Thermal Protection Material for Terminal High Altitude Area Defense (THAAD) Interceptor

The government is seeking new lightweight Thermal Protection System (TPS) materials that would allow the Terminal High Altitude Area Defense (THAAD) interceptor to survive and succeed in even more dynamic engagements. Such systems depend on advanced insulating materials and methods to reduce heat that is transferred through the aeroshell to heat-sensitive vehicle structures and internal equipment. One of the biggest challenges in developing such insulators for vehicle TPS applications is to provide a sufficiently lightweight thermal insulation that is also adequate, structurally, at extreme operating temperatures. Ceramic nanofiber are attractive materials for use in realizing high temperature structural insulators due to their high-temperature resistance, oxidation/chemical stability, and contribution to improved mechanical performance. There is a strong interest in alternative form-factor variants of nanofibers to enable new improvements to extreme environment insulating materials, and specifically in casting processing with the ability to produce rigid structural insulators from nanofibers. Thus, the long-term objective of this effort is to leverage prior Polymer Derived Ceramic (PDC) materials and component casting processes, and develop revised formulations integrating nanofibers and other nano materials into the PDC materials to realize improved manufacturable TPS structural-insulator materials for extreme environments, and demonstrate performance in simulated operating environments. This direct to-Phase II effort will focus on work to complete the fundamental materials and casting process development, with an emphasis on materials testing/demonstration and completing the Technology Readiness Level (TRL)/Manufacturing Readiness Level (MRL) milestones needed to foster technology transition and adoption. Approved for Public Release | 25-MDA-12052 (27 Mar 25)