This study focused on the thermal stability and ablative behavior assessment of five newly developed composite TPS configurations. All ten test samples were 3D printed via FDM using various fire-retardant thermoplastic materials, with and without reinforcement. Eight samples integrated a new thermal management internal air chamber conceptualized architecture. A prompt feasible approach for the flame resistance preliminary assessment of ablative TPS samples was developed, using an in-house oxy-acetylene torch test bench. Experimental OTB ablation tests involved exposing the front surface samples to direct flame at 1450 ± 50 °C at 100 mm distance. For each configuration, two samples were tested: one subjected to 30 s of flame exposure and the other to 60 s. During testing, internal temperatures were measured at two backside sample contact points. Recorded temperatures remained below 46 °C, significantly under the maximum allowable back face temperature of 180 °C set for TPSs. The highest mass losses were measured for PC and PETG FR materials, achieving around 19% (30 s) and, respectively, 36% (60 s), while the reinforced configurations showed overall only a third of this reduction. The study’s major outcomes were the internal air chamber concept validation and identifying two reinforced configurations as strong candidates for the further development of 3D-printed ablative TPSs.
Badea et al. (Thu,) studied this question.