FP7/Space Project "SMARTEES". Towards a New TPS Reusable

15-11-2012 / 1
 The purpose of this presentation is to sum up all the actions to be carried out
in the next few months.
 As indicated during the kick-off meeting it is very important to start the
development
of theFP7
TPS
withProject
a simple
approach.
SMARTEES
Space
– Towards
a New TPS Reusable Concept for
Atmospheric Reentry From Low Earth Orbit
 We can have baseline, which can become more and more complex as we
progress with the1 project.1
1
1
2
2
3
J. Barcena , M. Lagos , I. Agote , C. Jimenez , C. Badini , E. Padovano , S. Gianella , D.
Gaia3, V. Liedtke4, K. Mergia5, S. Messoloras5, P. Yialouris5, Y. Panayiotatos5, A. Ortona6, C.
Then, we can think about a very
simple
TPS
assembly
design in order
6, and C.
7
D’angelo
Wilhelmi
to carry
out a “bottom-up” approach and after we could get the baseline for
Tecnalia (Spain), Politecnico di Torino (Italy), Erbicol (Switzerland), Aerospace & Advanced Composites (Austria),
manufacturing,
andSUPSI
testing.
Nationalcharacterisation,
Center for Scientific Researchsimulation
“Demokritos” (Greece)
(Switzerland), EADS (Germany)
1
2
5
3
4
6
7
The research leading to these results has received funding from the European Union Seventh Framework Programme (FP7/2007-2013)
under grant agreement n° 283797
OUTLINE
15-11-2012 / 2
 INTRODUCTION AND MOTIVATION OF THE WORK
 CONSORTIUM
 RESULTS
 CONCLUSIONS, LESSONS LEARNT AND FUTURE WORK
 ACKNOWNLEDMENTS
INTRODUCTION AND MOTIVATION
15-11-2012 / 3

There is a strong interest in the development of reusable systems to accessing and return
from Space. I.e. reusable capsules.

This reusable systems demands a huge effort, not only in the development of new materials
but also in the integration of them into the subsystems.

On the one hand, ESA’s TPS technology are based on existing materials high TRL and
mission oriented. On the other hand, EC space programmes allow the development of
critical/disruptive technologies for advanced materials on TPS. On this context
SMARTEES proposes innovative TPS concepts for ISS return systems and future launchers.
Space tourism are potential candidate uses as well.

Future space transportation, equipped with re-usable components will greatly reduce the
cost of launching a payload into space. This issue is of great importance, i.e. ESA
technology strategy and long term plan.

SMARTEES addresses the development of advanced ceramic composites structures for
reusable thermal protection systems. The solution will be based on a novel reusable TPS
architecture which can withstand the extreme environment conditions
CONSORTIUM
15-11-2012 / 4
 CONSORTIUM MEMBERS LOCATION
The core group of SMARTEES project is
composed of 7 public and private organisations
coming from 6 different European countries:
Spain, Italy, Greece, Switzerland, Germany and
Austria.
5 - EADS - IW
6 - SUPSI
7 - AAC
1 - TECNALIA
(Coordinator)
3 - ERBICOL
4 - NCSRD
2- POLITO
15-11-2012 / 5
WP1: TPS design
WP2: Materials
development
WP3: Joining
processes
WP4:Simulation
WP5:TPS Sample
Assembly
WP6: Ground testing and validation
Proof TPS design
TPS manufacture chain
Mockup assembly
Delivery for ground testing
Validation process
WP7: Use and dissemination
WP8: Coordination and reporting
WORKPACKAGES: STUDY LOGIC
RE-SCHEDULE OF THE PROJECT
Schedule after
27 months
15-11-2012 / 6
REQUERIMENTS & TPS DESIGN

15-11-2012 / 7
A current Mission is selected based on the Advanced Re-entry Vehicle*:
 Re-entry module evolved from ATV. It is a real mission owned by ESA and developed by
Astrium GmbH, which consist of a capsule-like concept for a service module to the ISS.
 There are two versions for cargo or crew system. The re-entry will be from LEO (500 km).
The first flight will be not reusable and currently there is a trade-off of designs (the currently
favoured one is similar to Apollo).
For more details go to ARV’s webpage: http://www.esa.int/esaMI/ATV/SEMNFZOR4CF_0.html
*ARV data have been produced by Astrium GmbH in the frame of a Contract with ESA
REQUERIMENTS & TPS DESIGN
15-11-2012 / 8
REQUERIMENTS & TPS DESIGN

The following specifications have been collected:
 Heatfluxes
 Time (during peak & total)
 Pressure profile
 Mechanical load
 3 different scenarios have been envisaged
15-11-2012 / 9
TPS DESIGN

A preliminary TPS design is ready and detailed design is on-going:
 Materials & structure levels
 Shape and thicknesses
 Joining definition
 Stand-off attachments
Schematic concept design (as an example)
15-11-2012 / 10
MATERIALS DEVELOPMENT

External protective multilayers based on high and ultrahigh temperature ceramics:
 High temperature (SiC based) suitable for environments for temperatures below 1700 ºC.
 Ultrahigh temperature ceramics (ZrB2 based) suitable for temperatures above 1700 ºC.
15-11-2012 / 11
MATERIALS DEVELOPMENT
External protective multilayers
15-11-2012 / 12
MATERIALS DEVELOPMENT
15-11-2012 / 13
External protective multilayers. UHTC based
More details given under the presenation by Prof. Badini (Tuesday 9th at 9.25, Newton)
MATERIALS DEVELOPMENT
CMC External skins
CMC (Cf/SiC) from EADS (PIP Process)
15-11-2012 / 14
MATERIALS DEVELOPMENT
SiSiCFoams: TPS Insulating Core
15-11-2012 / 15
MATERIALS DEVELOPMENT
SiSiCFoams: TPS Insulating Core
15-11-2012 / 16
MATERIALS DEVELOPMENT
SiSiCFoams: TPS Insulating Core
15-11-2012 / 17
MATERIALS DEVELOPMENT
SiSiCFoams: TPS Insulating Core
15-11-2012 / 18
JOINING PROCESSES

15-11-2012 / 19
Definition, selection and implementation of the bonding processes.
 External hot-structure to CMC assembly
 Assembly of stand-offs to the structure
Multilayer/CMC Joining, Credit:NCRSD/TECNALIA
CMC/Stand-off Joining, Credit:NCRSD/TECNALIA

Thermo-mechanical characterization and high temperature oxidation testing:
 Thermal conductivity
 Emissivity
 Mechanical loads
 Coefficient of thermal expansion
 Cataliticity
More details under the presenation by Dr. Mergia (Tuesday 9th at 11.25, Newton 2).
MODELING & SIMULATION

15-11-2012 / 20
Modelling of the different parts of the TPS (aided by computed tomography)
Credit: RX Solutions (France) made with ERBISIC ceramic foams (Erbicol S. Gianella)

Themo-mechanical analysis
 Inputs for WP1 (specifications), WP2 (materials) and WP3 (processes)
 Definition of temperature distribution
 The output has allowed to calculate critical design parameters (WP1), such as aerial mass.
Temperature distribution
(C. D´Angelo, SUPSI)
Stress distribution
(C. D´Angelo, SUPSI)
TPS TECHNOLOGY SAMPLE ASSEMBLY

15-11-2012 / 21
Scale-up of materials and processes to build-up a technology sample
WP1: TPS design
WP2: Materials
development
WP3: Joining
processes
WP4:Simulation
WP5:TPS Sample
Assembly

This sample will be a TPS tile with functional properties -> First assembly trials

Foreseen dimensions 150 x 150 mm.

Full characterisation of the technological sample: mechanical and thermo-physical.

Characterisation at the ground test re-entry rig.
Ceramic multilayers (POLITO E. Padovano)
ERBISIC ceramic foams (Erbicol S. Gianella)
CMC/SiC sandwiches progress (EADS-IW, C. Wilhelmi)
GROUND TESTING AND VALIDATION
15-11-2012 / 22
 Bottom-up approach for testing in a ground facility simulating the re-entry conditions.
 The testing is determining the fundamental performance and the degradation mechanisms.
 This final step will give insight into the overall performance of the TPS, identify possible modes of failure,
and assess the efficiency of the thermal insulation and the heat fluxes into the sub-structure of a spacecraft.
 Testing outputs will be reviewed in comparison with the TPS requirements and specifications.
 Testing of foams (open vs. filled cells) -> Between 1400°C and 2100 °C (vacuum, at equivalent heat
flux)
Test Rig Chamber & Set-up
Credit:V. Liedtke (AAC)
1613 °C
1794 °C
2053 °C (10 cycles)
2163 °C
2053 °C
2163 °C (10 cycles)
High insulation capability is maintained
until the foam degradation starts (at 2100
°C, after 10 cycles) !
GROUND TESTING AND VALIDATION
15-11-2012 / 23
 Testing of Multilayer/CMC joints.
Recording of the
temperature at the
back side
heat
SiC CMC
Initial tests did not result in catastrophic failure, but more detailed investigations are necessary.
Testing of CMC/foam sandwich and further Multilayer/CMC joints in air are planned for 2013
CONCLUSIONS AND FUTURE WORK
15-11-2012 / 24

SMARTEES aims at obtaining a novel “proof-of reusability” of a thermal protection system
(TPS) concept with multifunctional properties. i.e. insulation and oxidation resistance. The
TPS architecture will combine the use of advanced ceramic composites and porous
structures.

The project is in its final year and is progressing towards the final design and the
technological sample assembly.There is a big challenge as the project deals with the
development of new materials, but also new joining technologies and further testing.

Future work, outside the scope of the project, has to be focused to the sample integration for
a whole TPS concept for a re-entry vehicle, capsule or exploration probe.

Positive effects of European Cooperation:
 Europe will benefit from the results of SMARTEES by improving its access to space
critical technologies. The next generation launcher (NGL) will take advantage of this
concept. Another important asset is the contribution to the creation of an independent
industrial supply chain and open new doors for collaboration with space fairing nations.
 Space exploration in general may take advantage of the novel reusable TPS
technologies. Potential for its use in cargo and crew space return vehicles. I.e. for a cost
effective, safe and reliable return from the international space station (ISS), future
launchers, space tourism.
ACKNOWLEDGMENTS
15-11-2012 / 25
 Astrium GmbH (W. Fischer)
 European Space Agency (M. Bottacini and B. Jeusset )
 European Commission
 Research Executive Agency (C. Ampatzis)
 EADS-Innovation Works (C. Wilhelmi, F. Meistring).
 NCSRD (S. Messoloras, K. Mergia and P. Yialouris).
 ERBICOL SA (D. Gaia and S. Gianela)
 Aerospace and Advanced Composites GmbH (V. Liedtke)
 SUPSI (C. D’Angelo and A. Ortona)
 Politecnico di Torino (E. Padovano and C. Badini)
 Tecnalia Research & Innovation (X. Hernandez, C. Jimenez, M. Lagos
and I. Agote)
WEB PAGE
15-11-2012 / 26
For more details visit the Project webpage: www.smartees-project.eu
15-11-2012 / 27
END OF PRESENTATION
Many thanks for your
attention
Please visit the showcase at
the exhibition!