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  • MCDAC Heatshield Design Manual

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    Manual for the design of reentry vehicle heatshields

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    Manual for the design of reentry vehicle heatshields

    Hak Cipta:

    © All Rights Reserved
    Unduh sebagai PDF atau baca online dari Scribd
    Tandai sebagai konten tidak pantas
    10 tayangan7 halaman

    MCDAC Heatshield Design Manual

    Diunggah oleh

    rdugas
    Manual for the design of reentry vehicle heatshields

    Hak Cipta:

    © All Rights Reserved
    Unduh sebagai PDF atau baca online dari Scribd
    Tandai sebagai konten tidak pantas
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    MCDONNELL DOUGLAS AEROSPACE DESIGN MANUAL 32.62 23.4.8 Continued inwinsic streneth properties. The resut is talure Carbor-caron composites are less sensitive to high thermal gradiente and thermally induced stress Consitions than other matarias ike polyerystaline or pytoiyic graphites. Ths high resistance to thermal Ehest is due to the low expansion coefficient, ‘moderately high thermal conductivity, moderately low ‘medulus, and high stvangth of the composites. tis postulated that the stress levels within the carbone carbon composites may also be characteristcaly tow, because of voids and cracks which provide space for expansion during heating. The thermal Suess resistance of mulidirectional reinforced composites is superior to that obtained with two Simensional reinioreed. materials. The best performance has been oblainod with orthogonal filament wound and tot reinioread, in the order of cecreasing mori (6) Ablation - Carbon-carbon composites exhibit low surface recession and excellent shape retention luring exposure to very high temperatures or heating rates. They are useful in a variety of thermal protection applications. During heating, the materials. lose mass in the surface region by vaporization, ‘sublimation and possibly thermo-chemical oxidation. ‘The matrix is preferentially removed leaving behind a roughened surface. Fibers exposed at the composite surface are subsequently removed by degradation at selected fiber sites, or due to the acion of shear forces. The surface temperatures of ablating composites, characteristically the multidirectionally reinforced composites, exhibit ablative recession rates as low or lower than all other known materials duting extremely high heating. Quantitatively, they expend between 18,000 and 40,000 Bu per pound of material removed. Even at very high pressures and surface shear stresses, the materials ablate at a relatively low and predictable (7) Anisotropic Features - Composite properties aro highly anisotropic as one would expect. This condition is due to transverse orientation in the composite. 8. Designing with Two or Three Dimensional Garbor-Carbon Billets (1) The required design properties for a specific part right best be obtained from either a two-dimensional ora three-dimensional laminate. To detail the differences between the two, a short explanation follows: (2) A two-dimensional billet is a sories of alternating layers of graphite cloth (composed of warp and fil 7 Aug. 1995 23.34 sso-s0r6s, ‘graphite or carbon fiber yarn bundles) and an impregnating matrix. Cure, carbonization and high temperature graphitization follow to produce a ‘carbon-earbon composite. Tape wrazping, braiding fo rosetie layup permits the use of unidirectional ‘carbon or graphite fibers. @) Three dimansional billats are woven or hand layed-up with fibers in the X (warp), ¥ (fil) and Z (xia) Grection (4) For bath two and three-dimensional billets, the umber of impregnating, curing, carbonization, and ‘raphitzation cycles will determine the bilet density ‘and porosity. The range of billet density is 1.45 to 2.05 gm/cc. Generally, the two dimensional carbon- ‘carbon bilats ara used in nozales as short inlet and throat rings and as long exit cones, while three imensional carbon-carbon composites are used in the nose inlet throat area of nozzles, demonstrating more resistance to erosion. Delaminations and racks are less prevalont in the more costy three- imensional siuctures. 22.4.9 Physical And Thermal Propartes Of Carbon. (Gerbon Materials Carbon-carbon physical and thermal properties have been complied and are found in Table 23-11. Physical and thermal propertios of a commercial graphite material (ATJ-S) have boon included to Serve as a comparison with carbon-carbon material. 235 HEAT SHIELDS 235.1 General A. A heat shield is the component of a missile or other aerodynamic vehicle which protects the interior components of the vehicle from the effects of ‘aerodynamic heating. A variety of materials have been developed for heat shield applications, and selection of a material for a specific application ‘must consider both the thermal environment in Which the heat shield will perform as well functions other than thermal protection hheat shield will be expected to provide. B. Tho environments in which hoat shields are required to perform vary widely. The heat shield may bbe used, for example, in ascent or in atmospheric reentry. tt may have a simple parabolic balistc fight path or may be required to undergo in-atmospheric maneuvers in high velecity. High acceleration fight fof short duration may result in high exterior surtace ‘This information is subject to the data legend on fist page. MCDONNELL DOUGLAS AEROSPACE - DESIGN MANUAL 3262 23.48 Continued ssc-40168 tna ew cow set cso ay. Sr mene ten Figure 23.42. CARBOWCARBON PROCESSING temperature up to about 3000°F, or higher temperatures. Both the matrix and reiriorcemant at these temperatures bogin to yield considerably. The strain-to-failure then increases and the modulus decreases. Composites containing carbonaceous: matrices or reinforcements undergo additional changes at high tomperatures and as a result, their variation in properties with temperatures tend to be inconsistent. (4) Thermophysical Properties - The thermal Conductivity of all carbon-carbon composites is relatively high, but with large differences betweer materials. The highest conductance valves are obtained with graphitic matrices, graphitic feinforcements, and filaments traversing the ‘composite from ond to end, 23.33 ie -texre este pen fesinP en nanos 2. Garbon-carbon composites exhibit exceptional dimensional stabilty with changes in temperature. ‘Their costiciont of thermal expansion is relatively low, which contributes to their high resistance 10 ‘thermal stesses. ‘The lowest expansion coefficients are obtained by heat treating matrices at the highest possible tomperature, using graphitic reinforcements {and proper alignment of the reinforcement in the composites. b._ Carbor-carbon composites store a significant amount of heat by gradual temperature rise. Thoit specific heat ison the order of 0.3 Btulb. °F at room temperature and about 0.5 Biulb -°F at 3500°F. (6) Thormal Suess Resistance - When materials are heated on one sido to very high temperatures or heating rates, a large thermal gradient exists through the thickness. Thormally induced stresses are ‘created within the material, which may exceed 7 Aug. 1995 ‘This information is subject to the data legend on frst page. MCDONNELL DOUGLAS AEROSPACE DESIGN MANUAL o2se ssonss 2351 Conines ‘Table 23-11. TYPICAL POLYCRYSTALLINE GRAPHITE AND CARSON.CARBON PROPERTIES A sr |, [museum | svc) anf Material Properties |Temperaure | Wit | Across |Temperanue | invoiuie [Temperance | x0« | ZDi te ere | das | ese [Pome [Ian [| Be | AB — Te ef [Seen Farsayse|——7s-} “so 8 Ft et 0 a fee 4500 _| 7900| _€200 yo00_| 9330 | 7090} __s000_| 28400) — arpaas | — S89 Seg) eae ix 19 4500 | 160] 1.06 | 3000 v7 | 138 3000 81 = ss ane} — oH eye ore eee | el el a | eR) ee | eT Seis | St ae ee ce | 08 [Eis Bae ass Be | Es [ae ae aie 3 : aes a fiieeo| oss | tl 1B) wes is] Za aie = 2 SEE TE} SEER Fae we) e| = secs Gade] —= [ae | === = Se ioe Be A Be \Condvetvity, «oo | | 2 | woo | ‘oe | 2) veo | sis | 75 sone | mae SEE] TERETE OT EEE ES Eqpronnnx| oe | as] at | SOS “| eae | a] al [7 Commercial Grade ATI-S Graphite Union Gabige 2 The cone was manulactured by Hico from WCA Carbon-carbon Cloth impregnated with phenolic resin which was cut ay SE pasttan rn ter Sle tetracaine Se eee Fas IA asd tai Scale as Ete ae |? 223 3-D carbon-carbon billet (150-686 billet yam) was received it after Chemical Vapor Deg mand underwent five impregnations, carbonizatons and graphitizations. Data was obtained from MDA Report No. | SRI Eibach okay cae ese ee | “Mericianal Direction A Usted for information oni. | | serous St emt Lemoore wth «relatively lw best content. D._In acon tothe thermal and esha Ser masln wot may recor lng crear retemerts pad by fag poe Ponsa Nghe tion voeetywnch oretowrets argh Oster stu popes engine surface temperatures but which result in higher heating loads imposed on the heat shield, ©. Generally, heat shields are not required to provide structural integrity to the vehicle on which ‘they are used. However, the heat shield material must possess sufficient mechanical strength to maintain its own structural integrity during the period of aerodynamic heating. Heat shield material damage and weight loss resulting from thermal effects or aerodynamic shar forces should 'be confined to surface or near-surface layers and in- depth damage should be avoided. 23.35 performance of a heat shield and the environment in Which itis to perform. The functional requirements for a heat shield must be fully defined to enable selection of a suitable hoat shield material. Some ‘of the material properties which may be of importance in this selection include but are not necessarily limited tothe folowing: (1) Low thermal conductivity (2) Good thermal shock resistance (@) High heat of ablation and specific heat 7 Aug. 1995 Tris information is subject to the data legend on fist page. MCDONNELL DOUGLAS AEROSPACE —- DESIGN MANUAL 3262 235.1 Continued (4) Favorable thermal decomposition behavior (high Cher yield, char strength and char adherence, frinimal in-depth damage and spalling, high melting point and high melt viscosity or absence of Secomposition products resulting in excessive downstream erosion). (6)_ Good resistance to erosion from rain, dust and paticle impact. (6) High shape stability in thermally erosive ‘environment. (7) Good resistance to radar detection (8) Transmission of spe without excessive attenuation or distortion. {@) Low content of alkali metals or other elements of tow ionization potential, especially sodium. (10) Low density and good strength to weight ratio (11) Long term storage stability (12) Resistance to corrosion and the effects of high hhumicity, salt spray and low temperatures (13) Compatiility with propellants (fumes and splash) (14) Availabilty of raw materials (15) Low capital investment and low unit cost Composites exhibit superior propertias in many of these properties in comparison with alternate candidate heat shield materials. E. Potential heat shield materials include heat resistant metals, ceramics and composites. Metals may be used in designe where the heat shield wil be exposed only 10 moderate or low aerodynamic heating. In these cases, the heat shield is combined into one component with the load carrying soucture ‘and is sized to provide @ heat sink for the thermal input. This offers a simplified design of relatively low cost with high strength and stiffness, with minimal properties variation and high reliability. AS Borodynamic heating temperatures increase, the weight penalties associated with the heat sink Tequirement become excessive and high temperature internal insulation is often required. Melting and oxidative failure mit metal heat shields to relatively Tow temperatures (about 100° to 2000*F). 7 Aug. 1995 23.38 ‘ss0-40168 F. Ceramics are britle and have high densities and high thermal conductivities and are not generally competitive with the charring ablator composite materials as heat shield for the load-carrying Substructure of aerodynamic vehicles. The ceramics, however, have excellant electrical properties, greater thermal stablty and superior erosion resistance; and, have been favored in radome applications for Supersonic vehicles, At extremely high ‘cselerations, however, thermal shock sivesses place ‘extreme demands on the brittle ceramics and ‘suitable attachment methods are dificult to achieve. In these cases, the use of a non-charring composite may offer advantages over the ceramic material. G. In contrast to the metallic heatshields, limited to temperatures below 2000°, charring ablator composites have been used in applications such as Teertry bodies where surface temperatures exceed 410,000°F, These heat shields materials undergo thermal decomposition in a near-suriace zone and provide thermal protection by @ combination of factors: (1) Low thermal conductivity and a low rate for penetration of the thermal decomposition zone into the heat shiel. {2) Absorption of large quantities of heat required to bring about the thermal decomposition of the ‘composite material {8)_ The formation of a high temperature resistart, Figh emissivity char which provides protection to the Lunderying heat shield material (4) Loss from the vehiole of decomposition products ‘with a high heat content. (6) The presence of high temperature resistant feinforcements which provide thermal shock resistance and stvengthen and support the protective ‘char layer. ‘At lower temperatures, composite properties such 25 radio frequency tansparency, good resistance to Tadar detection, acoustical energy attenuation or high ‘Specie strength may favor a composite in preference 0.a metal heat shield design. ‘This information is subject tothe data legend on first page. MCDONNELL DOUGLAS AEROSPACE - DESIGN MANUAL 3262 235.2 Anplcable Documents ‘A. Both material selection and process methods for heat shield composites are highly dependent on specific operating environments and heat shield functional requirements. Availablity of these vary. Specialized materials aiso change frequently. For these reasons, materials and process methods evaluated and used at MDA may not be suitable for future applications, and M&PE should be consulted for the current status of heat shield composite materials 2353 Materials A. Flat Laminate Composites (refer to 23.5.5A) 1P2010 - Glass Fabric, Phenolic Resin, Preimpregnated, "B* Stage Vacuum Bag Laminating 'STM0454-01 - Epoxy Abiative Insulation B. Shingle Angle Composites (refer to 23.56.58) ‘A mumber of matorials have been used as charting ablator composites. The three most frequently used are described below. (3) High silica reinforced phenolic composites. Properties of this material are as follows: a. High meting point reinforcement . High viscosity melt . Very low erosion rato 1d. Good thermal shock resistance 2. Low mechanical strength {. Relatively high thermal conductivity (2) Quanz reinforced phenolic composites. This material has properties very similar tothe previously mentioned high siica composites except i has good mechanical strengths. The material cost is high, (3) Carbon fabric reinforced phenolic composite. Properties of the material are ae folows: a. Low density 'b. Very high thermal shock resistance ‘c. Outstanding thermal stability einforcoment does ot melt and is stable at temperatures above 6000") 4. Strength increases with temperature 23.07 ssc-so16a. ©. Low erasion rate 1. High thermal conductivity ._Non-Charring Abiators (refer to 23.5.5C). The non-charting ablators consist of a fivorocarbon polymer, which may be a Virgin polymer or may be polymer teinforced with a high temperature resistant ‘ceramic fiber. Several materials are available which

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