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Porous Hybrid Composite for Enhanced Thermal Protection Systems (ComTPS)

Award Information
Agency: Department of Defense
Branch: Air Force
Contract: FA9550-14-C-0003
Agency Tracking Number: F10B-T27-0028
Amount: $749,668.00
Phase: Phase II
Program: STTR
Solicitation Topic Code: AF10-BT27
Solicitation Number: 2010.0
Solicitation Year: 2010
Award Year: 2013
Award Start Date (Proposal Award Date): 2013-02-01
Award End Date (Contract End Date): 2015-01-31
Small Business Information
2780 Skypark Drive Suite 400
Torrance, CA 90505
United States
DUNS: 000000000
HUBZone Owned: No
Woman Owned: No
Socially and Economically Disadvantaged: Yes
Principal Investigator
 Principal Investigator
 (310) 626-8360
Business Contact
 Zoltan Feher
Title: Manager, Contracts and Pricing
Phone: (310) 626-8384
Research Institution
 University of Washington
 Lynne Chronister
4333 Brooklyn Ave NE
United States

 (206) 543-4043
 Nonprofit College or University

ABSTRACT: The proposed research will demonstrate feasibility of a high temperature insulating, load bearing thermal protection system (TPS) using a hybrid composite technology. This program will incorporate a hierarchically porous ceramic core material in a sandwich structure with a conventional polymer matrix composite (PMC) and ceramic matrix composite (CMC) to fabricate an enhanced TPS. This material will protect the underlying structure from high temperatures, variable heating rates (Mach 4-6), and loading schemes. The core will be fabricated using an inexpensive manufacturing process from a pre-ceramic polymer that can be tailored for thickness and gradient of porosity without a substantial increase in weight to the structure. During Phase II, the NextGen team will focus on the development of the core material in near-net shape form and optimization of thermal protection properties to withstand external temperatures of 2000F and internal temperatures of 600F. These properties will be modeled to predict thermal performance, and an integrated adhesion technique will be developed for 3-component structural assembly. Near-net shape prototypes will be manufactured and characterized in a relevant environment to verify mechanical and thermal properties of the core and 3-component part. Phase III will focus on commercialization of the technology for military and commercial applications. BENEFIT: The anticipated benefits of the porous hybrid composite thermal protection system include simultaneous thermal insulation and load-bearing capabilities and low density. The ceramic foam itself also has a lower thermal conductivity than that of the baseline SiC foam. Due to the unique fabrication and bonding/assembly methods to be developed, the structure will have good machinability in the pre-ceramic form, minimal required machining due to near-net shape casting and minimal volume shrinkage, and minimal outgassing of bonding agents from the integrated bonding approach. All of these factors and the low materials and equipment cost contribute to lower overall manufacturing cost. Additionally, the focus on near-net shape forming reduces assembly difficulties and expedites the integration process into subsystems and systems. Potential applications for this technology include high temperature structures such as hypersonic vehicles, ballistic missiles, various space structures, and re-entry vehicle parts. Other commercial products that would benefit from this technology include automobiles and commercial aircraft. The ComTPS technology could protect surrounding parts from the high temperatures produced by automobile and jet engines or be used as brake disks in aircraft or racecars.

* Information listed above is at the time of submission. *

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