Smart Thermal Protection Systems for Hypersonics

The Wireless Smart Thermal Protection System (Smart TPS) represents a next-generation solution to the challenges of high-temperature monitoring for hypersonic vehicles and atmospheric re-entry systems. By integrating passive, wireless sensors into critical USAF materials such as carbon phenolic and carbon-carbon composites, Smart TPS enables real-time monitoring of temperature, strain, and structural integrity in extreme environments beyond 1000 °C. This innovation directly supports USAF goals to improve system performance and readiness through enhanced materials functionality, monitoring capabilities, and reduced costs for integration and maintenance. Planned Innovation Development Efforts: Sensor Integration: Develop and demonstrate methods for embedding wireless sensors into carbon phenolic and carbon-carbon TPS materials without compromising structural integrity. Sensor Upgrades: Enhance sensor hardware to support multiplexed operation and increased operational temperature thresholds (?1000 °C). Performance Characterization: Quantify metrics such as repeatability, readability, and operational duration, under simulated flight conditions. System Validation: Collaborate with USAF and industry partners to validate sensor integration and data interface with onboard electronics through shock, vibration, and vacuum testing. Arc Jet Testing: Conduct arc jet trials to verify sensor performance under simulated hypersonic environments and ensure results meet or exceed thermocouple performance standards. Acceptance Criteria: Demonstration of robust wireless data transmission in environments exceeding 1000 °C and under aerodynamic loads typical of hypersonic and re-entry systems. Validation of Smart TPS durability and operational capability through repeated thermal, mechanical, and environmental testing. Successful completion of flight-condition simulations, including shock, vibration, and vacuum exposure.