CORK BASED THERMAL PROTECTION SYSTEM FOR SOUNDING ROCKET APPLICATIONS – DEVELOPMENT AND FLIGHT TESTING

Abstract

The application of aerospace thermal protection systems (TPS) is not limited to orbital flight and re-entry vehicles. Although less critical in terms of the thermal load’s magnitude, it is also an essential part of sounding rocket primary structures. For a large variety of launch vehicles, DLR’s Mobile Rocket Base (MORABA) uses thermal protection systems on primary structures such as fin, nose cone, conical adapter and heat shield assemblies. Hereby, an ablative, epoxy based, two component thermoset coating has been the material of choice over several decades. Using relatively simple manufacturing methods, it can be sprayed onto almost any geometry. However, its noxious fumes released during the spraying process, its limited shelf life, its extensive storage requirements and above all, its residues polluting adjacent payload components during the ablation phase, are the key drivers for the development of a new thermal protection system using a special cork material. This paper presents the development and manufacturing process as well as flight testing and post-flight analyses for different cork protected structural components flown on recent scientific missions (e.g. MAIUS 1, MAPHEUS 6, etc.). Results are discussed and a future outlook is given.