Optimized Hybrid Leading Edge for Reusable Launch Vehicles to Maximize Lift, Cross Range and Durability

This effort explores using innovative hybrid reinforced carbon-carbon, refractory ceramics, super alloys and composite materials as thermal protection system (TPS) in Hybrid composite leading edges for reusable launch vehicles (RLV). The RLV leading edge is the primary TPS that space vehicles use re-entering the atmosphere or traveling at hypersonic speeds. Depending on the Mach number spacecraft surface temperatures are as high 4000°F. The shape of the RLV leading edge, primarily the radius affects the functionality of the spacecraft including RLV drag, lift and leading edge aero-thermal heating. Sharper leading edges create more lift and re-entry cross range capabilities. The downside of a sharp leading edge is that aero-thermal heating is increased, resulting in steep thermal gradients in the leading edge. These thermal gradients create high thermal stresses. Blunt leading edges leading edges have less thermal gradient and therefore thermal stresses are lower. However, the cross range capabilities of the vehicle are reduced. This effort seeks to parametrically define hybrid composite material architectures optimizing the RLV leading edge for maximum lift, cross range and durability at temperatures of 4000°F. The goal is finding the optimal hybrid composite material combinations and architectures for given leading edge radii on the specified RLV. Required analyses for hybrid leading edge designs include: Micro-mechanical materials computations for hybrid material properties, calculation of leading edge Aero thermal heating heat transfer coefficients, heat rates and pressure loads as a function of leading edge radius. Transient heat transfer analyses for calculation of leading edge thermal gradients. Thermal stress analyses using resulting temperature gradients. Evaluation of leading edge response, as a function of hybrid material architecture via material failure ratios. The result of these analyses will provide the best hybrid material candidates and RLV leading edge designs. MR&D's core business is design and structural analysis of high temperature composite materials. The fundamental technology and design tools developed in this SBIR program will allow us to expand our client base and offer more capabilities to our existing customers. Additionally, the technology developed here will be translated to other commercial and government applications to expand the market for refractory materials in hybrid material leading edges, nozzles, hypersonic airframes and ramjet engines. Potential commercial users of the hybrid leading edge materials are companies including, NASA, Boeing, Rockwell, Thiokol, Lockheed Martin, ATK numerous others.