Support structures and thermal protection

High-performance ceramics offer a unique combination of thermal stability (> 2000°C), low density and high specific stiffness. Due to their low density compared to superalloys, high-performance ceramics enable significant weight savings with increased thermal performance. Fiber-reinforced ceramic composites (CMC) also have a high damage tolerance and thermal shock resistance. These properties make them ideal materials for thermally and mechanically highly stressed support structures and protective components:

• Ceramic heat shields (Thermal Protection Systems, TPS) and surface coatings (EBC) that protect spacecraft during re-entry into the atmosphere and sensitive components from direct sunlight
• Hot gas-carrying components such as nozzle inserts or combustion chamber linings that withstand cyclic thermal loads and corrosive media (e.g. during the transition from -150°C in orbit to >1000°C during engine ignition or during frequent start-stop operation)
• Support structures such as telescope structures, mirror and antenna supports, cantilevers or solar panel frames, which have superior rigidity combined with high temperature and dimensional stability. This is particularly important for the precise alignment and mounting of antennas, measuring instruments or optical systems.

Fraunhofer IKTS qualifies high-performance ceramics and fiber-reinforced ceramic composites for specific application scenarios in the aerospace industry. We open up new fields of application through the targeted combination of structural and functional material properties and the necessary multi-material processing. We are also developing new test methods and simulations to validate material performance under extreme conditions.

Highlights
 

• Carbide and ultra-high temperature ceramics (e.g. SiC, B_{(4) C}, ZrC, TiC, TaC): for demanding heat protection and lightweight constructions, also with electrical or sensory functions
• Transparent ceramics: for optical and protective applications
• CMC (ceramic matrix composites): processes such as winding with subsequent precursor infiltration (PIP) or liquid silicon infiltration (LSI) ensure dense, resilient components
• Fiber coating: continuous coating of fibers with BN, PyC or BN/SiC using CVD (Chemical Vapor Deposition)
• High-temperature joining by soldering or diffusion bonding: thermally stable joints that are individually adapted to the materials and application parameters
• Electrical functions: for precise heating, good electrical and thermal conductivity and stable contacts – from low to high temperatures
• Extended design freedom: complex structures with integrated functions can be produced using multi-material processing – ideal for smart, customized components
• Testing: analysis of microstructure, strength and resistance to high temperatures, oxidation and corrosion

Downloads
 

• SiC/SiC composite material for the highest demands
• Material characterization high-temperature strength
• High-temperature stable solders for SiC-SiC composites
• High-temperature probe heads made from silicon nitride ceramics