Ceramic Additive Manufacturing to develope future Hypersonic Missiles

Additive manufacturing of ceramic materials might be the key to develop future hypersonic missiles.

Ceramic materials such as Silicon OxyCarbide (SiOC) can withstand incredible temperatures.

If shaped into complex geometries, the SiOC material could be exactly what engineers are looking for: “If a material can withstand those temperatures – roughly 3,200 degrees Fahrenheit [1.760 degrees Celsius] – it could be used for hypersonic aircraft engine components like struts or flame holders,” Jamie Szmodis, a hypersonic research engineer with the Air Force Research Laboratory’s Aerospace Systems Directorate, said.

But that is only if materials like SiOC can be shaped into the complex structures needed for hypersonic flight where heat stresses are extreme. To harness the potential of the material, the Air Force is partnering with private laboratories that are pioneering novel manufacturing processes. The Air Force recently signed a Cooperative Research and Development – Material Transfer Agreement with HRL Laboratories to test its novel manufacturing processes: “The potential of the HRL-produced materials for demanding Air Force applications became apparent while Aerospace Systems Directorate scientists were searching for new thermocouple radiation shields,” reads a release from the Air Force Research Laboratory. “The SiOC materials were produced through an additive manufacturing process utilizing a pre-ceramic resin. Following part fabrication, the pre-ceramic resin was heat treated to convert the component to a fully ceramic state. AFRL scientists became interested in HRL’s novel process taking advantage of state-of-the-art 3D printing capabilities and pre-ceramic resin chemistry as well as the possible performance of the final SiOC materials at high temperatures.”

The agreement is also beneficial to HRL Laboratories, which can receive early feedback from what is likely to be its largest customer. “The extreme temperature testing that AFRL performed revealed the limits of our new material and challenged us to improve it,” Dr. Tobias Schaedler, a senior scientist from HRL, said. If the Air Force and HRL Laboratory’s collaboration pays off, they could potentially solve the biggest outstanding challenge with developing hypersonic air vehicles, which is essentially material sciences. Right now, there are no materials that can withstand the extreme heat and stress generated during hypersonic flight. 3D printed ceramics might just be the solution to that problem. Time, of course, will tell. The partnership agreement is beneficial for the Air Force because it is not just a customer but, rather, the service participates in the development process, gaining valuable expertise: “Without the material transfer agreement, we would have purchased the samples to test them. We would have been a customer, as opposed to a collaborator,” Szmodis said. “With the agreement we are able to provide test results to HRL and provide feedback that is valuable to both parties.”