Ultra Low Diffusivity High Temperature Insulation

This proposal is aimed at developing an extremely light-weight and affordable Thermal Protection Systems (TPS) for use on of DARPAs Mach 10 Experimental Space plane (XS-1) and other Expendable Hypersonic Vehicles launched from the XS-1 platform. Mentis Sciences, Inc. (Mentis) proposes to partner with Aspen Aerogels, Inc. (Aspen) to develop a structurally-sound TPS by encapsulating and curing low thermal conductivity (TC)/low diffusivity aerogels in Nextel cloth (an aluminum silicate fiber) using a stitching technique to create a mechanically-fasten able system with minimal thermal paths through the thickness. The TPS can be fabricated in a variety of shapes and sizes required for the various mission requirements. Aspen has already produced a fiber reinforced Aluminum Silicate aerogel that has been tested at 1.3 E-7 m2/sec which will be improved on with the addition of opacifiers. A YSZ aerogel material, with added dopants to reduce diffusivity though enhanced opacification and increased phonon scattering will also be developed as a candidate material. One of the core materials will be selected, and then Mentis will strengthen the chosen material by encapsulating it in woven ceramic. A coating will be applied to the woven surface that will stiffen following a cure. Additional coating layers will be added to facilitate attaching the insulation bat to a metal or CMC TPS that is capable of acting as the outer skin of the hypersonic vehicle.