High Temperature Tensile Testing

Military systems operating in the hypersonic regime are next generation weapons and surveillance capabilities that offer superior lethality for the U.S., allies and adversaries alike. The United States has conducted foundational research into the challenges of flying at hypersonic speeds since the 1950s. Since then, our adversaries have accelerated their development of hypersonic systems. China and Russia have made significant progress with the later claiming to have deployed hypersonic weapons in the Ukraine war. In last yearÆs annual report to Congress the Pentagon stated that China already possesses ōthe worldÆs leading hypersonic arsenalö and is working to aggressively field additional advanced capabilities. The U.S. lags with insufficient offensive or defensive hypersonic systems. The hypersonic flight domain is extremely harsh, with operating temperatures of around 3,000░C due to friction from flying at high speeds in the atmosphere. This challenges the ability materials to maintain strength for the duration of the flight. The ability to develop new materials and the ability to test them in a manner that simulates flight conditions is paramount for success. The lack of laboratory materials test systems has forced our military to use an Edisonian approach of gathering data empirically through actual flight tests. The cost probative nature of the current testing, using sacrificial flight test vehicles severely limits the pace of development. Ideally testing should be done in controlled laboratory settings rather than flight. Thus, there is a need to develop 3000░C mechanical test equipment to speed up the pace of hypersonic materials development. The equipment must accurately test a materialÆs mechanical properties at flight temperatures. Also the test equipment must not contaminate subject samples while maintaining uniform heating and accurately gathering data. The objective of this project is to create a system capable of applying and measuring mechanical properties (YoungÆs modulus, proportional limit, strain rate, ultimate tensile stress) on materials at temperatures up to 3000oC without contaminating the subject sample. Oxy-Gon is best positioned to provide this test equipment. The companyÆs FR210-2800 materials test system, which was recently delivered to National Aeronautics and Space Administration Glenn, achieving technology readiness level-7, serves as the basis to meet the requirements of this SBIR. Phase I will modify Oxy-GonÆs 2800oC design to achieve 3000oC operating temperature measuring mechanical stresses on subject materials in an inert environment. Phase II will be a development effort, in partnership with a prime contractor, to perform high temperature tests on real-world system materials using a finished system. Phase III is commercialization of the Oxy-Gon system across the Department of Defense (DoD), prime contractors, and aeronautics companies. Approved for Public Release | 24-MDA-11906 (16 Sep 24)