TECHNOLOGY AREA(S): Materials/Processes

ACQUISITION PROGRAM: NAE Chief Technology Office

The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with section 3.5 of the Announcement. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws.

OBJECTIVE: Develop innovative, affordable thermal/mechanical test methods for hypersonic material systems under a relevant hypersonic environment in a range of Mach 5-20.

DESCRIPTION: Hypersonic vehicles and their propulsion systems have significant challenges in their design and development attributed to their extreme operational environments. One of the key challenges in hypersonic vehicles is their thermal protection materials and management systems. Recent progress in the research and application of hypersonic material systems has significantly contributed to our understanding of materials� behavioral aspects under extreme hypersonic environments. However, ever-increasing demands of hypersonic vehicles in in terms of function, operation, and life expectancy require continuous technological innovations. In addition, there is a need for advanced test methodologies for hypersonic materials to ensure operational reliability and durability of hypersonic vehicles. Therefore, there is a need to develop innovative, affordable thermal/mechanical test methods under a relevant hypersonic operational environment. The target hypersonic environment ranges between Mach 5-20. The environment must recreate operational conditions including temperature, heat flux, thermal/pressure loading, atmosphere and plasma. The test methods must be able to assess thermomechanical properties of candidate hypersonic material systems with respect to strength, creep, and life coupled with relevant test frames. Subsequently, the test methods must be able to characterize environmental durability of the materials in terms of oxidation, ablation, and catalytic/plasma effects. Candidate hypersonic materials are primarily targeted for leading edge applications in which appropriate thermal management architectures (e.g., for thermal gradient or cooling, etc.), although not required, may be taken into account. Consider employing Finite Element Analysis (FEA), computational fluid dynamics (CFD), and Integrated Computational Materials Engineering (ICME) or any other physics/chemistry-based analytical tools to design optimized target test conditions in conjunction with test coupons/sub-elements and test facility. Collaborations with research institutions could strengthen the efficacy of research efforts and are thus encouraged.

Work produced in Phase II may become classified. Note: The prospective contractor(s) must be U.S. owned and operated with no foreign influence as defined by DoD 5220.22-M, National Industrial Security Program Operating Manual, unless acceptable mitigating procedures can and have been implemented and approved by the Defense Security Service (DSS). The selected contractor and/or subcontractor must be able to acquire and maintain a secret level facility and Personnel Security Clearances. This will allow contractor personnel to perform on advanced phases of this project as set forth by DSS and NAVAIR in order to gain access to classified information pertaining to the national defense of the United States and its allies; this will be an inherent requirement. The selected company will be required to safeguard classified material IAW DoD 5220.22-M during the advanced phases of this contract.

PHASE I: Design and develop initial conceptual model(s) of proposed thermal, environmental, mechanical test methods��� under the required hypersonic environment of Mach 5-20. Determine and demonstrate the feasibility of the designed model(s). The Phase I effort will include prototype plans to be developed under Phase II.

PHASE II: Fully develop and optimize the approach formulated in Phase I. Demonstrate and validate the approach using selected hypersonic material systems. Develop and deliver a laboratory-scale test cell prototype with thermal/environmental provisions.

Work in Phase II may become classified.� Please see note in Description paragraph.

PHASE III DUAL USE APPLICATIONS: Perform final testing and transition the approach to hypersonic leading edge sub-elements to assess their related operational capabilities under simulated Mach 5-20 environments. The topic, if successful, will have both private-sector commercial potential and dual-use applications due to its unique nature of new, affordable technology development. Test Methodologies would also allow the energy sector to quantify material properties for high-temperature materials and composites, which in turn allows the validation of modeling and simulation.

REFERENCES:

1. Evans, A.G., Zok, F.W., Levi, C.G., McMeeking, R.M., Miles, R.M., Pollock, T.M., & Wadley, H.N.G. �Multidisciplinary University Research Initiative on �Revolutionary Materials for Hypersonic Flight'.� Final Report, Office of Naval Research, 2011. https://apps.dtic.mil/dtic/tr/fulltext/u2/a552599.pdf

2. Glass, D.E. �Ceramic Matrix Composite (CMC) Thermal Protection Systems (TPS) and Hot Structures for Hypersonic Vehicles.� Proceedings of the 15th AIAA Space Planes & Hypersonic Systems & Technologies Conference, April 28-May 1, 2008, Dayton, OH.� https://ntrs.nasa.gov/archive/nasa/casi.ntrs.nasa.gov/20080017096.pdf

3. Bond Jr., J. W. �Plasma Physics and Hypersonic Flight.� Journal of Jet Propulsion, Vol. 28, No. 4, 1958, pp. 228-235. https://arc.aiaa.org/doi/abs/10.2514/8.7284

4. Shashurin, A., Zhuang, T., Teel, G., Keidar, M., Kundrapu, M., Loverich, J., Beilis, I. I., & Raitses, Y. �Laboratory Modeling of the Plasma Layer at Hypersonic Flight.� Journal of Spacecraft and Rockets, Vol. 51, No. 3, 2014, pp. 838-846. DOI: 10.2514/1.A32771

KEYWORDS: Hypersonic; Hypersonic Materials; Hypersonic Thermal Management; Hypersonic Thermal Protection Materials; Ceramics; Ceramic Matrix Composites