TECHNOLOGY AREAS: Air Platform, Materials/Processes

ACQUISITION PROGRAM: PMA-231 E-2C/E-2D ACAT I

The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), which controls the export and import of defense-related material and services. Offerors must disclose any proposed use of foreign nationals, their country of origin, and what tasks each would accomplish in the statement of work in accordance with section 3.5.b.(7) of the solicitation.

OBJECTIVE: Develop an innovative thermal barrier coating system for aircraft surfaces (metal and fiberglass) capable of exposure to moderate short-duration heating.

DESCRIPTION: In many situations encountered in military aircraft there is a need for a spray-in-place coating which has superior thermal efficiency, has extremely low weight, and is capable of protecting the surface for a brief period of time from heating by moderate-temperature air up to 500�F. One example in military aircraft occurs in the outer wing panels of the aircraft: when these wing panels are folded on the ground with the engine running and the exhaust from the engine cooling system impinges on the panels with adverse fatigue effects. Other examples may include over heating of fiberglass structural components. The developed thermal barrier coating material should have thermal conductivity values in service conditions that are very low (e.g. < 25 mW/m-K at 400 F) at bulk coating densities lower than 200 kg/m3. Previous research has shown that nanoporous materials such as aerogels can be applied using spray techniques yielding a highly insulating coating system; however, these systems do not meet durability and application requirements.

To be successful, the developed coating system must have low aerial weight, be mechanically robust, insensitive to environmental factors such as rain and moisture, and highly thermally insulating per unit thickness. The thermal protection systems must provide a thermal barrier to protect the substrate when heated for a minimum of 10 minutes at temperatures up to 500 degrees F. In addition, application of the coating must use a room temperature spray process that produces a consistent and uniform thickness.

PHASE I: Develop a coating system formulation for application to aluminum and fiberglass/epoxy surfaces and demonstrate the feasibility of the approach through limited thermal testing.

PHASE II: Fully develop the thermal protection system including the sprayable application process. Demonstrate the spray application process and the ability of the system to protect aircraft components of relevant size to operational aircraft. Validate thermal and mechanical performance of the coating in realistic environmental tests.

PHASE III: Perform full scale thermal ground testing of the thermal protection system on actual aircraft components. Transition the developed technology to other aircraft applications.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: Private sector application and dual-use applications exist in any industry/product requiring low weight, durable, thermal insulating coatings.

REFERENCES:
1. Akimov, Yu. K., Fields of Application of Aerogels (Review), Instruments and Experimental Techniques (Translation), 46, 2003, 287-299

2. Jones, S.M., Aerogel: Space Exploration Applications, Journal Sol-Gel Sci Techn, 40, 2006, 351-357

KEYWORDS: aerogel; spray-in-place insulator; spray-on insulator; nanoporous materials; aerospace; thermal barrier coating

** TOPIC AUTHOR (TPOC) **

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