Description: The primary role of Thermal Protection Systems (TPS) in re-entry vehicles is to regulate the heat input into the vehicle to control the maximum temperature of the underlying structure. For reentry vehicles where the heating is low enough to allow a non-ablative TPS solution a combination of ceramic TPS (shuttle tiles), carbon-carbon TPS for leading edges, and blanket TPS for leeward surfaces has historically been used. The Space Shuttle is a good example of this approach. Every TPS approach has advantages and disadvantages. The “Operational Fragility” of the Space Shuttle was noted by Administrator Michael Griffin when the Space Shuttle was retired, and many companies trying to design space launch systems desire rapid turn around between flights. Metallic TPS, which was substantially developed during the X-33 program, has the potential to offer improvements over traditional TPS systems in the areas of operability, inspection, repair and refurbishment, durability and reliability. An additionally benefit over shuttle tiles is that the time consuming and environmentally-hazardous re-waterproofing step is not required between flights. In recent years multi-use launch vehicles and space vehicles have been under development. To enable reusability, we need to push the performance, durability, and reliability of current TPS solutions, while lowering the operation cost and improving the ability to inspect, repair, and refurbish TPS. The goal of this project is to develop Metallic TPS (MTPS) that could be used on the windward surface of a re-entry vehicle. The focus areas of this activity are design optimization, prototyping, and testing at material level as well as generating large, assembled sections.

Benefits: Technology Description: Metallic TPS with improved damage tolerance, and lower cost compared to other TPS solutions. Significant acreage TPS solutions have been identified for re-entry vehicle that fall within high temperature metallic alloy thermal capabilities. Commercial Impact: Availability of low-cost TPS has direct impact on the operation cost of reusable reentry vehicles by reducing the need for high cost TPS and reducing the refurbishment time between flights. Blue Origin’s vision is millions of people working and living in space for the benefit of earth. Our mission is to reduce the cost of access to space, primarily by reusing vehicles (launch vehicles, second-stage vehicles). A key to achieving that goal is improved reusability and increased availability, which requires weather-proof commercial launches. Quick turnaround time between launches (result of improved inspection, refurbishment, durability, and mass) is critical to achieving a lower cost access to space. This goal can be achieved with a TPS that lasts over 30 flight cycles with minimal touch time and is easily replaceable. Goals include launch cadences that are 50% more frequent, such as 2 flights per month. In contrast, current industry frequencies are 60-120 days.