Application of inflatable aeroshell structures for Entry Descent and Landing

Future space missions will require improvements in the Entry, Descent, and Landing (EDL) phases of the mission architecture. The focus of this paper is to discuss recent advances in analysis, fabrication techniques, ground testing, and flight testing of a stacked torus Hypersonic Inflatable Aerodynamic Decelerator (HIAD) and its application to the future of EDL. The primary structure of a stacked torus HIAD consists of nested inflatable tori of increasing major diameter bonded and strapped to form a rigid structure after inflation. The underlying structure of the decelerator is covered with a flexible Thermal Protection System (TPS) capable of high heat flux. The inflatable aeroshell and TPS are packed around a centerbody within the launch fairing and deployed prior to atmospheric reentry. Recent fabrication of multiple HIADs between 3 and 6 meters has led to significant advances in process control and validation of the scalability of the technology. Progress has been made in generating and validating LS-DYNA FEA models to replicate flight loading in addition to analytical models of substructures. Coupon and component testing has improved the validation of modeling techniques and assumptions at the subsystem level. A ground testing campaign at the National Full-Scale Aerodynamics Center (NFAC) wind tunnel at NASA Ames Research center generated substantial aerodynamic and loading data to validate full system modeling with comparable dynamic pressures to a hypersonic reentry. The Inflatable Reentry Vehicle - 3 (IRVE-3) sounding rocket flight test was conducted with NASA Langley Research Center in July 2012. The IRVE-3 mission verified the structural and thermal performance of the stacked torus configuration. Further development of the stacked torus configuration is currently being conducted to increase the thermal capability, deceleration loads, and understanding of the interactions and effects of constituent components. The results of this research have expanded the feasible flight envelope of stacked torus HIAD designs over a range of sizes, loading conditions, and heating.