Space Rider: Thermal Protection System and Control Surfaces design, development and qualification status
- Paper number
IAC-22,C2,4,12,x74202
- Author
Dr. Giuseppe Rufolo, Italy, CIRA Italian Aerospace Research Centre
- Coauthor
Dr. Mario De Stefano Fumo, Italy, CIRA Italian Aerospace Research Centre
- Coauthor
Dr. Roberto Gardi, Italy, CIRA Italian Aerospace Research Centre
- Coauthor
Mr. Roberto Fauci, Italy, CIRA Italian Aerospace Research Center, Capua
- Coauthor
Dr. Francesca Maria Pisano, Italy, CIRA Italian Aerospace Research Centre
- Coauthor
Mr. Manrico Fragiacomo, Italy, CIRA Italian Aerospace Research Centre
- Coauthor
Ms. Barbara Tiseo, Italy, CIRA Italian Aerospace Research Centre
- Coauthor
Dr. Francesco Di Caprio, Italy, CIRA Italian Aerospace Research Centre
- Coauthor
Dr. ROBERTO SCIGLIANO, Italy, CIRA Italian Aerospace Research Centre
- Coauthor
Dr. Valeria De Simone, Italy, CIRA Italian Aerospace Research Centre
- Coauthor
Dr. Angelo De Fenza, Italy, CIRA Italian Aerospace Research Centre
- Coauthor
Dr. Lorenzo Cavalli, Italy, Petroceramics SpA
- Coauthor
Mr. Massimiliano Valle, Italy, Petroceramics SpA
- Coauthor
Mr. Fabio Giacometti, Italy, Petroceramics SpA
- Coauthor
Mr. Yasir Akram, Italy, Petroceramics SpA
- Coauthor
Mr. Matteo Boiocchi, Italy, Petroceramics SpA
- Coauthor
Mr. Michela Cantù, Italy, Petroceramics SpA
- Year
2022
- Abstract
ESA Space Rider Program has the ambitious objective to enable European routinely access to LEO and return back to earth, allowing a wide spectrum of in-orbit experimentation capabilities while reducing mission costs through reusability. A key role for effective reusability implementation is played by the Thermal Protection System and the Control Surfaces Hot Structure that allows respectively to manage the tremendous heat generated during re-entry into the atmosphere and to steer the vehicle counteracting a harsh combination of dynamic pressure and very high temperature. CIRA, in partnership with PETROCEARMICS, has developed a ceramic composite material, named ISiComp\textsuperscript{®}, based on Liquid Silicon Infiltration of pyrolized phenolic based carbon fiber pre-preg fabric. The applied process, inherited from high-end automotive sector for braking disc production, offers significant advantages in terms of costs and production time over other CMCs manufacturing techniques (e.g. CVI, PIP). ISiComp\textsuperscript{®}, initially developed in the frame of the Italian National Aerospace Research Program, PRO.RA.-SHS, has demonstrated its effectiveness for the manufacturing of hot structures for re-entry application through a series of successful development tests of a full scale prototype of Space Rider Body Flap. Following these positive results, in the frame of the phase D of the Space Rider program, CIRA has the responsibility for the design, development and qualification of the entire Ceramic Thermal Protection System including the monolithic nose, the windward tiles, the landing gear door TPS and the hinge TPS in addition to the Body Flap Assembly Control surfaces. The paper presents the status of design, manufacturing and testing activities. Building on lessons learnt from the successful IXV re-entry demonstration, Space Rider TPS and Hot Structure design has been focused on reducing manufacturing complexity while improving easiness of integration that in turns allows for faster post flight inspection and refurbishment. In parallel with design activities a fast-paced testing program is being carried out to demonstrate on one side the manufacturing feasibility of the large ceramic components and on the other side the capability to withstand the mission environment from launch to atmospheric re-entry, passing through LEO operations, ensuring full reusability up to six times.- Abstract document
- Manuscript document
IAC-22,C2,4,12,x74202.pdf (🔒 authorized access only).
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