SBIR-STTR Award

One of the biggest challenges in developing structural insulators for hypersonic vehicle thermal protection system (TPS) applications is to devise a sufficient thermal insulation that is also adequate structurally. Established commercial insulation products are not typically intended for structural load bearing applications, and their manufacturing processes tend to be complex, slow, and expensive. There is a need for the development of reliable, uniform insulation materials with low thermal conductivity comparable to existing commercial products that also provide higher strength at temperature and can be inexpensively manufactured to produce near net shape components in form-factors applicable to Navy hypersonic flight vehicles. Sporian Microsystems has extensively researched and developed advanced ceramic materials for harsh environments, with a particular focus on materials and sensor technologies based on novel, polymer-derived ceramics (PDC) for ultra-high-temperature applications. However, while prior work has resulted in processes capable of producing highly advanced bulk thermal insulating materials/foams and hot structure components, this technology has not yet been fully optimized to take advantage of several emerging methods to improve material manufacturability and uniformity as well as process flexibility. The long-term objective of this proposed work is to heavily leverage and expand upon prior PDC-based insulating materials development to improve processes and materials that can be used to cost effectively realize lightweight, high-temperature-operable, ceramic structural insulating materials and components for hypersonic aerial vehicles TPS. The Phase I effort will focus on working with technical partners and industry stakeholders to understand system requirements and develop transition roadmaps, evaluating candidate processes for improved manufacturability, and proof-of-feasibility testing/demonstration. Following Phase I, Sporian will be well positioned for Phase II efforts focused on producing full demonstration units for DOD testing.

Benefit:
In order to enable hypersonic flight capabilities, advanced materials are needed that can structurally and thermally protect the aircraft and its systems. The proposed technology will offer weight reductions while still providing higher-temperature operation and increased survivability of hypersonic vehicles. This, in turn, will progress advanced aircraft development and promote increased mission capability, increased savings through use of a single thermal protection system and improved fuel usage. An ultra-high-temperature, corrosion-resistant structural material has great benefit in commercial sectors as well. These applications include space exploration, components for advanced engine development (military/commercial, aerospace/land), improved component lifecycles for energy generating systems (nuclear, CSP, fossil fuels), high-temperature furnace insulation, harsh environment materials processing, and oil and gas systems, among many others.

Keywords:
Thermal Protection Systems, Thermal Protection Systems, reentry vehicles, high thermal diffusivity, thermal protection materials, hot structures, High Temperature Materials, hypersonic

One of the biggest challenges in developing structural insulators for hypersonic vehicle thermal protection system (TPS) applications is to devise a sufficient thermal insulation that is also adequate structurally. Established commercial insulation products are not typically intended for structural load bearing applications and their manufacturing processes tend to be complex, slow, and expensive. There is a need for the development of reliable, uniform insulation materials with low thermal conductivity comparable to existing commercial products that also provide higher strength at temperature and can be inexpensively manufactured to produce near net shape components in form-factors applicable to Navy hypersonic flight vehicles. Sporian Microsystems has extensively researched and developed advanced ceramic materials for harsh environments, with a particular focus on materials and sensor technologies based on novel, polymer-derived ceramics (PDC) for ultra-high-temperature applications. However, while prior work has resulted in processes capable of producing highly advanced bulk thermal insulating materials/foams and hot structure components, this technology has not yet been fully optimized to take advantage of several emerging methods to improve material manufacturability and uniformity as well as process flexibility. The long-term objective of this proposed work is to heavily leverage and expand upon prior PDC-based insulating materials development to improve processes and materials that can be used to cost effectively realize lightweight, high-temperature-operable, ceramic structural insulating materials and components for hypersonic aerial vehicles TPS. Phase I laid the foundation for processes capable of cost effectively producing highly advanced, near-net shape, bulk thermal insulating materials and hot structure components using processes with highly improved manufacturability. Phase II will focus on efforts to complete the fundamental process development, with an emphasis on completing the technical and manufacturing milestones needed to foster technology transition and adoption.

Benefit:
In order to enable hypersonic flight capabilities, advanced materials are needed that can structurally and thermally protect the aircraft and its systems. The proposed technology will offer weight reductions while still providing higher-temperature operation and increased survivability of hypersonic vehicles. This, in turn, will progress advanced aircraft development and promote increased mission capability, increasing cost savings through use of a single thermal protection system and improved fuel usage. An ultra-high-temperature, corrosion-resistant structural material has great benefit in commercial sectors as well. These applications include space exploration, components for advanced engine development (military/commercial, aerospace/land), improved component lifecycles for energy generating systems (nuclear, CSP, fossil fuels), high-temperature furnace insulation, harsh environment materials processing, and oil and gas systems, among many others.

Keywords:
hot structures, thermal protection materials, Thermal Protection Systems, high thermal diffusivity, reentry vehicles, High Temperature Materials, hypersonic