Aerogel Spray Thermal Barrier

A need exists for new weapon types that can rapidly strike targets around the globe within minutes. One current focus is the development of hypersonic strike weapons. Hypersonic weapons will have increased effectiveness, decreased time to target, and increased range. However, hypersonic projectiles will experience significant aerothermic heating necessitating thermal protection. This key technology requirement is driven by the need for extremely robust, high g and high temperature tolerant structures. Nanoporous solids such as aerogels are of interest in such thermal protection applications. To make full use of the potential of these nanoporous materials in thermal protection for hypersonic projectiles, novel aerogel formulations and new methods of integration and application on structures is required. Ocellus has successfully developed aerogel composites with high temperature stability, insulation, and acoustic/shock tolerance. In this Phase I effort, we will assess various aerogels and aerogel composites to identify those materials or family of materials that are suited to this application, using thermal conductivity/heat transport models we developed for analyzing aerogels and aerogel composites at high temperature. Based on these results, a novel aerogel formulation suitable for spray deposition will be demonstrated and its thermal and mechanical properties characterized at high temperature.