Abstract
S. D. Miller and Associates Research Foundation (SMARF) has requested assistance in the design and manufacturing of a high insulating, low density honeycomb ceramic material for use on hypersonic aircraft.
Although low-temperature, insulated honeycomb panels are commercially available, SMARF intends to demonstrate a design capable of repeated exposure to 2200 °F, that will not deteriorate, for use on spacecraft. Insulated honeycomb may be useful in the Structurally Integrated Thermal Protection System now under development at NASA to protect spacecraft upon reentry into the Earth’s atmosphere.
Using finite element analysis models and calculations to compare multiple solutions, a rounded hexagonal core proved to be the most efficient for strength, material usage, and best for manufacturability. For manufacturing, we investigated a molding method as well as a paper method. Both manufacturing techniques proved to be viable options for honeycomb panel production. SMARF will decide on a final method once NASA approves.