tps for reusable launch vehicles alloys and coating
TRANSCRIPT
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Alloys and Coating Development for MetallicTPS for Reusable Launch Vehicles
William D. Brewer*Keith Bird*
Terryl Wallace*S.A. Sankaran**
*Metals and Thermal Structures BranchStructures & Materials Competency
NASA Langley Research CenterHampton VA
**Analytical Services and MaterialsHampton VA
Langley ResearchCenter
National Space & Missile Materials Symposium28 Feb. - 2 Mar. 2000
San Diego CA
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¥ Constituents and Fabrication Development for Metallic TPS- Alloy evaluation- Coating development
¥ Metallic TPS Concepts- Design/size alternative metallic TPS- Fabricate & test full size panel array- System performance & model validation
¥ Cryogenic Tank Subcomponent Development- Design, fabricate & test full-scale PMC LH2 tank
subcomponent.
¥ Integrated PMC Cryogenic Tank and TPS Structure Demonstration- Full-scale integrated PMC tank/metallic TPS panel tests- Evaluate thermal and mechanical behavior
Reusable Launch VehicleFocused Airframe Systems Technologies
Langley ResearchCenter
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Acreage TPS for Windwardand Leeward Surfaces
Hot Structure Control Surfaces
Leading Edges and Nose Caps
TPS for Reusable Launch Vehicles
Langley ResearchCenter
Metallic TPS
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Foil encapsulatedinsulation
Attachment standoffbrackets
Externalcryotank stiffeners
Outer metallichoneycomb
Fasteneraccesscovers
Panel-to-panel seal
X-33 TPS ¥ Outer surface pressure-hot seals ¥ Hot fasteners ¥ Little acoustic/vibration damping ¥ Simpler construction
Alternative Design ¥ Cool, sub-surface pressure seals ¥ Cool, sub-surface fasteners ¥ Unload outer surface from pressure ¥ Provides damping ¥ More complex construction
Langley ResearchCenter
TPS Design Concepts
High temp.Insulation
Outer metallichoneycomb
FastenerAccess covers
Inner metallichoneycomb
Cryo foam insulation
Support brackets
Cool surface attachments
Cryogenictank wall
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0
500
1000
1500
2000
0 1000 2000 3000 4000
Outer FacesheetInner FacesheetBox Beam TopLower Foil LayerRing FrameFoam SurfaceTank
Reentry time, seconds
Tem
pera
ture
, F
Representative Temperature HistoriesFor RLV Reentry Langley Research
Center
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Key Alloy/Surface Requirements
¥ High specific strength and modulus at max service temperature¥ High creep strength¥ Microstructural stability during service life¥ Easily processed to sheet and foil gages¥ Minimum effects of secondary processing¥ Light weight
¥ Oxidation resistant Minimal property degradation¥ Emittance > 0.8 maximize re-radiation¥ Catalytic efficiency <.03 required - minimize heat input
¥ Coating thickness: < 0.002 in. Minimize weight.¥ Cure time: Short - minimize fab.¥ Cure temperature Low - enhance field repair¥ Durability: No crack/spall in handling or service¥ Repair: In the field¥ Service Temp: At least as high as metal operating T.
ALLOYS
COATINGS
Langley ResearchCenter
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¥ Evaluate candidate alloys and fabrication practice for foil gage product form and TPS concepts
OBJECTIVES
¥ Develop durable, field repairable coatings for environmental protection and thermal control
¥ Improved structural/thermal efficiency¥ Lower weight, lower risk, cost competitive¥ Integrated TPS materials/concepts/structure
EXPECTED RESULTS
Langley ResearchCenter
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RLV Metallic TPS DevelopmentMaterials Systems for Outer Surface
Prime Candidates
¥ Inconel 617 (X-33 TPS)¥ PM 1000 (MA 754)¥ PM 2000 (MA 956)¥ Titanium Aluminides
- Gamma- Orthorhombic
¥ Conventional titanium alloys (Leeward TPS)
Alternative Alloys
Alloy 602CA (Krupp)- ~10% less dense than In617. Cold roll to foil.
¥ MA 965-HT (Inco High Al alloy)- Better oxidation resistance than standard 956.
¥ CRF Hi Cr alloys (Plansee )- Potential higher temperature use than PMxxxx alloys.
Langley ResearchCenter
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¥ Effects of fabrication processes and service environments on properties and microstructure
of constituent materials.
¥ Process optimization for maximum panel performance and metallurgical joint efficiency.
¥ Properties of sub-elements in isothermal and simulated mission environments.
Alloy/process Evaluation & DevelopmentLangley Research
Center
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Concept for Coating DevelopmentLangley Research
CenterMulti-layer Sol-Gel Coating Design
Reactionbarrier
High emittance layer Low catalysis layer
SubstrateSol-Gel
¥ Thin, light¥ Easily applied (dip, spray, brush)¥ Relatively cheap¥ Field repair¥ Scalable
Effective?
Base layer Sealing layer
Oxidationresistantlayer
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Langley ResearchCenter
Coatings Evaluation
Static OxidationMech. PropertiesWeight changeMicroscopyEmittance
Thermal ControlDynamic oxidation(Mach 3-4 air flow)Catalytic efficiencyEmittance
Mission simulation (T,P,t)
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0
10
20
30
40
50
60
70
80
90
100
0 20 40 60
Exposure time, hrs
Yield strength,
ksi
Yield Strength of 602CA & Inconel 617Sheet and Foil Exposed in Air at 1800¡F
Langley ResearchCenter
602CA (0.045-in)
602CA (0.003-in)
602CA (0.002-in)
IN617 (0.006-in)
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0
10
20
30
40
50
0 20 40 60
Exposure time, hrs
Plastic strain,
%
Langley ResearchCenter
Ductility of 602CA & Inconel 617 Sheetand Foil Exposed in Air at 1800¡F
602CA (0.045-in)
602CA (0.003-in)
602CA (0.002-in)
IN617 (0.006-in)
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0
1
2
3
4
0 20 40 60 80 100 120
0
10
20
30
40
0 1 2 3 4
Weightgain,
%
Exposure time, hours
PlasticStrain,
%
Weight gain, %
Performance of Alloy 602CA Sheet & Foilin Air at 1800 oF
Langley ResearchCenter
0.045 in. sheet0.003 in. foil0.002 in. foil
Uncoated
Coated
0.003 in. foil
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Microstructure of 0.003-Inch Thick 602CA Foil
Uncoated - no exposure Coated - no exposure
Uncoated - 50 hrs @ 1800 oF Coated- 50 hrs @ 1800 oF
50 mm
Langley ResearchCenter
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Microstructure of Coated 0.003-Inch Thick 602CA Foil
(Exposed In Air at 1800¡F for 50 Hours)
coating
foilsurface
S
T
Langley ResearchCenter
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Thermal Oxidation of Coated GammaTitanium Aluminide
-1
0
1
2
3
4
5
6
0 50 100
Coated TiAl3 only
Un-coated
TPG-RE/Al2O3
Sealant TPG/TPG-RE/Al2O3Sealant TPG/TPG-RE/TiAl3
Sol-gel sealantSol-gel O2 diffusion barrier (TPG-RE)Reaction Barrier - TiAl3 - Sol-gel Al2O3
Langley ResearchCenter
Ti-48Al-2Cr - 1650 ûF
Weight change,mg/cm2
Exposure time, hrs
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Effectiveness of Coating System for Oxidation Resistance and Emittance Enhancement
Evaluated on IN-617 After Oxidation Exposure at 1800¡F
Emittance from Total Reflectance Weight Change
Em
itta
nce
Wei
gh
t C
han
ge,
mg
/cm
2
0.4
0.2
0.0
-0.2
-0.4
-0.6
-0.8
Exposure Duration, hours Exposure Duration, hours
0 604020 0 604020
Oxidation Coating
Oxidation + Emittance Coating
Coating Approach
Substrate
Sol-Gel Emittance Coating
Reaction BarrierOxygen Barrier
Langley ResearchCenter
1.0
0.9
0.8
0.7
0.6
0.5
Oxidation Coating
Oxidation + Emittance Coating
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Langley ResearchCenter
Performance of Embedded EmittanceCoating System
Evaluated on IN-617 After Oxidation Exposure at 1800 ¡F
Emittance from Total Reflectance Weight Change
Em
itta
nce
Wei
gh
t C
han
ge,
mg
/cm
2
0.6
0.4
0.2
0.0
-0.2
-0.4
-0.6
Exposure Duration, hours Exposure Duration, hours
0 1208040 0 1208040
Coating Approach
Substrate
Sol-Gel Emittance CoatingReaction Barrier
Oxygen Barrier
Langley ResearchCenter
1.0
0.9
0.8
0.7
0.6
0.5
Oxidation + Emittance Coating
Oxidation CoatingOxidation Coating
Oxidation + Emittance Coating
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Hypersonic Materials EnvironmentalTest System (HYMETS)
¥ Simulated entry flow environment¥ Mach 3 - 5 air flow¥ 1400 ûF - 2400 ûF
¥ Flow effects on one-inch-diameter specimens¥ Mass change (Oxidation, surface loss)¥ Surface catalytic efficiency measurements¥ Surface emittance of exposed specimens
Test
Specimen
Langley ResearchCenter
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Candidate Coatings for IN617
-8-7
-6-5-4-3-2-10
0 0.5 1Exposure Time, h
Uncoated Pyromark Sol-Gel Plasmaguard
0
0.1
0.2
0 0.5 1Exposure Time, h
CatalyticEfficiency
WeightChange,mg/cm2
HYMETS Exposure at 1800°FMach 3.5 Air Flow
Langley ResearchCenter
Uncoated Sol-Gel coating Commercial coatings
Exposure Time, hoursExposure Time, hours
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Alloys
¥ 14 alloys considered- Fe/Ni/Cr superalloys, TiAl
¥ Focusing on PM1000, 602CA, Gamma TiAl
Coatings¥ Good oxidation coatings developed for selected materials
¥ Promising emittance & catalysis coating developed - Need further development & evaluation
Summary - Materials & Coatings TaskLangley Research
Center
- Coating compatibility & environmental effects
- PM1000, IN 617, 602CA, Gamma TiAl
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Near Term Activities
¥ Continue to optimize coatings for alloys of choice.- Some emphasis on emittance & catalysis
¥ Validate alloy/coating systems in long term dynamic tests.¥ Assess scale-up/application technique issues for full scale TPS
Alloy/Coating Development & evaluation
Alloy/Processing¥ More focus on joining processes for foil materials.¥ Effects of exposures on face sheet & honeycomb sandwich.
Langley ResearchCenter
Design & manufacture full-scale TPS multi-panel array for Integrated TPS/Cryogenic fuel tank component test.
X-37 metallic TPS flight experiment
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Full Scale Metallic TPS/Cryo-tank Tests
Design, fabricate & test full scale TPS panel arrayIntegrated with cryo-tank subcomponent.
Thermal Vacuum test - Thermal performance in re-entry temperature/pressure
simulation (1400 - 1800 F)
Cryo-pressure box test - Thermal, mechanical performance in ground hold, fueling, launch & ascent simulation.
Langley ResearchCenter
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Cryogenic Pressure Box Facility
Check-out panel in facility
Langley ResearchCenter
¥ Axial & circumferential mechanical tension loads
¥ Surface thermal load (1000 F)
¥ Backside pressure and cryo thermal loads
Simulate ground hold, fueling, launch, assent
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Metallic TPS Experiment For X-37
Multi-Panel Array - Details TBD¥ Location/application
¥ Panel size (6Ó-18Ó) depends on location
¥ Panel-to-panel joint configuration
Technology demonstration¥ First entry flight tests near maximum
heating capability of reusable metallic TPS
¥ Next generation concept
¥ Advanced metallic materials/fabrication
¥ New surface coatings
¥ Optimized insulation package
¥ Efficient attachment scheme
Langley ResearchCenter