Affordable Integrated Surface Modification of Ceramic and Refractory Substructures with UHTCs for High Temperature Resilient Thermal Protection System

Spark Thermionics proposes to advance the development and application of slurry-coated Ultra-High Temperature Ceramics (UHTCs) for boost-glide hypersonic vehicles (re-entry vehicles for ICBMs being a secondary application). This proposed multi-phase program will focus on optimizing the slurry-based coating process, enhancing the thermal and mechanical properties of the coating--substrate systems, integrating UHTCs with additively manufactured components, expanding the application to additional hypersonic programs, and developing a robust supply chain to align with DLA Strategic Materials and DLA R&D goals. The slurry-based UHTC coating process, developed in collaboration with Oak Ridge National Laboratory, is compatible with multiple deposition techniques and can be applied using various heat sources, including furnaces and laser heating. This innovative process is pressure-less, significantly reducing tooling costs, and is designed to be scalable and cost-effective. The proposed research and development activities will ensure consistent quality and performance of the coatings, validate their effectiveness under realistic operational conditions, and leverage the benefits of additive manufacturing.