Scalable application of UHTC coatings for hypersonic systems

Current technology around leading edges and nose tips for hypersonic vehicles does not ensure shape stability during hypersonic flight due to rapid heating, oxidation, and aerodynamic forces. Canopy Aerospace, in partnership with Purdue University and University of Colorado ¢ Boulder, proposes to fill this capability gap by leveraging predictive material response modeling to rapidly design and then apply ultra-high-temperature ceramics (UHTCs) to advanced composite materials using plasma spray. Leveraging rapid deposition techniques will allow for rapid screening and maturation of UHTC materials, enabling high-rate production with minimal scrap. The proposed technology is made possible by the unique innovations that include: (1) unique hardware implementation of on-demand powder mixing to allow continuously-graded coatings, (2) new manufacturing routes that mitigate the composite thermal expansion mismatch problem and enhance coating durability/adhesion, and (3) New coating material formulations that provide multiple functionalities to enhance high-temperature performance. Phase II will optimize the plasma UHTC coating to prepare for testing in a realistic environment and reach a technology readiness level of 6. Approved for Public Release | 24-MDA-11673 (8 Jan 24)