Effects of Thermal Cycle and Ultraviolet Radiation on 3D Printed Carbon Fiber/Polyether Ether Ketone Ablator

Abstract

The extreme heating environment during re-entry requires an efficient heat shield to protect a spacecraft. The current method of manufacturing a heat shield is labor intensive. The application of 3D printing can reduce cost and manufacturing time and improve the quality of a heat shield. A 3D printed carbon fiber/polyether ether ketone (CF/PEEK) composite was proposed as a heat shield material. The aim was to develop a heat shield and the structural member as a single structure while maintaining the necessary recession resistance. Test samples were exposed to thermal cycles and ultraviolet (UV) radiation environment. Subsequently, a tensile test was performed to evaluate the effect of thermal cycle and UV radiation on the mechanical properties. The sample’s recession performance and temperature behavior were evaluated using an arc heated wind tunnel. Exposure to thermal cycle and UV radiation have limited effect on the mechanical properties, recession behavior and temperature behavior of 3D CF/PEEK. Results from the arc heating test showed an expansion of the sample surface and better recession resistance than other existing ablator materials. Overall, 3D CF/PEEK has excellent recession resistance while maintaining mechanical properties when exposed to high temperature, thermal cycle and UV radiation.

Keywords

• 3D printing
• additive manufacturing
• ablation
• arc-heated
• carbon fiber
• heat shield