Thermal Protection System (TPS) for Hypersonic Applications

High temperature resistant Thermal Protection System (TPS) materials are critical to the success of new hypersonic weapons and related U.S. defense modernization priorities. Each material's temperature capability, durability and weight determine the extent of its application on the vehicle. Improvements to these materials have been the subject of much research as enhanced capability material (i.e., more durability, higher temperature capability, greater thermal shock resistance and lower thermal conductivity) improves thermal protection material and vehicle performance. Once developed and implemented within a design, these materials often possess a single point of failure (SPOF) or multiple SPOF’s within a single supply chain. The DoD has identified SPOF as a significant threat to defense rated programs. One such product is Rayon Carbon replacement material “Low-Fired-Stretch-Broken-PAN-Fiber” (LFSP). LFSP is coated with phenolic resin into a prepreg system then processed into rocket motor exit cones by tape wrapping or employed within acreage area Hypersonic Aeroshells via carbon-carbon (C-C) processing. Alkemix Corporation is pleased to offer a solution that is independent of the current LFSP supply chain. Development will be focused on the following: 1) a domestically sourced and sustainable LFSP; 2) a high char yield resin matrix which will meet ablative thermal properties; and 3) the prepreg system developed must perform in a C-C processing environment.  Finally, the deliverable will strive to increase the current domestic production capacity, reduce C-C process cycle times, increase affordability, and enhance supply chain resiliency.