Lessons learned from the recovered heatshield of the USERS REV capsule

The USERS Reentry Vehicle (REV) capsule carried out reentry flight from the low earth orbit and was successfully recovered on the sea in May, 2003. This paper presents the post-flight analysis of the recovered heatshield of REV capsule and summarizes the lessons learned. REV capsule, totally about 670 kg, has the combined shape of the nose hemisphere and the rear cone part, and its size is about 1.5 m in diameter and 1.9 m in length. REV is thermally protected against the aerodynamic heating by the carbon phenolic ablator heatshield. The recovered REV heatshield was scrutinized based on the outside aspect and the cross-sections. In general, the temperature profiles of the heatshield have been compared between the flight data and the prediction. The origin of the surface shallow cracks and slight delamination observed in the heatshield have been investigated based on the flight data and taking account of the ablator internal pyrolysis gas pressure, the thermal stress, and the allowable stress. The heatshield has proven to satisfy thermal protection requirements, and the validity of the designing has been confirmed.