Thin, Flexible Oxidation-Resistant Coatings for 3D-Woven Carbon Fabric TPS Materials

The flexibility of deployable decelerators enables more efficient use of the launch vehicle payload shroud volume through smaller packed volume, reducing design constraints on entry vehicle structures and thermal protection systems (TPS). Mission applications for this technology cover a variety of classes and scales, ranging from sample return from planets and moons to payload recovery from low Earth orbit. Some mission applications use ADEPT (Adaptable Deployable Entry and Placement Technology), a state-of-the-art mechanically deployed hypersonic decelerator, to enable sample return and Earth aerocapture missions for a range of payload sizes and masses. ADEPT utilizes a three-dimensionally (3D) woven flexible carbon aeroshell combined with a rigid nose made of a phenolic ablative TPS material such as PICA. Currently, 3D-woven carbon fabric materials have been tested and integrated into small-scale hypersonic heat shields in ADEPT configurations. While demonstrating excellent survivability under heat fluxes as high as 250 W/cm2, 3D-woven carbon fabric materials lack sufficient oxidation resistance that would enable missions to Mars, Venus, and other solar system destinations. In this project, Ultramet will investigate the use of titanium carbide (TiC) as an oxidation-resistant coating material for ADEPT applications. The high temperature oxidation resistance of TiC combined with the flexibility of thin TiC films makes it an ideal material for use on carbon fiber TPS. Ultramet will leverage its expertise in chemical vapor deposition (CVD) to develop a process to infiltrate and deposit uniform TiC coatings on carbon fibers.

The improved oxidation resistance of TiC-coated 3D-woven carbon fabric TPS materials will increase the applicability of ADEPT systems for hypersonic deceleration applications. Currently limited to small-scale heat shields where carbon fabric recession due to oxidation is limited, expanding ADEPT’s capabilities to oxidizing environments will enable its insertion into applications of interest where oxidation is expected. Namely, increased oxidation resistance will enable missions to Mars, Venus, and other solar system bodies. 3D-woven carbon fabrics and composites are materials of choice for hypersonic air vehicles as they provide excellent strength-to-weight ratios, impact resistance, and design versatility. Enhancing their survivability through application of an oxidation-resistant coating will enable broader application of these materials for longer flight times and more extreme environments.

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.

None of these are guaranteed paths for this specific project — TechPort itself doesn't have an "apply" button. Reaching out to the contact(s) above with a specific question is usually the fastest way to find out what's actually open.