Design and Testing of the Inflatable Aeroshell for the IRVE-3 Flight Experiment

Inflatable Aerodynamic Decelerators (IADs) have been identified as a key technology for descent and landing of large payloads on Mars and other planetary bodies. The reduction in ballistic coefficient of the entry vehicle, facilitated by the low mass increase in drag area, offers lower heating rates, greater payloads, and increased mission flexibility using existing boosters. Under NASA’s guidance and support, the team of Airborne Systems, including our Lake Elsinore facility (formerly Vertigo), and Oceaneering developed an Aeroshell configuration to meet and exceed the IRVE-3 (Inflatable Re-entry Vehicle Flight Experiment) mission requirements. In addition to the Flight Unit, two Aeroshell Engineering Development Units (EDUs) including a Thermal Protection System (TPS) have been designed and fabricated to finalize the design and optimize structural performance of the inflatable stacked torus configuration. Material, seam and joint, subsystem, and system tests were performed to validate the design and fabrication techniques. Packaging tests were conducted to demonstrate the repeatable packaging and robustness required for efficient low volume stowage. A series of deployment tests demonstrated the capability of all components to achieve the required flight geometry. An innovative flight load test was successfully conducted to demonstrate the structural and system integrity at flight-like aerodynamic loading conditions. FEA capability using LS-DYNA was developed in parallel and supported the design and test activities. The Flight Unit incorporated all lessons and successfully passed all acceptance tests in preparation for a suborbital flight scheduled for May 2012. 1 Program Manager, 3000 W. Segerstrom, Santa Ana, CA 92704, AIAA Senior Member 2 Design Manager, 3000 W. Segerstrom, Santa Ana, CA 92704, AIAA Senior Member 3 Analysis Manager, 3000 W. Segerstrom, Santa Ana, CA 92704, AIAA Senior Member 4 Program Manager, Engineering Services, 20590 Cereal Street, Suite 100, Lake Elsinore, CA 92530, AIAA Senior Member 5 Chief Engineer, Engineering Services, 20590 Cereal Street, Suite 100, Lake Elsinore, CA 92530, AIAA Associate Fellow 6 Senior Engineer, Engineering Services, 20590 Cereal Street, Suite 100, Lake Elsinore, CA 92530 7 Chief Engineer, Thermal Systems, Oceaneering, Houston TX 77058, AIAA Member 8 IRVE-3 Chief Engineer, Atmospheric Flight and Entry Systems Branch, NASA LaRC/MS489, AIAA Member 9 IRVE-3 COTR, Atmospheric Flight and Entry Systems Branch, NASA LaRC/MS489, AIAA Member 53rd AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics and Materials Conference 20th AI 23 26 April 2012, Honolulu, Hawaii AIAA 2012-1515 Copyright © 2012 by Airborne Systems. Published by the American Institute of Aeronautics and Astronautics, Inc., with permission. American Institute of Aeronautics and Astronautics 2