Development of Durable, Fiber-Reinforced Refractory Composites for Thermal Protection Systems (TPSs)

Next-generation endo/exoatmospheric hypersonic vehicles require durable thermal protection systems (TPSs) for leading edges, control surfaces and skin acreage that are resistant to impact damage. Multilayered material systems are in development to meet the TPS aero-thermal and mechanical attachment requirements of the next-generation hypersonic vehicles. The aeroshell is a quasi-isotropic, two-dimensional (2D), carbon fiber reinforced carbon matrix (C/C) laminate composite coated with silicon carbide (SiC). Backing the 2D C/C-SiC aeroshell are layers of varying density foam filled with phase change material for thermal management. Current 2D C/C-SiC composites tend to delaminate when subjected to debris impact due to insufficient interlaminar shear strength that can result in progressive and catastrophic failure, especially under fatigue or high loading conditions. This proposed Phase II program will design, fabricate and characterize vertical, through-thickness reinforced C/C-SiC aeroshell materials for leading edge applications. An iterative model-design-analysis approach will be used to generate a geometrically-shaped leading edge structure that will be fabricated and assessed by testing under representative conditions. A successful program will provide technology benefits resulting from an improved TPS architecture with low/high velocity impact resistance, the ability to integrate existing substrate materials, and a predictive modeling tool for use in continued TPS leading edge development.