Aerogel Spray Thermal Barrier Navy STTR FY2005 Sol No.: Navy STTR FY2005 Topic No.: N05-T015 Topic Title: Aerogel Spray Thermal Barrier Proposal No.: N054-015-0356 Firm: Ocellus, Inc. 450 Lindbergh Avenue Livermore, California 94551-9552 Contact: Michael Droege Phone: (925) 606-6540 Web Site: www.ocellusinc.com Abstract: 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. Benefits: Immediate benefit from this Phase I activity is the design of an aerogel-based spray deposition insulation system for thermal protection of hypersonic projectiles. The ability to tailor the aerogel insulation system allows it to be a flexible solution to meet future technological needs. This technology has the potential to impact a range of hypersonic military applications such the CAV, ECAV, and HCV. Additionally, a variety of commercial opportunities are available to this technology. For example, advanced TPS materials are needed for upgrading the current Shuttle fleet and for planned space vehicles such as Reusable Launch Vehicles and other expendable launch and reentry vehicles. Return