Compressed SiC Aerogels for Hypersonic Insulating Structures

Hypersonic flight presents new and unique engineering challenges. For instance, leading edges and hypersonic system radomes are exposed to thermal stresses that commonly exceed 1400°C. Furthermore, leading edges of reentry vehcicles can undergo compressive forces of 250 MPa or higher. Given this, new materials that can insulate critical componets from the harsh environment and resist high compressive forces are ctirical to future hypersonic systems. To address this need, Luna and our partners will develope a compressed SiC aerogel that is stable above 1600°C, is resistant to oxidation, and has a compressive strength over 1.0 ksi.  Taking advantage of Luna’s extensive background in silica chemistry, we will prepare SiC aerogels that can be easily tuned through common aerospace manufacturing processes. The Phase I program will develop a scalable SiC aerogel synthetic process to manufacture thermal insulating components with tight form factor tolerances that are suitable for aerospace applications.  This will be achieved using established processing methods. The performance metrics will be validated through extensive mechanical, thermal, and physical characterization. This technology is expected to impact both military and civilian markets.