Hypersonic Seeker Window Attachment for Hypersonic Flight Systems

OUSD (R&E) MODERNIZATION PRIORITY: Hypersonics TECHNOLOGY AREA(S): Sensors; Materials OBJECTIVE: Demonstrate innovative infrared (IR) and radio frequency (RF) window materials and integrated antenna technology for hypersonic flight systems. DESCRIPTION: The Government is seeking innovative solutions to enable hypersonic missile systems with seeker capabilities. Advanced windows are generally only available in small quantities and manufactured by traditional processes in laboratories. The Government would like to establish an additive manufacturing method to produce window materials that are reliable, consistent, and optimized to perform in hypersonic environments. Materials will need to demonstrate that RF and/or IR signals can be transmitted through the materials while in high temperature ranges expected for hypersonic applications (>500-1,000 C). In addition, load testing at elevated temperatures is required to analyze thermal gradient effects on the material. Window materials will need to interface and attach to hot structural hypersonic aeroshell materials including but not limited to carbon composites. The Government is interested in utilizing state of the art additive manufacturing technology to design and manufacture window materials. Additive manufacturing is highly desired to allow near net shape manufacturing of components to reduce manufacturing time and to lower costs. Additive manufacturing also allows for material customization and optimization for specific applications to enhance performance. The goals of this development effort center on (1) leveraging new materials and technology to produce RF and/or IR seeker windows that survive the hypersonic environment while interfacing with aeroshell materials and (2) implementing an additive manufacturing approach that provides cost and schedule advantages over existing technologies. Material production should be automated to provide consistent and quality components that can survive in extreme hypersonic thermal and structural environments while maintaining optical efficiency. PHASE I: Demonstrate the technical feasibility of the proposed material approach. Provide technical demonstration that material solution(s) are viable in hypersonic environments via material properties and analysis. Develop test plans to demonstrate manufacturing design parameters and thermo-structural and optical ground testing of window and attachment components. Develop manufacturing and quality approach for full-scale components. PHASE II: Actively demonstrate the innovative material approach by manufacturing subscale coupons of window and attachment materials for laboratory and ground testing. Evaluate material performance in hypersonic relevant environments via analysis and testing. Conduct manufacturing assessments to determine statistical parameters of quality and repeatability. Provide the Government with preliminary cost and schedule projections of material components compared to the current state-of-the-art. PHASE III DUAL USE APPLICATIONS: Demonstrate use of full-scale components in hypersonic environments. Develop full-scale manufacturing capabilities providing data on quality and reliability of components. Provide full-scale cost assessments for production. REFERENCES: Chan, C. B. and Singh, N. Calculation of refractive index around a hypersonic vehicle with infrared sensors. Proceedings IEEE Southeastcon'92, April 1992, pp. 562-565. https://doi.org/10.1109/SECON.1992.202416. Krell, A.; Baur, G. M. and Dahne, C. Transparent sintered sub- m Al2O3 with IR transmissivity equal to sapphire. International Society for Optics and Photonics, Window and Dome technologies VIII, Vol. 5078, September 2003, pp. 199-207. https://doi.org/10.1117/12.485770. KEYWORDS: Seeker Window; Sensors; Hypersonic; High Temperature; Additive Manufacturing; Advanced Materials