Direct-Homogenization-Based Plate Models of Integrated Thermal Protection System for Reusable Launch Vehicles

Integrated thermal protection systems of reusable launch vehicles (RLVs) can have a corrugated core sandwich structure and experience location-dependent thickness-wise temperature gradient. The sandwich structure can be optimized depending on the location on RLV using finite element method simulations of RLV components. However, such analysis can be computationally challenging due to the disparate length scales between the RLV components and features of the sandwich structure. Two different equivalent plate models based on first-order shear and normal deformation theory, and first-order shear and second-order normal deformation theory (FSSNDT) have been utilized in this work to address this drawback. A direct homogenization technique involving unit cell and cantilever beam analysis has been developed to calibrate the equivalent plate properties for different thickness-wise temperature variations. The accuracy of the plate models has been evaluated by comparing their responses with a full-scale model for different thickness-wise temperature gradients and a uniform pressure. The comparisons clearly indicate that the FSSNDT-based plate model calibrated via direct homogenization captures both the displacements and strains in the in-plane and transverse directions accurately, and can be used to perform RLV component analysis efficiently to obtain location-specific optimal design of corrugated core sandwich structures.