Improved Carbon-Carbon for Hypersonic Vehicles

A recent flight test of a hypersonic vehicle resulted in failure that was traced to thermostructural damage in the carbon-carbon aeroshell. When the vehicle was exposed to peak thermal gradients, interlaminar shear stresses were created that caused external plies to delaminate. The structural failures caused aerodynamic disturbances that led to vehicle instability. The program proposed here seeks to develop improved carbon-carbon materials that are resistant to catastrophic delamination. Specifically, the project will focus on needled 3D carbon-carbon; and tape wrapped and involute 2D carbon-carbon materials. 3D carbon-carbon will be considered for leading edges, nosetips, strakes, and control flaps. 2D involute and tape-wrapped carbon-carbon will be de-signed for high lift-to-drag aeroshells. The proposed tasks include: a) design and analysis; b) 2D and 3D carbon-carbon development; c) material property characterization, and: d) fabrication of demonstration hardware including arc jet specimens. The program will be performed by a team of Materials Research & Design (MR&D), Allcomp, Northrop (formerly Orbital-ATK), and Southern Research Institute (SRI). MR&D will manage the program and be responsible for de-sign and analysis. Allcomp will develop and fabricate 3D needled carbon-carbon. Northrop will develop and fabricate 2D carbon-carbon. SRI will measure material properties and assist in arc jet testing. Approved for Public Release | 18-MDA-9817 (23 Oct 18)