Structural Design, Qualification and Post-Flight Assessment of Crew Module Fairing

Crew Module Fairing (CMF) for Pad Abort Test (PAT) of Crew Escape System (CES) is configured and designed with the objective of flight qualifying necessary features like external aerodynamic shape, thermal protection system, along with Escape Motors (namely Low-altitude Escape Motor (LEM) and Highaltitude Escape Motor (HEM)), with interfaces simulated as in actual flight. For improving the aerodynamic stability of the vehicle, four grid fins are attached at the aft end of CMF. Interfaces for mounting LEM, HEM, grid fins along with its deployment mechanisms and Crew Module through CM–CES attachment have been provided on CMF.

The design was supported by rigorous analysis, both 2D as well as 3D, of different sub-assemblies and interface joints for the respective critical load cases. To meet the challenges of launch requirements and schedule, the feasibility of combining tests of varying nature has been explored. By meticulous planning of the test scheme, set-up, load cases and instrumentation, and through a judicious combination of test and analysis, structural qualification of CMF could be achieved meeting the mission schedule. CMF has been successfully flown in PAT, as evident from radar monitoring. Post-flight analysis of strain data indicates the integrity and good health of CMF during the entire phase of the mission.