Aerogel Spray Thermal Barrier

Hypersonic weapons are being developed to meet the war fighter's requirements of increased weapon effectiveness, decreased time to target, and increased fly out range. Of importance to hypersonic missiles and projectiles, aerothermic heating caused by the friction of air passing the weapon body, is one area of intensive research. At Mach 4, as the hypersonic weapon passes through the lower atmosphere, its surface reaches about 1200 degrees Fahrenheit. At Mach 6, however, the surface temperatures exceed 2800 °F and at Mach 8 over 5600 °F. This key technology requirement is extremely robust, high g and high temperature tolerant structures and insulation for hypersonic vehicles. We have developed a novel composite aerogel-based spray-on thermal barrier film. We have demonstrated that the aerogel composite formulation is suitable for spray application using commercial spraying equipment and that it forms an excellent insulation film for high temperature exposure. The Phase II effort is focused on further development and optimization of the Aerogel Spray Insulation, expanding testing to environmentally relevant conditions, further developing the spray application method, and developing an enhanced design tool. These activities will increase our Aerogel Spray Insulation technology to a TRL of 5 or 6. BENEFITS: While the activities of this project are focused on the Navy's need for high temperature insulation under extreme conditions, it is clear that our Aerogel Spray Insulation technology has the potential to impact broader DOD technology needs. For example, the FALCON program is seeking technologies that can evolve to provide both a near-term operational capability and also enable development of a reusable Hypersonic Cruise Vehicle for the far-term. In addition, variety of thermal protection needs exist on hypersonic missile fuselages, radomes, and airframes. For these applications and more, the key technology need for lightweight and durable high temperature insulation material can be met by our Aerogel Spray Insulation.