Search Results (35)

In order to satisfy the requirement for lightweight, highly reliable sprayable silicone rubber insulation material (SASI) in next-generation spacecraft, and to achieve a synergistic balance among the sprayability, mechanical properties and ablation resistance of SASI, this paper describes the preparation of nanostructured magnesium silicate (n-MS) via a hydrothermal method and systematically investigates its effects on the sprayability, mechanical properties and ablation resistance of sprayable SASI. The findings suggest that when the n-MS loading is set at 15 parts, the linear ablation rate and mass ablation rate of the SASI under oxy-acetylene conditions are as low as 0.10 mm/s and 0.07 g/s, respectively, representing reductions of 41.8% and 67.1% compared to the unmodified samples. Building upon this enhancement in ablation resistance, the tensile strength was also increased by 3.70 MPa, representing a 19.3% increase. It is crucial to note that during the spraying process, the viscosity of the silicone rubber system remained within a narrow range of 540–550 mPa·s following the addition of this filler. This finding indicates that the introduction of n-MS had no significant adverse effect on the spraying process. In summary, n-MS has been demonstrated to enhance the mechanical strength and ablation resistance of silicone rubber materials while maintaining adequate spray coating performance. In comparison with conventional filled silicone rubbers, the sprayable silicone rubber insulating material developed in this study provides a new material basis for the future lightweight and intelligent development of aerospace engines. Full article

This study focused on the development of a new concept for ablative thermal protection material, using a relatively new polymer matrix based on polysiloxane resin, which exhibits high-performance thermal properties. As a reinforcing element, graphite felt (GF/UHT) was selected. These new ablative materials were tested and characterized to evaluate their thermal properties through comparison with established/standard ablative materials based on phenolic resin and graphite felt (GF/Isophen). To evaluate them, two distinct types of thermal tests were performed. The first consisted of subjecting the ablative materials to a temperature of 1100 °C for a total duration of 10 min (with three different dwell times: 30 s, 120 s, and 300 s). A mass loss of 31% was recorded for the GF/UHT ablative material samples compared to the GF/Isophen material, where the mass loss reached approximately 68%. The second test consisted of exposure to an oxyacetylene flame at a temperature of 1600 °C. The GF/UHT samples had an improved behavior compared to the GF/Isophen samples, the latter being completely penetrated at the end of the test. Additionally, differential scanning calorimetry (DSC) tests were performed and characterized by FTIR spectroscopy and scanning electron microscopy. Full article

This study investigates seven advanced hybrid composite thermal protection system (TPS) prototypes, featuring an innovative internal air chamber design that reduces heat conduction and enhances overall thermal protection performance. Specimens were manufactured by fused deposition modeling (FDM), an additive manufacturing technique, using a fire-retardant thermoplastic. Selected configurations were reinforced with continuous carbon or glass fibers, coated with ceramic surface layer, or hybridized with carbon fiber reinforced polymer (CFRP) layers or a CFRP laminate disk. To validate performance, a harsh oxy-acetylene torch (OAT) protocol was implemented, deliberately designed to exceed the severity of most reported typical ablative assessments. The exposed surface of each specimen was subjected to direct flame at a 50 mm distance, recording peak temperatures of 1600 ± 50 °C. Two samples of each configuration were tested under 60 and 90 s exposures. Back-face thermal readings at potential payload sites consistently remained below 85 °C, well under the 200 °C maximum standard threshold for TPS applications. Several configurations preserved structural integrity despite the extreme environment. Prototypes 4.1 and 4.2 demonstrate the most favorable performance, maintaining structural integrity and low back-face temperatures despite substantial thickness loss. By contrast, specimen 6.2 exhibited rapid degradation following 60 s of exposure, which served as a rigorous and selective early-stage screening tool for evaluating polymer-based ablative TPS architectures. Full article

The research investigated the potential of five novel additively manufactured (AM) fiber-reinforced thermoplastic composite (FRTPC) configurations as alternatives for ablative thermal protection system (TPS) applications. The thermal stability and ablative behavior of ten samples developed via fused deposition modeling (FDM) three-dimensional (3D) printing out of fire-retardant thermoplastics were investigated using an in-house oxyacetylene torch bench. All samples featured an innovative internal thermal management architecture with three air chambers. Furthermore, the enhancement of thermal benefits was achieved through several approaches: ceramic coating, mechanical hybridization, or continuous fiber reinforcement. For each configuration, two samples were exposed to flame at 1450 ± 50 °C for 30 s and 60 s, respectively, with the front surface subjected to direct exposure at a distance of 100 mm during the ablation tests. Internal temperatures recorded at two back-side contact points remained below 50 °C, well under the 180 °C maximum allowable back-face temperature for TPS during testing. Continuous reinforced configurations 4 and 5 displayed higher thermal stability the lowest values in terms of thickness, mass loss, and recession rates. Both configurations showed half of the weight losses measured for the other tested configurations, ranging from approximately 5% (30 s) to 10–12% (60 s), confirming the trend observed in the thickness loss measurements. However, continuous glass-reinforced configuration 5 exhibited the lowest weight loss values for both exposure durations, benefiting from its non-combustible nature, low thermal conductivity, and high abrasion resistance intrinsic characteristics. In particular, the Al₂O₃ surface coated configuration 1 showed a mass loss comparable to reinforced configurations, indicating that an enhanced surface coat adhesion could provide a potential benefit. A key outcome of the study was the synergistic effect of the novel air chamber architecture, which reduces thermal conductivity by forming small internal air pockets, combined with the continuous front-wall fiber reinforcement functioning as a thermal and abrasion barrier. This remains a central focus for future research and optimization. Full article

This study focused on the thermal stability and ablative behavior assessment of five newly developed composite TPS configurations. All ten test samples were 3D printed via FDM using various fire-retardant thermoplastic materials, with and without reinforcement. Eight samples integrated a new thermal management internal air chamber conceptualized architecture. A prompt feasible approach for the flame resistance preliminary assessment of ablative TPS samples was developed, using an in-house oxy-acetylene torch test bench. Experimental OTB ablation tests involved exposing the front surface samples to direct flame at 1450 ± 50 °C at 100 mm distance. For each configuration, two samples were tested: one subjected to 30 s of flame exposure and the other to 60 s. During testing, internal temperatures were measured at two backside sample contact points. Recorded temperatures remained below 46 °C, significantly under the maximum allowable back face temperature of 180 °C set for TPSs. The highest mass losses were measured for PC and PETG FR materials, achieving around 19% (30 s) and, respectively, 36% (60 s), while the reinforced configurations showed overall only a third of this reduction. The study’s major outcomes were the internal air chamber concept validation and identifying two reinforced configurations as strong candidates for the further development of 3D-printed ablative TPSs. Full article

In solid rocket propulsion systems, overload effects induced by aircraft maneuvers can lead to gas accumulation in the afterburning chamber, resulting in severe localized ablation of thermal insulation layers and significantly compromising overall operational stability. Traditional ablation experimental methods (e.g., oxyacetylene and plasma ablation) exhibit poor correlation with the actual thermal environments in solid rocket ramjets, thereby posing substantial challenges for simulating real operational conditions. To address this issue, an oxygen-kerosene engine-based ablation device was developed. Methodologically, the CEA-optimized oxygen-to-fuel ratio (3.5) enabled authentic combustion simulation, while 3D compressible flow modeling (Ansys Fluent 2020 R2) quantified critical parameters such as chamber pressure and achieved precise control of surface temperature. Ablation experiments were conducted on diverse ablative materials using this device, yielding a maximum error in mass ablation rate of only 5.67%. This demonstrates the high accuracy of the device, which meets the requirements for ablation experiments. This reliable simulator (with an error <6%) provides a validated platform for high-fidelity evaluation of ablation performance in maneuverable solid rocket ramjets. Full article

The effects of HfC content on the ablation resistance of W-HfC composites were systematically studied. The oxy-acetylene flame ablation test was conducted at 2800 °C. Post-ablation samples were characterized via XRD, section morphology, and EDS. W-10HfC showed the best ablation resistance, with a linear ablation rate of just 0.0175 mm/s. This enhanced performance is attributed to the formation of a dense HfW₂O₈ oxide layer with negative thermal expansion properties, reinforced by uniformly dispersed blocky HfO₂ particles. However, excessive HfC content induces a stratified oxide structure. The thermal expansion coefficient mismatch between HfW₂O₈ and HfO₂ causes microcrack formation, ultimately degrading ablation resistance. These findings establish critical guidelines for HfC content optimization in W-HfC composite design. Full article

Using low-cost transition-metal chlorides and furfuryl alcohol as raw materials, the (TiZrHfNbTa)C precursor was prepared, and a three-dimensional braided carbon fiber preform (C/C) coated with pyrolytic carbon (PyC) was used as the reinforcing material. A C/C-(TiZrHfNbTa)C composite was successfully fabricated through the precursor impregnation pyrolysis (PIP) process. Under extreme oxyacetylene ablation conditions (2311 °C/60 s), this composite material demonstrated outstanding ablation resistance, with a mass ablation rate as low as 0.67 mg/s and a linear ablation rate of only 20 μm/s. This excellent performance can be attributed to the dense (HfZr)₆(TaNb)₂O₁₇ oxide layer formed during ablation. This oxide layer not only has an excellent anti-erosion capability but also effectively acts as an oxygen diffusion barrier, thereby significantly suppressing further ablation and oxidation within the matrix. This study provides an innovative strategy for the development of low-cost ultra-high-temperature ceramic precursors and opens up a feasible path for the efficient preparation of C/C-(TiZrHfNbTa)C composites. Full article

One of the most widely used processes in ship hull plate manufacturing is the flame forming process (FFP). In this work, the fabrication of saddle-shaped specimens with FFP using a spiral irradiating pattern is studied experimentally. The deformation of the deformed plates by FFP based on the spiral irradiating pattern is affected by process parameters such as the pitch of spiral passes (PSP), the radius of the starting circle (RSC), and the number of irradiation passes (NIP). However, in this work, the effects of process parameters on the deformation of SSS are statistically examined by the design of experiment (DOE) method based on response surface methodology (RSM). The experimental and statistical results show that the deformation of flame-formed SSS increases with the increase in RSC and NIP and the decrease in PSP. In addition, the results of the optimization procedure demonstrate that the maximum value of deformations of flame-formed saddle-shaped specimens is achieved by adjusting the process parameters as follows: PSP = 10 mm, RSC = 75 mm, and five NIPs. Full article

To enhance the operational life of hydraulic machinery, protective coatings against wear, particularly cavitation erosion, and corrosion might be applied on the surfaces of components. The experiments conducted in this study aimed to assess the suitability of 80/20 NiCrBSi/WC-Co composite coatings for this purpose. A coating of NiCrBSi self-fluxing alloy, which served as the reference material, was deposited alongside a NiCrBSi coating reinforced with 20% WC-Co, both applied by flame spraying onto X3CrNiMo13-4 substrates, the martensitic stainless steel type frequently utilized in turbine blade manufacturing. The improved density of the coatings and adhesion to the substrate was achieved by remelting with an oxyacetylene flame. The cavitation and corrosion performance of both the reference and composite coating were evaluated through cavitation tests and electrochemical measurements conducted in the laboratory. The results demonstrate that the addition of 20% WC-Co significantly enhances the cavitation resistance of the composite material, as evidenced by the reduction to 3.76 times of the cumulative erosion (CE), while the stabilization rate remained at half the value observed for the reference self-fluxing alloy coating. Conversely, the addition of WC-Co into the NiCrBSi coating resulted in a slight decrease in the corrosion resistance of the self-fluxing alloy. Nevertheless, the corrosion rate of the composite coating (124.80 µm/year) did not significantly exceed the upper limit for excellent corrosion resistance (100 µm/year). Full article

Ablative materials are widely employed to protect space vehicles from the extreme thermal conditions experienced during their flight into a planetary atmosphere. Carbon-phenolic ablators are composed of a phenolic matrix and a fibrous carbon reinforcement. In the present study, the fibrous reinforcement has been modified through the deposition of thin protective layers of zirconium oxide and aluminum oxide, with the objective of reducing fiber recession and oxidation. The depositions were carried out via atomic layer deposition (ALD), a method that allows for the controlled deposition of uniform and conformal coatings on the carbon felt fibers. The depositions were subsequently evaluated through SEM-EDS analysis. Pristine and ALD-modified felts were impregnated with a phenolic resin matrix and the ablation performance of the composite materials was evaluated through oxyacetylene flame tests. The results demonstrated that, in comparison to uncoated ablators, the ALD-modified samples exhibited enhanced performance in terms of mass loss and surface recession: compared to uncoated ablators, the former was 14% lower and the latter was diminished by 50%. Moreover, the morphological characterization of the tested specimens revealed a significantly reduced degree of oxidation of the coated fibers which were directly exposed to the flame. Full article

To study the ablation properties and differences of plain-woven SiC/SiC composites under single and cyclic ablation. The ablation test of plain-woven SiC/SiC composites was conducted under an oxyacetylene torch. The results indicate that the mass ablation rate of cyclic ablation is lower than that of single ablation, whereas the line ablation rate is higher. Macro-microstructural characterization revealed the presence of white oxide formed by silica on the surface of the ablation center region. The fibers in the central region of the ablation were ablated layer by layer, and the broken fiber bundles exhibited a spiky morphology with numerous silica particles attached. The oxide layer on the surface and the silica particles on the fibers, which are in the molten state formed in the high-temperature ablation environment, contribute to resisting ablation. Thermal shock during cyclic ablation also played a role in the ablation process. The thermal shock causes cracks in the fiber bundles and matrix of the SiC/SiC composites. This study helps to apply SiC/SiC composite to complex thermal shock environments. Full article

To reveal the ablation performance of C/SiC-ZrC composites under different ablation modes, C/SiC-ZrC composites were prepared using chemical vapor deposition, precursor infiltration, and pyrolysis. Single ablation and cyclic ablation tests were conducted on the C/SiC-ZrC composites using an oxyacetylene flame, in order to obtain ablation parameters, as well as macroscopic and microscopic ablation morphology for the different ablation modes. The results show that the linear ablation rate and mass ablation rate of different ablation modes decrease with increasing time. The linear ablation rate and mass ablation rate of cyclic ablation are 12% and 24.2% lower than those of single ablation. Within the same ablation time, the C/SiC-ZrC composites subjected to cyclic ablation exhibit shallower and more evenly distributed pits, caused by high-temperature airflow ablation. The material surface has a white oxide layer composed of SiO2 and ZrO2, and the carbon fibers inside are wrapped by oxide particles, enhancing the ablation resistance of C/SiC-ZrC composites. Full article

To investigate the effect of ZrC on the ablative properties of C/SiC composites in a high-temperature environment, the oxidative ablation of C/SiC and C/SiC-ZrC composites at high-temperatures was examined through ablation tests. In this study, two ceramic matrix composites, C/SiC and C/SiC-ZrC, were prepared by chemical vapor deposition and precursor impregnation pyrolysis. The ablation properties of the materials were tested and analyzed using an oxyacetylene flame to simulate a high-temperature environment. The results revealed that the line ablation rate of C/SiC-ZrC was 8.48% and 20.81% lower than that of C/SiC at 30 s and 60 s, respectively. At the same ablation time, the depth of the crater resulting from erosion of the C/SiC material by the high-temperature airflow was deeper than that of C/SiC-ZrC. The traces of the fibers subjected to erosion were more prominent. In a longitudinal comparison, the mass ablation rate of C/SiC-ZrC material decreased with the increase in time, while the line ablation rate initially increased rapidly and then decreased. From 30 s to 90 s of ablation, the line ablation rate and mass ablation rate decreased by 55.62% and 89.5%, respectively. The overall trend for both rates was a decrease with the increase in time. Under the same ablation time, the ablation rate of C/SiC-ZrC was generally lower than that of C/SiC. This is because the generated molten ZrO₂ was more viscous and denser than SiO₂, effectively blocking oxidizing gases from penetrating the interior of the material. The molten ZrO₂ provided better protection for the substrate in the high-temperature environment. Full article

Materials used in aircraft engines, gas turbines, nuclear reactors, re-entry vehicles, and hypersonic structures are subject to severe environmental conditions that present significant challenges. With their remarkable properties, such as high melting temperatures, strong resistance to oxidation, corrosion, and ablation, minimal creep, and advantageous thermal cycling behavior, ceramic matrix composites (CMCs) show great promise as a material to meet the strict requirements in these kinds of environments. Furthermore, the addition of boron nitride nanoparticles with continuous fibers to the CMCs can offer thermal resistivity in harsh conditions, which will improve the composites’ strength and fracture toughness. Therefore, in extreme situations, it is crucial to understand the thermal resistivity period of composite materials. To forecast the ablation performance of composites, we developed six machine learning regression methods in this study: decision tree, random forest, support vector machine, gradient boosting, extreme gradient boosting, and adaptive boosting. When evaluating model performance using metrics including R2 score, root mean square error, mean absolute error, and mean absolute percentage error, the gradient boosting and extreme gradient boosting machine learning regression models performed better than the others. The effectiveness of machine learning models as a useful tool for forecasting the ablation behavior of ceramic matrix composites was effectively explained by this study. Full article