Materials for Integrated Foam Core Structure

The development of a ceramic-polymer composite structure offers the promise of air vehicle structure with integrated load bearing and thermal protection capability. The outer skin which is exposed to high heating rates will be fabricated from a C/SiC composite. The inner structure will be fabricated from a high-performance polymide (PETI) composite. The connecting structure will be low density ceramic foam developed to provide mechanical and thermal coupling. The polymer to ceramic composite joining will be by co-curing the foam directly to the polymer composite.Typical Air Force missions will be identified to define loads and thermal requirements. Thermal/structural finite element analysis correlated with coupon testing will define material properties necessary to prevent failures. The experimental program will conclude with the test of a small scale integrated panel . Performance and cost benefits will be assessed comparing this approach to the current technology of an aluminum structure with a parasitic thermal protection system.