Uncontrolled re-entry of satellite parts after finishing their mission in LEO: Titanium alloy degradation by thermite reaction energy

Analytical and experimental studies conducted at Semenov Institute of Chemical Physics for investigating the use of pyrotechnic compositions, i.e., thermites, to reduce the risk of the fall of thermally stable parts of deorbiting end-of-life LEO satellites on the Earth are described. The main idea was the use of passive heating during uncontrolled re-entry to ignite thermite composition, fixed on the titanium surface, with the subsequent combustion energy release to be sufficient to perforate the titanium cover. It is supposed, that thus destructed satellite parts will lose their streamline shape, and will burn out being aerodynamically heated during further descending in atmosphere (patent FR2975080). On the base of thermodynamic calculations the most promising thermite compositions have been selected for the experimental phase. The unique test facilities have been developed for the testing of the efficiency of thermite charges to perforate the titanium TA6V cover of 0.8 mm thickness under temperature/pressure conditions duplicated the uncontrolled re-entry of titanium tank after its mission on LEO. Experiments with the programmed laser heating inside the vacuum chamber revealed the only efficient thermite composition among preliminary selected ones to be Al/Co3O4. Experimental searching of the optimal aluminum powder between spherical and flaked nano- and micron-sized ones revealed the possibility to adjust the necessary ignition delay time, according to the titanium cover temperature dependency on deorbiting time. For the titanium tank the maximum temperature is 1100 °C at altitude 68 km and pressure ~60 Pa. Under these conditions Al/Co3O4 formulations with nano-Al spherical particles provide the ignition time to be 13.3 s, and ignition temperature as low as 592±5 °C, whereas compositions with the micron-sized spherical Al powder reveal these values to be much higher, i.e., 26.3 s and 869±5 °C, respectively. The analytical and experimental studies described in this paper provide a portion of the basic information required for the development of pyrotechnic device to reduce the risk of the fall of thermally stable parts of deorbiting end-of-life LEO satellites on the Earth.