DLA-23A-003/ L23A-003-0025: ōLow Cost MLMI as a Hypersonic Aerostructure with T.P.Sö Phase II

Multi-Layer Metal Insulation (MLMI) has proven to be a viable candidate for Thermal Protection Systems (T.P.S) with integrated structure for Hypersonic vehicles (see Figure 1). MLMI uses C103, a high temperature Niobium alloy for TPS with titanium for primary structure to provide over a 75% cost reduction compared to the current Carbon-Carbon based designs. The AirForce, Navy, Army and MDA all consider Hypersonics a high priority and to reach the required production number of vehicles/systems, cost will be a major driver for success. Current system designs are cost prohibitive. The successful Phase I confirmed that plastic forming, and a diffusion bonding process called Liquid Interface Diffusion Bonding will yield advanced Hypersonic aerostructure designs from high temperature niobium alloys. This Phase I approach advances MLMI manufacturing and further reduces and controls cost, giving designers another method to achieve a critical, low-cost goal. This approach enables the production of advanced shapes, configurations and high-performance features using proven production methods. This Phase II proposal builds upon Phase I and results in testing of prototypes.