Functionally Graded Coatings For Enhanced Oxidation Resistance of Sharp Hypersonic Leading Edges

Faraday Technology, will partner with the University of Virginia, and Physical Sciences Inc., to develop and demonstrate an oxidative resistant, functionally graded, metallic coating that is applied to metallic, additively manufactured, sharp hypersonic leading edges. We will demonstrate the material properties of oxidation and thermal resistance at the Laser Steam Load test facility at the University of Virginia and develop a thermomechanical model based upon the coating’s resulting performance and compositional properties. When successful, we will scale the coating application process such that additively manufactured winglets and airfoils with sharp leading edges can be manufactured and tested in Phase II. The application process under development is scalable, and amenable to industrial implementation. We anticipate working closely with hypersonic system integrators and Missile Defense Agency (MDA) to provide testing evidence that the coatings can control erosion and oxidation during hypersonic operations at target test facilities. Additionally, we will demonstrate the flexibility of the coating process to enable cost effective application onto metallic hypersonic structures. Approved for Public Release | 24-MDA-11673 (8 Jan 24)