The thermal protection system is essential for hypersonic spacecraft safety during take-off, orbital operations, and re-entry. Ceramic fiber insulation tile (CFIT), as its key heat-resistant material, is a porous, brittle, 3D network material with complex mechanical behavior. It is typically coated with a high-emissivity coating during use and must withstand hypervelocity impact (HVI) from space debris on orbit. In this study, numerical simulation and experiment are used to study the mechanical response of CFIT under HVI. First, numerical simulation of CFIT’s HVI response was conducted using ABAQUS/Explicit, combined with the smoothed particle hydrodynamics (SPH) method and incorporating a user-defined material model (VUMAT). The validity of the model was verified by comparing the fragment cloud distribution and the maximum penetration depth obtained from numerical simulation and experiment. Second, the effects of different projectile shapes (spherical and cubic) and sizes on the impact response of CFIT were investigated, with systematic analysis of CFIT’s velocity/mass loss, maximum penetration depth, and stress distribution. Furthermore, based on the established model, the material thickness required to effectively resist space debris HVI was determined. This was achieved by analyzing the velocity dissipation and energy absorption characteristics of spherical projectile under different impact velocities and thickness conditions. Finally, the impact failure mechanism of coated CFIT was studied and the optimal coating thickness was specified. Overall, this study can provide theoretical guidance for the thickness design of CFIT and its surface coating to resist HVI in spacecraft.
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