Advanced, Thermally Resilient RF Cables and Connectors for Hypersonic Systems

Current commercial radio frequency (RF) cables and connectors are not suited to survive temperatures exceeding 1,200°C. For hypersonic systems, such as missiles, aircraft, or spacecraft, RF cables and connectors must be able to transmit telemetry, targeting, and other signals during flight. Considering the temperatures imposed on the leading edge of a vehicle traveling at hypersonic speeds (>1,800°C), the inner environment of the vessel will equilibrate to temperatures above 1,200°C, leading to material degradation and complete functional failure of commercial RF cables and connectors, regardless of location. Current cable and connector components including the signal carrying conductor, dielectric insulators, electrically conductive grounding, protective jacket, and metal connector housing cannot survive and function at these temperatures because of their material composition. It is the goal of this Phase I program to identify and down-select materials for new and innovative RF cables and connectors that can maintain structure and functionality up to 1,500°C over extended flight times. Working with established corporate partners Lockheed Martin, New England Wire Technologies (NEWT), and FIRST RF, materials will be chosen, supplied, and characterized at NanoSonic for prototyping and eventual inclusion into conventional manufacturing processes. Specific materials that will be investigated, but are not limited to, include ceramic fabrics for dielectric sleeving, steel alloys for conducting and shielding members, as well as 3D-printed steel and ceramic powders. Through an extensive design of experiments, materials that exhibit optimal performance once exposed to temperatures ranging from 1,200°C to 1,500°C will be down selected for prototyping.