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Research Papers

Optimization Design and Analysis of Multilayer Lightweight Thermal Protection Structures Under Aerodynamic Heating Conditions

[+] Author and Article Information
Gongnan Xie

e-mail: xgn@nwpu.edu.cn

Weihong Zhang

Engineering Simulation and Aerospace Computing (ESAC),
The Key Laboratory of Contemporary Design and Integrated Manufacturing Technology,
Northwestern Polytechnical University,
P.O. Box 552,
Xi'an 710072, Shaanxi, China

Bengt Sunden

Division of Heat Transfer,
Department of Energy Sciences,
Lund University,
P. O. Box 118,
SE-22100 Lund, Sweden
e-mail: bengt.sunden@energy.lth.se

Giulio Lorenzini

Professor
Department of Industrial Engineering,
University of Parma,
Parco Area delle Scienze, 181/A,
43124 Parma, Italy
e-mail: giulio.lorenzini@unipr.it

Manuscript received July 31, 2012; final manuscript received October 17, 2012; published online March 18, 2013. Assoc. Editor: Ranganathan Kumar.

J. Thermal Sci. Eng. Appl 5(1), 011011 (Mar 18, 2013) (7 pages) Paper No: TSEA-12-1125; doi: 10.1115/1.4007919 History: Received July 31, 2012; Revised October 17, 2012

The purpose of thermal protection system (TPS) is to maintain the structural temperature of the hypersonic aircraft within acceptable limits due to intense aerodynamic heating during reentering earth's atmosphere. In the context of hypersonic aircraft design, a major issue is to obtain the optimal thickness of the insulation layers for TPS. In this study, an idea combining a transient heat transfer model and an efficient optimization model is introduced for multilayer insulation of TPS. The TPS geometric dimensions in the thickness direction are particularly considered as the design variables and the objective function is the total mass of the thermal protection structure with the limitation of the extreme temperatures of the hypersonic aircraft structure. In order to decrease the computational complexity, the globally convergent method of moving asymptotes method is specially used to search the optimal solution. The temperature profiles at various surfaces along the thickness direction are presented and analyzed. It is shown that the usage of multilayer insulation materials for the TPS can save more than 17% weight compared with a single-layer TPS. The detailed analysis and comparison indicate the advantages of the presented optimization model.

Copyright © 2013 by ASME
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References

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Figures

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Fig. 1

A typical corrugated-core sandwich structure

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Fig. 2

A unit-cell of the simplified ITPS design

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Fig. 3

Aerodynamic pressure load on ITPS

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Fig. 4

Typical mesh for 2D FE heat transfer model

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Fig. 5

Heat flux (solid line) and convection (dashed) profile with reentry time on ITPS outer surface: heat flux is imposed before 2300 s, after that convection is imposed

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Fig. 6

The optimization process of the design variables, constraints values and objective function for case 1: one layer filled with Saffil

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Fig. 7

The radiation equilibrium temperature profile of case 1

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Fig. 8

The temperature profiles along the thickness direction of case 1 at selected time steps: 600 s, 1100 s, 1600 s, 2100 s, 2600 s, 3600 s

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Fig. 9

The optimization process of the design variables, constraints values and objective function for case 2: two layers filled with Saffil and glass-wool, respectively

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Fig. 10

The temperature profiles along the thickness direction of case 2 at selected time steps: 600 s, 1100 s, 1600 s, 2100 s, 2600 s, 3600 s

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Fig. 11

Temperature profiles of contact surface temperature, T1, and bottom surface temperature, T2, with reentry time under case 2

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Fig. 12

The optimization process of the design variables, constraints values and objective function for case 3: two layers filled with Q-fiber and glass-wool, respectively

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Fig. 13

The temperature profiles along the thickness direction of case 3 at selected time steps: 600 s, 1100 s, 1600 s, 2100 s, 2600 s, 3600 s

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Fig. 14

Temperature profiles of contact surface temperature, T1, and bottom surface temperature, T2, with reentry time under case 3

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Fig. 15

The optimization process of the design variables, constraints values and objective function for case 4: three layers filled with Saffil, IMI and Q-fiber, respectively

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