Plasma Electrolytic Oxidation (PEO) thermal barrier coatings for hypersonic application

Hypersonic vehicles are highly expensive crafts that operate at speeds above Mach 5 in low altitude trajectories. In such conditions, rapid heating (e.g., 500 ?C/s) and high heat flux (e.g., 1000 W/cm2) lead to high temperatures (e.g., 1000 ?C) sustained for tens of seconds. While heat concentrates on the exterior and leading edges, other areas of the hypersonic craft also experience significant ambient thermal loads. Indeed, these harsh conditions can lead to heat damage to critical internal subsystems (e.g., sensors and avionics equipment) onboard the hypersonic vehicle.   To resist the punishing thermal environment, ultra-high temperature ceramics and composite materials have been used to shield external structures. However, while these advanced materials survive the high heat load, they fail to prevent heat transfer to the interior of the hypersonic vehicle, which threatens the sensitive equipment onboard.   Currently, thermal blankets are widely used to insulate internal components; however, these bulky blankets can add significant weight and occupy significant amounts of space on a relatively small vehicle. An advanced coating system is needed to provide a lightweight, low-profile thermal protection system for the interior of hypersonic vehicles.  IBC Materials & Technologies, LLC (IBC) proposes Plasma Electrolytic Oxidation (PEO) coating technology as a unique solution for thermal protection of interior systems on hypersonic vehicles. PEO coatings are applicable to lightweight alloys such as titanium alloys, a key material for hypersonic vehicles. PEO coatings are relatively thin (e.g., 30 microns), have exceptionally strong adhesion to the substrate, boast low thermal conductivity (<0.2 W/m.k), and have extreme high temperature durability, resisting thermal shock and degradation.   As a lightweight, low-profile thermal barrier, PEO coating will provide superior thermal protection, reducing weight and reducing the burden on thermal management systems. PEO coatings will improve performance and allow increased range and capability for hypersonic vehicles, which may lead to increased field advantage for US defense systems.  IBC uniquely provides both machining and PEO coating. IBC manufactures and PEO-coats large, complex USAF parts (e.g., LAU-12X rails) in quantities of hundreds per year. In this way, IBC is uniquely positioned for vertical integration of both manufacturing and coating for hypersonic vehicles, improving logistics and mitigating supply chain issues.?  Key target markets for PEO coating on hypersonic vehicles include aerospace, defense, and space industries. IBC has received customer interest from USAF and MDA for PEO technology for hypersonics. Additionally, IBC has support from Lockheed Martin and Raytheon RTX, world leaders in hypersonics, to assist with transitioning PEO coating to hypersonic vehicles.