EXPENDABLE HYPERSONIC VEHICLE LEADING EDGES WITH PASSIVE THERMAL MANAGEMENT

America’s warfighter needs hypersonic technology that works now. The primary challenge that arises with metallic hypersonic vehicle Leading Edge (LE) design is managing the severe aerothermal loading in high-speed (Mach 5-6+) flight. Current high-speed solutions are expensive, low TRL, and long lead. Proposed here, GHI will design internal geometry for metallic LE designs using topology optimization and produce hardware using additive manufacturing that tailors conduction paths and manages thermal stress. The hardware will be inspected via radiographic techniques to determine manufacturing process validity and tested in the AFRL LEEF Test Facility to verify thermal-structural performance. The results of a successful program will be affordable, low lead-time, low-risk metallic LE solutions enabling commercial and defense vehicles to fly at Mach 5-6+. The knowledge gained in the design and testing activities will be leveraged to design and manufacture an air-breathing inlet and a control fin with advanced LEs. Hardware assembly test plans will be developed with the goal of test execution after a Phase III transition occurs. GHI has the experience, personnel, and tools to successfully complete this Phase II, transition the technology to a flight test in Phase III, and bring the technology to market to support the warfighter.