Improved Metallic Thermal Protection Systems for Reentry Vehicles: Thermomechanical and Impact Considerations

A design for a metallic thermal protection system (TPS) panel made of SS304 stainless steel was developed to withstand a simulated aerodynamic heating rate of [Formula: see text]. The TPS panel, which comprised an outer sandwich structure, thermal insulation material, stand-off brackets, and an interior base frame, faced challenges from its thermomechanical and impact properties. These challenges were addressed through a combined analytical and numerical approach, optimizing the design parameters, namely, deflection, low-velocity impact peak load, and weight balance, to enhance the performance of the sandwich structure. The results indicated consistency between the analytical and numerical models, effectively predicting deflection and initial peak load for the TPS design. The proposed TPS design was then manufactured and evaluated through both experimental and numerical analysis to assess its thermomechanical behavior. The underlying structure of the TPS panel remained within specified temperature limits, and the exterior sandwich structure demonstrated acceptable levels of impact energy. The experiment confirmed the feasibility of the TPS panel design, with no significant damage observed after 10 simulated flight missions. This study not only validates the proposed analytical method for initial TPS development stages but also confirms the viability of a SS304 stainless-steel TPS panel design for high thermal-stress environments, marking a significant step in advancing thermal protection technology.