development progress on cmc torque actuated control surfaces by re-entry verification test

Paper number

IAC-08.C2.1.1

Author

Dr. Harald Lange, MT Aerospace, Germany

Coauthor

Dr. Karin Handrick, Germany

Coauthor

Mr. Armin Steinacher, Germany

Coauthor

Mr. Stefan Weiland, Germany

Coauthor

Mr. Ingo Fischer, Germany

Year

2008

Abstract

The development of hot control surfaces out of ceramic matrix composites (CMC) making possible the active control of future re-entry vehicles is pushed forward by MT Aerospace since early 90s.
In order to improve the design flexibility of such components special focus is presently put on rudders and body flaps that are not actuated via a rod linked to the control surface’s body but by means of a torque drive directly connected to the hinge line.
The required hot structure technologies, especially a novel integral manufacture process (so called in-situ joining), and promising design concepts including dynamic seals, a torque introduction device and CMC bearings were investigated in the past on basis of several development tests at room temperature.
Recently a further major development step was achieved by the re-entry simulation testing of a flap demonstrator in the facilities of DLR/Stuttgart. This test campaign including the design of the demonstrator was sub-contracted to MT-Aerospace by NGL prime in the frame of the ESA FLPP1, Material & Structure program. The demonstrator showing all design principles and components of a real torque actuated body flap was manufactured at MT out of Keraman® C/SiC which was previously applied and qualified for different components of NASA’s X-38 vehicle. The demonstrator was subjected to in total 27 thermal test cycles, each being representative for the flap performance during typical re-entry. Remarkable test parameters concern the exposure in partial air environment with maximum temperature up to 1600°C and the application of cyclic movements under varying mechanical loading.
From the evaluation of the measurements and post test inspections the potentials of the design concept and involved technologies are obvious. The results are furthermore reviewed to work out the logic for required future developments to increase the technology readiness for torque driven CMC control surfaces.

Abstract document

IAC-08.C2.1.1.pdf

Manuscript document

IAC-08.C2.1.1.pdf (🔒 authorized access only).

To get the manuscript, please contact IAF Secretariat.