Design and Validation of the Structure of a Flap System for the Hypersonic Sounding Rocket ATHEAt

Abstract

Sounding rocket flight experiments play a crucial role in developing and improving future space transportation systems. Within this context, the ATHEAt project focuses on key technologies for sustained flight at very high Mach number, between 9 and 10, representative of the demanding conditions encountered during high-energy re-entry of reusable first or upper stages. One of the key features implemented in the ATHEAt scientific payload was a system of four flaps, in order to collect precious aerothermal data for control surfaces in hypersonic regime. The flaps were connected to a pneumatic actuator in order to be moved simultaneously one time from a 5° initial deflection angle to the extreme case of 20° during the sounding rocket flight. The present paper gives an overview on the structural design process of such a system, from the definition of its configuration and the choice of materials to the numerical simulations and preliminary laboratory tests for its thermo-mechanical validation.