missions : an important step for Solar System Exploration • After collecting samples, any return mission will end by high-speed re-entry in Earth’s atmosphere. • This requires strong technological bases and a good understanding of the environment encountered during the Earth re-entry. • Investment in high speed re-entry technology development is thus appropriate today • to enable future planetary exploration missions in the coming decades. • Mars Sample Return, Marco Polo...  Rastas Spear project • to increase Europe’s knowledge in high speed re-entry vehicle technology Sample Return Capsule Other potential applications : ARV, Venus 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3

  6. Objectives of the project • OBJ1 (WP1, WP2, WP4 + WP5)To better understand phenomena during high speed re-entry enabling more precise Capsule sizing and reduced margins. • OBJ2 (WP2) :To identify the ground facility needs for simulation • OBJ3 (WP3) : To master heat shield manufacturing techniques and demonstrate heat shield capabilities. • OBJ4 (WP3+WP4) : To master damping at ground impact and flight mechanics and thus ensure a safe return of the samples 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3

  7. WBS WP1 Review of System Requirements WP6 Management, Dissemination and Exploitation 1.1 Atmosphere modelling 6.2 Dissemination & Exploitation 1.2 Trajectories 1.3 Aerodynamics & ATD 1.4 Vehicle Design WP2 Ground Facilities Improvement WP3 Key Technologies for High Speed Entry WP4 Ablation- Flight Mechanics Coupling assessment WP5 Gas-Surface Interactions Modelling 2.1: Analysis of Current Ground Facilities 3.1: Choice of TPS + Joints 4.1 Tools coupling 5.1: Review of surface roughness and blowing influence 6.1 Management 2.2: Shock tube technology 3.2: Flow tests 4.2 Ablation coupling assessment 5.2: Ground Experiment Preparation 2.3: Ballistic Range Technology 3.3: Breadboard manufacturing 4.3 Engineering modelling Correction by CFD 5.3: CFD Modelling 2.4: Plasma Generator Technology 3.4: Crushable Structure 5.4: Synthesis of WP 2.5: Synthesis 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3

  8. WP 1 results: Review of System Requirements • Main objective  provide with general inputs for any others WP • WP 1.1: Atmosphere modelling • - Atmosphere compositions for Earth and Venus, • Thermochemical model (kinetic model + thermal model) available, with identification of all possible species and chemical reactions. 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3

  9. WP 1 results: Review of System Requirements • WP 1.2: Trajectories • - Identification of generic aeroshapes with respect to candidate exploration missions. We focus our investigation on Earth entry, • Trajectories have been computed including usual design criteria • Flight domain determined with constraints on : • max heat flux, max heat load, max g-load • Sphere cone 45° • Diameter D =1100 mm • Nose radius Rn = 275 mm 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3 May 3rd 2011

  10. WP 1 results: Review of System Requirements • WP 1.3: Aerodynamics & Aerothermodynamics • - Aerodynamics: Newton Preliminary analysis • - Aerothermodynamics (Aerothermal environment) • Engineering methods for convective heating, • Shock-layer radiation computations for radiative heating (CNRS activities) 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3

  11. WP 1 results: Review of System RequirementsWP 1.4: Vehicle design - Preliminary design of the generic capsule, and determination of TPS thickness, in order to define the Mass Centering and Inertia (MCI) assuming a given architecture - Preliminary requirements related to TPS for other WP : surface recession, mass loss, temperature evolution, gas flow rate,… Lid structure Lid TPS Rear Energy absorbing material AFT TPS IF Carrier Internal insulation Filling Foam FS Structure Internal structure Front Energy absorbing material FS TPS Sample Canister 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3

  12. Objectives: • Review High Enthalpy facilities and dedicated instrumentation • Identification of ground testing facilities to reproduce flight environment • Identification of testing facilities for TPS qualification • First design of hypervelocity facility for Super-orbital reentry simulation WP2: Ground Facilities Improvement Typical example: X2 facility in dual-driver expansion tunnel mode (UQ, Australia) 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3

  13. WP2: Ground testing strategy M>>1 Real flight situation Aerospace vehicle nose Upstream flow Wall Chemistry Gas Surface Interaction Ablation Thermal Chemical Bow shock Reacting BL NEQ Shock Tube facility Plasma wind Tunnel Boundary layer TPS Shock layer Radiation studies TPS qualification Shock wave • Two kind of ground based facilities are involved to reproduce the typical flight environment: • - Shock tube / Shock tunnels duplicate the shock layer and generate database for the radiation features • - Plasma wind tunnels duplicate the boundary layer around the vehicle and allow TPS qualification • WP2 will review those facilities, provide recommendations for required performances of test facilities and associated methodologies, and preliminary define the hyper-velocity facility dedicated to high speed entry 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3

  14. WP3: Key Technologies for High Speed Entry WP3.1. Iterative search for new joint and bonding adhesives • Search for advanced adhesives for better performance • Elementary characterisation • Compare with heritage adhesives and optimise • Develop new, efficient and lower cost manufacturing processes WP3.2. Arc Jet validation at CIRA/SCIROCCO • Heat flux up to 15MW/m² (tbc) • Testing of range of joints and geometries WP3.3. Manufacture a demo TPS shield to demonstrate the technologies developed in RASTAS SPEAR 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3

  15. WP3: Key Technologies for High Speed Entry WP3.4. Crushable Structures Material selection for light damping structures Material characterisation tests Static Low speed dynamic Crush Modelling of energy absorption structures Manufacturing of corresponding item for techno demonstrator, and numerical validation 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3

  16. WP4: Ablation – flight mechanics coupling assessmentObjectives Based on WP1 results as inputs : flight environment, vehicle configuration 1- To assess impact of massive ablation on aerodynamic performances and stability along the entry trajectory path. 2- To identify recession level that could be tolerated with respect to capsule aerodynamic performances and stability requirements. 3- To elaborate and validate an engineering tool that couples: - Aeroshape aerodynamic, - Trajectory and stability, - Aerothermal environments, - TPS material thermal response - and then recession determination resulting in aeroshape modification. 4- To translate these results into criteria for maximum recession requirements in relation with usual landing accuracy, g-loads, heating and incidence profile issues. 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3

  17. WP4: Ablation – flight mechanics coupling assessment WP4.3 – Engineering modelling Correction by CFD (AST – CIRA - CNRS) Work logic: WP4.1 – Tools Coupling (AST) Coupling of following tools: - Ablation & thermal TPS response code including Aeroshape modification - Assessment of Aeroshape modification (CIRA) - Shock shape & - Pressure distribution & - Aerodynamic coefficients determination by CFD code, including ablation gas products injection - Assessment of Radiation (CIRA-CNRS) - Assessment of Surface mass blowing (CIRA) - 6 DoF Trajectory Tool - Development of engineering tool to determine radiating heating vs. recession rate (AST) - Engineering correlation derivation from CFD computations (AST) WP4.2 – Tools Coupling Assessment (AST) - Assessment of Ablations-flight mechanics effects for candidate Earth Entry capsule - Sensitivity to TPS ablative properties - Identification of requirements for maximum TPS recession Synthesis 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3

  18. Coupling of tools Detailed inputs (radiation, blowing, shape change) Flow aerodynamics Thermal response Ablation - Ablation & thermal TPS response code including Aeroshape modification WP 4.3 – Engineering modelling Correction by CFD (AST – CIRA - CNRS) - Shock shape & - Pressure distribution & - Aerodynamic coefficients determination by CFD code, incl. ablation products injection Trajectory - 6 DoF Trajectory Tool Assessment of coupling effects Requirements for max TPS recession 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3

  19. WP5: Gas-surface interactions modeling • WP 5.1 Review of surface roughness • Critical analysis from real flight (Astrium/MSU) • Bibliography about roughness and blowing (Onera/MSU) • Turbulence model recommendations (MSU/Onera) • WP 5.2 Ground experiment • Tests in Mach 5 blow down wind tunnel (Onera) • Test analyses (Euler + boundary layer) • WP 5.3 Model implementation • Engineering model assessment (MSU/CFS) Next slides 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3

  20. WP5: Gas-surface interactions modeling Experiments in the blow down wind tunnel R2Ch • Test Objective : qualification of the wall heat-flux with different roughness and blowing rate • Wind tunnel characteristics : • Mach 5 nozzle with an • exit diameter : 326 mm • pst : from 5 105 Pa to 50 105 Pa ; Tst = 650 K • Re (L=1 m) = 4.25 106 from 42.5 106 • Model :Flat plate with a sharp leading edge, already available from a prior test campaign During tests : - Heat flux measurements by infrared thermography, - Schlieren photographs 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3 May 3rd 2011

  21. L = 225,8mm l= 46,3 mm l = 46,3mm k b 2b WP5: Gas-surface interactions modeling • Three porous ceramic insert (porosity 48 %) - without roughness - with roughness r1 (pyramid height 100 microns) - with roughness r2 (pyramid height 300 microns) • Characteristics of the roughness : pyramids joined and in staggered rows 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3

  22. WP5: Gas-surface interactions modeling • Consequence for the tests : blowing with three mass-flow rates up to 3.8 kg/m²/s : - m1 : without blowing (reference case m1 = 0) - m2 : moderate blowing (m2 = 0.5 m3 = 1.9 kg/m²/s) - m3 : maximal blowing (m3 = 3.8 kg/m²/s) mass-flow rate calculated on the maximum heat-flux trajectory (from Astrium MSRO study-2000) 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3

  23. Next Steps 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3

  24. Conclusion • Rastas Spear is a typical R&D project • Part of European Community Framework Programme n°7 (FP7) • Objective to increase the TRL of • Key technologies • Methodologies • Project is now on-track • Frame of the study has been defined • Focus on passive Earth Return Capsule • Remaining steps until end of study will allow completion of overall project objectives • Completion Fall 2012 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3

  25. Thank you for your attention More at www.rastas-spear.eu 3rd International ARA Days - Arcachon 2-4 May 2011 - Session TPS-3 25

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