Novel Additively-Manufactured Ultra-High Temperature Composite with Microgravity Improved Grain Structure (NACE HHS MICRO)

Nanoarmor has developed an advanced polymer-based ceramic precursor feedstock that can be used to fabricate high-temperature carbide ceramic parts at high densities, without the traditional extreme processing parameters associated with carbide ceramics. Furthermore, the Nanoarmor feedstock has been proven to be effective in certain additive manufacturing processes, allowing carbide ceramics to be explored for applications that were previously not possible due to processing constraints. Nanoarmor’s critical advantage over state-of-the-art approaches is its unique ability to structure nano-reinforcements into ceramic matrix composites (CMCs) without degradation during processing through low-temperature reaction bonding. This technology is ideal for application in reusable aerospace vehicles and hypersonic platforms and offers exceptional potential tactical and strategic advantages for NASA, the DoD, and other public and private organizations seeking to manufacture reusable, reinforced materials for hypersonic application in orbit or in low-gravity environments. For emerging thermal protection systems to enable next-generation hypersonic vehicle designs, novel materials and design architectures must exhibit high thermal conductivity, resist oxidation and ablation, withstand thermal shock during rapid heat flux, and survive tensile and compressive stress under dynamic and unpredictable loads. Nanoarmor’s unique ability to form lightweight, reinforced CMCs with superior performance capabilities already provides a critical advantage over state-of-the-art ceramics. The proposed research and development initiative is to advance Nanoarmor’s patent-protected process and technique for manufacturing ultra-high temperature ceramic matrix composites (UHT-CMCs) that facilitate dissimilar material integration (e.g. zirconium carbide (ZrC) with toughening additives such as boron nitride nanotubes (BNNTs)), non-extreme processing parameters, and additive manufacturing.

Reusable aerospace vehicles and hypersonic platforms offer exceptional potential tactical and strategic advantages for NASA. The survival of such TPS systems during atmospheric re-entry is paramount to vehicle survival, crew safety, and mission success. UHT-CMCs are desired for implementation on the nose tips, leading edges, air intake systems, and other high-loaded regions of hypersonic aircraft and re-entry vehicles in space applications, due to the utility and high-temperature resistance of these materials.

UHT-CMCs are desired by the DoD for implementation on the nose tips, leading edges, air intake systems, and other high-loaded regions of commercial spacecraft and re-entry vehicles due to the utility and high-temperature resistance of these materials. Nanoarmor carbides are also prime candidates for applications in high-temperature turbines, industrial processing, and energy production.

This is a mature technology (TRL 7) — the realistic path in is usually NASA's Technology Transfer Program: licensing an existing NASA patent, or a Space Act Agreement to use NASA facilities/expertise directly. NASA also runs a startup licensing program with no upfront fee for companies formed to commercialize a specific NASA technology.

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