Development and flight qualification of the C–SiC thermal protection systems for the IXV

• Coupon tests have been used to assess the thermal characteristics of the TPS.
• Thermo-mechanical analysis has been used to assess the flight margins.
• FE models have been substantiated by full scale thermal tests.
• Dynamic behaviour has been qualified by full-scale panel tests.
• TPS after flight are in good shape, demonstrating a successful flight.

The Intermediate experimental Vehicle (IXV) atmospheric re-entry demonstrator, developed within the FLPP (Future Launcher Preparatory Programme) and funded by ESA, aimed at developing a demonstration vehicle that gave Europe a unique opportunity to increase its knowledge in the field of advanced atmospheric re-entry technologies. A key technology that has been demonstrated in real conditions through the flight of this ambitious vehicle is the thermal protection system (TPS) of the Vehicle. Within this programme, HERAKLES, Safran Group, has been in charge of the TPS of the windward and nose assemblies of the vehicle, and has developed and manufactured SepcarbInox® ceramic matrix composite (CMC) protection systems that provided a high temperature resistant non ablative outer mould line (OML) for enhanced aerodynamic control. The design and flight justification of these TPS has been achieved through extensive analysis and testing:●Mechanical, Dynamical and thermo-mechanical analysis.●Coupons and technological tests.●Sub-scale tests specifically made to assess the behaviour of the TPS during re-entry.●Full scale qualification tests that addresses the flight envelope of the vehicle:
• Sine, Random and shock tests on nose and windward.
• Thermal test of the nose.
• Mechanical tests of nose and windward.This paper describes the Flight Model TPS design, as well as the development activities, tests and results that lead to the qualification of the nose and windward TPS assemblies.