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ICARUS

Inflatable Concept Aeroshell for the Recovery of a Re-Usable launcher Stage

Main Goals of the Project

ICARUS main objective is to strengthen European expertise and technological capabilities in the field of Inflatable Heat Shields (IHS) by designing, developing, and flight-testing a demonstrator of an inflatable re-entry system. Building upon the significant results achieved in its predecessor projects (EFESTO and EFESTO-2), ICARUS aims to further advance the Technology Readiness Level (TRL) of inflatable re-entry solutions, enabling their application in future European re-entry missions. Within this framework, ICARUS develops an innovative re-entry solution based on Inflatable Heat Shields, specifically conceived for the recovery of Launch Vehicle stages. Inflatable Heat Shields play a fundamental role in decelerating and protecting space systems during atmospheric re-entry, thus enabling safe re-entry and descent. In this context, ICARUS contributes by:

  1. Completing the ground-based maturation of key enabling technologies for Inflatable Heat Shields, namely Flexible Thermal Protection Systems (TPS) and Inflatable Structures;
  2. Conducting an integrated mission and system design loop leading to the development and flight of a meaningful-scale IHS demonstrator on a sounding rocket, allowing recovery of the rocket’s upper section using the inflatable system;
  3. Performing post-flight analysis and reconstruction to assess technology performance.

CIRA Activities in the Project

CIRA plays a fundamental role within the project, focusing its contribution on the design and experimental verification of the “Flexible Thermal Protection Systems” (F-TPS). The design activity started from 1D FEM analyses, essential to obtain a first estimate of the required thickness for candidate materials. Such modeling was then refined through more detailed 2D and 3D simulations. Alongside numerical modeling, a targeted material characterization campaign was conducted: Nextel and Sigratherm samples were subjected to Thermogravimetric Analysis (TGA) tests, whose purpose was to verify the compatibility and thermo-oxidative stability of materials in simulated environmental conditions, through exposure to different temperatures and various percentages of oxygen.

CIRA also took charge of validating the reliability of design choices, regarding both optimal thickness and material selection. This verification was conducted by means of furnace tests that confirmed the system's performance under high-temperature conditions. The verification program will culminate with two tests inside the Plasma Wind Tunnel (PWT). These tests will employ stack-ups specially configured to simulate the actual and severe atmospheric reentry conditions, providing the final assessment of the integrity and operational effectiveness of the F-TPS system.

General Project Information

Funding Programme: Horizon Europe (Grant Agreement No. 101134997)

Start Date: 05/06/2024; End Date: 30/04/2028

Official Project Website: https://www.he-icarus-project.eu/

Coordinating Organization: Deimos

Partners: DLR-MORABA, DLR AS-HYP, ONERA, PGZ, PoliTo, Atmos, HDES, Demcon

CIRA Contact: Roberto Gardi, r.gardi@cira.it