Lightweight Composite Thermal Protection System

As the technical capabilities of our adversaries improve, it becomes necessary to improve our Ballistic Missile Defense systems capability. Of particular interest are improvements in Thermal Protection Systems and aerostructures for missile interceptors. Greater aerothermal heating and higher stresses require that the outer structure survive higher heat loads and/or dissipate the heat to protect internal components. To address these problems, the team of KiON Defense Technologies (KDT) and our missile systems partner proposes the development of advanced lightweight TPS and aerostructural materials. In Phase I, KDT will demonstrate feasibility by producing composite articles and conducting appropriate tests. Specifically, KDT will employ a sandwich structure design comprising fiber-reinforced skins of proprietary hybrid resins and a syntactic foam core. The skins will be reinforced with quartz or carbon-based fabrics. The skins will be both mechanically attached and chemically bonded to the foam core. In Phase II, KDT will scale-up the process and conduct testing to optimize performance and reduce cost. Upon Phase II completion, KDT will supply materials and technical support for full-scale manufacturing. Successful program completion will provide enhanced ablation capability under thermomechanical stresses in the form of lightweight TPS and aerostructures that can withstand extreme conditions.