Project Details

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Flexible Thermal Protection System

Company: The Johns Hopkins University Applied Physics Laboratory

Major(s):
Primary: MATSE
Secondary: ME
Optional: ESC

Non-Disclosure Agreement: NO

Intellectual Property: NO

Concept: Extreme aerothermal heating threatens structural components during high-speed flight. Thermal protection systems (TPS) serve as resilient external insulation to withstand high temperatures, in excess of 1000°C, in oxidative environments. State-of-the-art materials are rigid ceramic coatings and polymer-ceramic composites that limit versatility in design. We propose to investigate flexible TPS materials that exhibit a high degree of flexibility and elasticity that will facilitate bonding to non-planar surfaces and mitigate thermally induced stresses associated with the dilation of heated materials. Description: The team will explore, identify, and characterize polymeric matrices and constituents that are conducive to thermal insulation and oxidation resistant behaviors while maintaining elastic properties. Common and low-cost polymer binders and glass-ceramic fillers will be combined and formulated into test coupons and prototypes materials. Oxidation resistance performance of prototype materials will be evaluated using high heat flux testbed (Oxy-acetylene torch/JHUAPL High Velocity Oxy-Fuel Testbed) to refine and iterate on formulation. Tasks/Deliverables: Perform analysis and material selection of matrix and constituent materials Identify suitable processing method(s) for mixing and applying material to substrates Produce representative prototype coupons Characterize properties and performance of material Analyzing test data for optimization of material composition and microstructure Final report and presentation Concepts Learned: Material Design – formulation and fabrication Material Processing/Handling – mixing (milling, grinding), coating, etc. Characterization – leverage test data and material science methods to extract properties and inform design decisions Testing – develop test fixtures and instrumentation (TC/pyrometry) for monitoring coupon temperatures