Metallic thermal protection system (MTPS) offers significant improvements over the ceramic based TPS for reentry applications. Space shuttle refurbishment time is estimated to be around 17000 man hours between flights. Metallic based TPS can be fabricated easily and provides wide range of design options for TPS. Adaptability and robustness of metallic thermal protection systems offers the potential for reusability. In this work, a unique manufacturing process has been evolved to realize light weight honeycomb panels through corrugation, laser welding and diffusion brazing of faceplates, where in 50 µm thick Inconel718 foil is used for making honeycomb core and 0.2 mm thick Inconel718 foil as faceplates. The compression and three point bend test on these panels have shown no debond between faceplates and honeycomb core. 150×150×5 mm size honeycomb panels were coated with YSZ and NiCrAlY based Thermal Barrier Coatings (TBC) and high temperature tests have shown thermal resistance of around 570 °C with front wall temperature of 1186 °C and back wall of 533 °C. Also these panels have been characterized for reusability by the testing of same panel at different heat flux levels. Though it is found that honeycomb panel has shown its integrity without debond a certain acceptable level of degradation in coating is observed. Thus Inconel718 based honeycomb panels with TBC coating are proved for use as thermal protection system for reusable launch vehicle systems.


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    Fabrication of prepackaged superalloy honeycomb Thermal Protection System (TPS) panels

    Blair, W. / Meaney, J. E. / Rosenthal, H. A. | NTRS | 1985


    Thermal characteristics of honeycomb-core panels

    NEVINS, R. / SAUER, JR., H. | AIAA | 1964



    Ceramic Honeycomb Panels

    Cagliostro, Domenick E. / Riccitiello, Salvatore R. | NTRS | 1989


    Reinforced Honeycomb Panels

    Bhat, Balakrishna T. / Akutagawa, Wesley / Wang, Taylor G. et al. | NTRS | 1989