Multilayer Thin Film Coating for Sensor Platform in Extreme Environments

Advanced sensor platforms that can be reliably applied under extreme environmental conditions is of critical importance for exploration and long-duration operation on the Venus surface because of its extremely high ambient surface temperature and pressure. To apply sensor platform reliably in such a condition, this project is aimed to develop a protective coating system. Despite recent advances in coating techniques and manufacturing, there are still two major challenges to be overcome: (1) development of a lightweight and durable coating system with excellent mechanical and structural stability under high temperature and pressure conditions and (2) design of the coating systems that could serve as a thermal insulation layer to prevent heat transfer in order to ensure the workability of the sensor platform by maintaining the relatively low temperature state for the sensors. With the recent progress in graphene, to overcome these challenges, it is hypothesized that a multilayer thin film coating based on aero-graphene (i.e., a bulk-like porous material) could serve as a protective coating system to enable long-duration operation for sensor application at Venus surface. It takes the advantages of the low density and thermal conductivity and exceptional mechanical properties of the aero-graphene. Specifically, the proposed multilayer thin film coating consists of mainly three sublayers including a sealing outer-layer made of metal alloy, an insulation middle-layer made of bulk aero-graphene, and a resin inner-layer for attachment of substrate or sensor platform. To achieve the stated goal, multiscale modeling, numerical analysis, and validating experiments will be integrated. The hypothesis will be tested by pursuing three main objectives: (1) computation-assisted design of graphene-based multilayer coating to insulate sensor platform; (2) experimental testing of sensor platform coated by the developed multilayer coating under high temperature and pressure condition; (3) integration of research into STEM education and curriculums. The proposed research will build upon our research team’s expertise on multiscale modeling, mechanics of materials, design and testing of smart coating and sensing platforms, and our collaboration with scientist at NASA, creating unique synergies that provide the crucial knowledge and skill set required to achieve the stated goals.

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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