N101-067 TITLE: Material Multi-Solution for Hypersonic Systems

TECHNOLOGY AREAS: Materials/Processes

ACQUISITION PROGRAM: IWS 3C, ONR Electromagnetic Railgun, MDA, Gun Launch Projectiles

RESTRICTION ON PERFORMANCE BY FOREIGN CITIZENS (i.e., those holding non-U.S. Passports): This topic is "ITAR Restricted." The information and materials provided pursuant to or resulting from this topic are restricted under the International Traffic in Arms Regulations (ITAR), 22 CFR Parts 120 - 130, which control the export of defense-related material and services, including the export of sensitive technical data. Foreign Citizens may perform work under an award resulting from this topic only if they hold the "Permanent Resident Card", or are designated as "Protected Individuals" as defined by 8 U.S.C. 1324b(a)(3). If a proposal for this topic contains participation by a foreign citizen who is not in one of the above two categories, the proposal will be rejected.

OBJECTIVE: Development of a novel, light-weight material for use within a hypersonic weapon system. The material must interface with system structural components and meet all engineering specifications for mission completion.

DESCRIPTION: Incorporating composites and other advanced materials into a hypersonic system can offer innovative solutions to engineering requirements while also providing a weight-benefit in a system’s overall design. Boron-aluminum with a unidirectional layup was used in space shuttle tubular struts, resulting in a 44 percent weight savings as compared to alternative material solutions. The National Aero-Space Plane (NASP) program employed the use of refractory composites and metal matrix composites to fulfill the X-30 airframe’s high temperature and high strength requirements. Carbon-carbon is widely used for its thermal management properties, specifically for the Air Force development of skin panels for air-breathing hypersonic vehicles.

As part of a hypersonic system, material solutions must be capable of fulfilling design requirements and surviving adverse mission environments. The proposed solution will consider a hypersonic launch environment at a minimum 45 k-Gee acceleration, and load thresholds of 450 ksi and 250 ksi in compression and tension, respectively. To maintain a weight benefit in an overall system design, it is expected the material density must be no greater than 0.125 lb/in^3. The fabrication process must also be capable of producing non-cylindrical geometries. The material must be capable of interfacing with system components made of other materials; for example, a steel ogive section of a missile airframe may interface with a composite aft-end at the tail section. The material must not exhibit elongation greater than 1%. It is expected that a hypersonic system will perform at super-elevated temperatures; therefore, a proposed solution may include exterior coatings for thermal management.

The Navy intends to promote exploration into advanced materials as an enabling technology for Navy guided munitions. It is also the intent to develop technologies as innovative design solutions for multiple hypersonic weapon systems. Incorporating composites or other advanced materials introduces the potential for a more robust solution to challenging design constraints, with the added benefit of a component weight reduction. It is recommended that a literature review be performed to assess the current state of the art (SOTA) composite materials development and fabrication techniques and their potential to interface with a hypersonic weapon system.

PHASE I: Based on an assessment of current SOTA composite materials development and fabrication techniques and their potential to integrate into a hypersonic weapon system, perform material characterization and concept development to meet the criteria defined in the description. The contractor will be expected to provide a feasibility report explaining the proposed concept and how it provides an innovative solution which fulfills all specified design requirements.

PHASE II: Implement strategies proposed in Phase I. Produce material for interface with full or partial-scale hypersonic system models. Systems will be tested in a hypersonic test facility for system demonstration of concept. Develop Modeling and Simulation (M&S) methodologies to capture material interface within a hypersonic system. Utilize M&S to understand material performance under mission requirements and environment.

PHASE III: Pending successful proof of concept and M&S validation, Phase III will focus on support of systems of interest. It is intended that Phase III will be supported by multiple agencies/programs for specific mission requirements.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: NASA, private aeronautical and space industry, materials development and processing industry.

REFERENCES:
1. Weisinger, MD, and Forest, JD, Miller, M, "Feasibility Demonstration Program for the Application of Boron/Aluminum to Space Shuttle," CASD-NAS-74-017, General Dynamics Corporation Convair Division, May 1974.

2. Barthelemy, R., "Recent Progress in the National Aerospace Plane Program," IEEE AES Magazine, pp. 3-12, May 1989.

3. Blevins, R. and Holehouse, I., "Thermoacoustic Loads and Fatigue of Hypersonic Vehicle Skin Panels," Journal of Aircraft, vol. 30, no. 7, pp. 971-974, Nov-Dec 1993.

KEYWORDS: advanced materials; composites; hypersonic; modeling & simulation; materials processing; projectiles

** TOPIC AUTHOR (TPOC) **

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