Novel Advanced Hypersonic Thermal Protection Composite Produced by Additive Manufacturing

Current advancement of hypersonic technologies across the DoD is hampered by the boundaries of established materials from their limited thermal stability to poor mechanical properties at elevated temperatures. The development of hypersonic munitions is a critical National Security interest, especially given the current geopolitical situations. As hypersonic vehicles are subjected to intense thermal effects, some thermal barrier systems have enabled working close to the projected operational temperatures. Nonetheless, hypersonic technology has plateaued due to the intrinsic limitations of materials at elevated temperatures, poor aging properties, and limited manufacturability. Providing overmatch capability via a new generation of hypersonic vehicles will thus require new approaches providing a holistic solution to the multiple challenges. Our program proposes innovative multi-dimensional solution to establish novel composites for high performance at high temperature and harsh weather conditions. Accordingly, we will develop and demonstrate phthalonitrile polymers infiltrated into carbon fibers axially defined by additive manufacturing. This approach combines the unique high chemical and thermal stability of phthalonitriles with ingenious design and fabrication of composite fibers for enhanced thermal conductivity. From a fabrication standpoint, these polymers are well-known for their processability, whereas additive manufacturing is an unmatched capability for design and commercial transition. In order to extend the aging properties of these composites, chemical additives will be used to provide resistance to other degradation mechanisms, such as UV light. MATSYS has unique expertise in customization of commercial polymers, whereas Pr. LeBlanc at GWU is a leading expert on additive manufacturing of novel materials, including hypersonic thermal protection systems.