Ceramic-Metal Joining for Hypersonic Vehicle and Missile Components

Advanced Navy systems such as the Hyper Velocity Projectile (HVP) and next generation high speed missiles will subject the airframe to severe aerothermal heating loads. Both the HVP fin and missile radome design problems can be solved through the development of ceramic-metal joining technology. The design problem is complex since the hardware is subjected to high inertial loads, severe aerothermal heating, and large aerodynamic pressures. Potential ceramics include Si3N4, SiC, ZrB2, slip cast fused silica, and oxides. Attractive metallic alloys include titanium, Inconel, Hastelloy, and stainless steel. Joining concepts include mechanical fasteners, brazing, diffusion bonding, and combinations of these. The Base program includes: 1) Compilation of Conditions; 2) Conceptual Designs; 3) Material Trades; 4) Thermostructural Analysis; 5) Fabrication of Mechanical Joints, and; 6) Testing of Mechanical Joints. The Option program includes: 7) Fabrication of Brazed/Bonded Joints; 8) Testing of Brazed/Bonded Joints, and; 9) Data Correlation, Design Improvements, and Radome Conceptual Joints. Phase I will be performed by a team of Materials Research & Design (MR&D), Exothermics, and Southern Research Institute (SoRI). MR&D will compile operational conditions, develop conceptual designs, and analyze the concepts. Exothermics will guide material selection and fabricate specimens. SoRI will measure the strengths to assess their capabilities.