Invention Reference Number
A liquid-based process has been developed to create ultra-high-temperature ceramic (UHTC) materials that serve as protective coatings or matrices for extreme environments. This innovation addresses the growing need for improved thermal protection systems (TPS) with greater temperature capability, oxidation resistance, reusability, and reduced manufacturing costs. The resulting UHTC exhibits exceptional stability at high temperatures, making it suitable for next-generation aerospace applications and reusable spacecraft systems.
Description
This technology introduces a liquid-phase route for producing advanced ultra-high-temperature ceramics (UHTCs) used as coatings or structural matrices in aerospace systems. The process employs a resin combined with a liquid refractory source to form a solid material after heat treatment. Upon thermal conversion, the material transitions to a stable UHTC structure capable of withstanding extreme thermal and mechanical stress.
The liquid formulation enables efficient application methods such as dip-coating or infiltration, providing faster and lower-cost production compared to traditional, labor-intensive techniques. The resulting UHTC demonstrates stability at temperatures surpassing conventional silicon carbide-based coatings, improving reusability and performance in harsh re-entry or propulsion environments. By simplifying the supply chain and enhancing material resilience, this approach offers a scalable, high-value solution for aerospace and related industries.
Benefits
- Lower-cost coating and matrix fabrication process
- Higher temperature capability and improved thermal stability
- Reusable and durable under extreme conditions
- Simplified, scalable manufacturing methods
Applications and Industries
- Thermal protection systems for spacecraft and re-entry vehicles
- Aerospace coatings and high-temperature structural components
- Advanced materials for commercial and defense aerospace manufacturers
Contact
To learn more about this technology, email partnerships@ornl.gov or call 865-574-1051.
