Structure Design of a Sounding Rocket Fairing with a Segmented Filament Winding-Ceramic Matrix Composite Thermal Protection System

Abstract

Sounding rocket flight experiments are of fundamental importance for the development and optimization of future space transportation systems. In this framework, the STORT project is focused on the key technologies for the flight at high Mach numbers (higher than 8) for a relatively long time, representative of the operating conditions of high-energetic re-entry flights for reusable first or upper stages. In particular the forebody of the flight experiment carrier, which is subjected to the highest heat loads during the mission trajectory, requires the use of a suitable ceramic matrix composite structure. The present paper describes the activities carried out for the design, validation and construction of the forebody thermal protection system, which is constituted by an inhouse-built C/C-SiC composite structure, made of a bulk conical nose element and four shell segments manufactured via wet filament winding of the carbon fibre with a phenolic resin and subsequent pyrolysis and liquid silicon infiltration.