SBIR-STTR Award

This proposal addresses some of the most challenging materials issues with respect to multi-mission, very high temperature, up to 4000�F, applications. The very successful, record breaking, NASA led X-43A hypersonic flight proved the ability to use state of the art (SOTA) material/coating system for short duration, single mission, and very high temperature applications. The transition into multi-mission applications requires a total paradigm shift. Allcomp proposes an extremely innovative solution to this problem by using functionally graded (FGM) CVD coatings to alleviate interfacial shear stresses and greatly reduce transverse thermal cracking, which historically have plagued ceramic coatings applied to very low thermal expansion coefficient 2-D C-C composite substrates. The success of this Phase I will totally open new avenues in the area of high temperature materials. That, in turn, will enable NASA designers to implement hot structure solution in lieu of parasitic passive insulation system, resulting in significant weight reduction in future NASA Space Exploration vehicles, as well as a plethora of other applications.

Potential NASA Commercial Applications:
(Limit 1500 characters, approximately 150 words) The primary focus is initially on new TPS solutions for NASA Space Exploration vehicles. In addition, this technology would also have applicability in future hypersonic applications.

Potential NON-NASA Commercial Applications:
(Limit 1500 characters, approximately 150 words) Several DoD organizations are actively pursuing hypersonic vehicles for both advanced missile systems, as well as sophisticated surveillance vehicles. The novel, low cost technology developed under this program will lead to DoD applications as well.

Technology Taxonomy Mapping:
(NASA's technology taxonomy has been developed by the SBIR-STTR program to disseminate awareness of proposed and awarded R/R&D in the agency. It is a listing of over 100 technologies, sorted into broad categories, of interest to NASA.) Coatings/Surface Treatments

There is a clear need to advance the state-of-the-art carbon-carbon coated Nozzle Extensions (NE) beyond the engine/mission performance currently established by Herakles technology, which is intrinsically limited to about 3000 F. The well-established SiC-based (CVD, pack cementation) technologies currently available also have upper temperature limits around 3000 F, imposing stringent limitations on increased performance and system level changes (i.e. hotter propellant) for future NASA missions. In addition, the intrinsic CTE mismatch between C-C substrate and refractory carbides/oxides further limits the use of many other classical coating technologies. The successful Phase I results established the feasibility of overcoming these limitations through the use of a novel, functionally graded (FGM) coating technology. The proposed Phase II builds on the success of the Phase I program and clearly increases its TRL by offering subscale component testing at representative engine conditions. A successful Phase II program will clearly offer a new dimension in the nozzle extensions by offering different coating systems for multi-cycle capability at temperatures from 3000 F up to 4000 F. The expected ability of the coating to survive such an aggressive testing combined with the sufficient retention of mechanical properties offers a direct path for a Phase III with many of the commercial space payload companies. The overall approach is based upon a multi-piece C-C NE concept, which focuses the requirements for high temperature oxidation protection to smaller diameters of the nozzle extension (e.g. A cone), allowing the CVD coating technology to remain within current SOTA CVD capabilities. Larger diameter segments, which are exposed to lower temperatures, will utilize non-CVD lower cost technology which is well suited for large diameter components. The direct benefit to NASA is undisputed with direct applicability to several planned future missions, including the very challeng

Potential NASA Commercial Applications:
(Limit 1500 characters, approximately 150 words) High performance domestically produced C-C Nozzle Extensions with reliable higher temperature capable anti-oxidation coating are one of the most critical and enabling technologies for future US launch systems. Potential applications are identified below: NASA Space Launch System (SLS) Exploration Upper Stage (EUS) - Upper stage with four RL10C engines is leading candidate (RL10C-1, RL10C-2). Other engine possibilities: J-2X, ESA Vinci (w/ C-SiC NE), commercial engines. NASA Robotic Missions - Example: Solar Probe Plus Mission - Orbital ATK Space Systems Star 48GXV solid motor with mid-size C-C exit cone. NASA Advanced Exploration Systems and In-Space Propulsion - Nuclear propulsion systems. Lunar and Mars lander descent and ascent stages.



Potential NON-NASA Commercial Applications:
:
(Limit 1500 characters, approximately 150 words) There are many potential non-NASA applications, but the primary applications for military applications would be 1) coating systems on leading edges for hypersonic vehicles and 2) nozzle extensions for various military programs, such as USAF Delta IV & Atlas V EELVs. In addition, there are opportunities to insert this technology into nozzle extensions for commercial rocket companies, such as Space X, Blue Origin and Sierra Nevada, and others. While the CVD based higher temperature coating system can provide higher temperature performance, it is however more expensive and is constrained by SOTA of CVD capability. Our non-CVD lower cost coating technology can be adapted to the commercial markets quickly with less facility constraints. Finally, this technology may also be inserted directly into commercial semiconductor applications (MoCVD), where current CVD SiC technology is the norm.

Technology Taxonomy Mapping:
(NASA's technology taxonomy has been developed by the SBIR-STTR program to disseminate awareness of proposed and awarded R/R&D in the agency. It is a listing of over 100 technologies, sorted into broad categories, of interest to NASA.) Atmospheric Propulsion Launch Engine/Booster