Evaluation of Thermal Management Materials for High Velocity Aircraft Protection

Image

Team Member(s) 
Isabella Elmore, Head Engineer
Eliot Hunter, Project Manager
Jack Klem, Operations Support Specialist
Michael Pasierb, Head of Research

Mentor(s) 
Dr. Saniya LeBlanc, MAE, GW Engineering

Project Sponsors
Dr. Cole Davis, Naval Surface Warfare Center, Crane Division

Instructor(s) 
Dr. Steven Shooter, MAE, GW Engineering

The project addresses the critical challenge of developing thermal protection systems capable of withstanding extreme temperatures, reaching up to 5000°F (2760°C), while directing heat in controlled ways. This problem is most relevant for high-speed flight applications, where materials must endure intense aerodynamic heating without structural failure. Current thermal protection solutions face limitations in durability, weight, and heat dissipation efficiency. By exploring different material configurations and their thermal properties, the project aims to create optimized protection systems that enhance the performance and longevity of high-speed aerospace vehicles.

Who experiences this problem in the world?

The problem is primarily experienced by industries and organizations involved in high-speed aerospace applications, including the military, space exploration agencies, and advanced aviation sectors. Specifically, the U.S. Navy, Air Force, NASA, and private aerospace companies face challenges in designing vehicles that can survive extreme thermal conditions during hypersonic flight, atmospheric re-entry, and other high-temperature environments. Engineers, researchers, and mission planners must address the limitations of current thermal protection systems to ensure the safety, reliability, and efficiency of high-speed aircraft, missiles, and spacecraft. Additionally, advancements in this field have broader implications for industries requiring high-temperature-resistant materials, such as energy production and advanced manufacturing.

Why is this problem important?

The problem is critical because extreme heat exposure in high-speed aerospace applications can cause material failure, leading to catastrophic mission loss, compromised national security, and potential loss of life. Current thermal protection systems struggle with limitations in weight, durability, and heat dissipation, restricting the development of faster, more maneuverable hypersonic vehicles. For the Navy and defense sectors, reliable thermal management is essential for hypersonic weapons and reconnaissance systems to maintain operational superiority. In space exploration, ineffective heat shielding can result in vehicle destruction during re-entry. Advancing thermal protection technology directly impacts the success of military operations, space missions, and future high-speed transport.

What is the coolest thing about your project?

The coolest thing about our project is seeing how theoretical concepts from coursework translate into real-world problem-solving for high-stakes applications. Initially, topics like heat transfer equations and material property analysis felt abstract and disconnected from practical use. However, this project has shown that the skills we developed—such as analyzing simple thermal models—are directly applicable to designing advanced thermal protection systems for critical Navy applications. It’s exciting to contribute to cutting-edge aerospace research, where our work has real potential to impact the development of high-speed defense and space technologies.

What were some technical challenges?

One of the biggest technical challenges is accurately modeling heat transfer at extreme temperatures and predicting material behavior under high thermal and mechanical stress. Many conventional heat transfer models break down at temperatures approaching 5000°F (2760°C), requiring advanced simulations and experimental validation. Another challenge is balancing thermal protection with weight constraints—materials must effectively dissipate or insulate against heat without adding excessive mass that could hinder vehicle performance. Additionally, identifying and optimizing composite material configurations that can withstand repeated thermal cycling without degradation is complex, requiring a deep understanding of material science, aerodynamics, and high-temperature physics. However, the most significant challenges will arise later when stakeholders attempt to apply this research in real-world applications. Finding materials that meet the exact thermal and mechanical properties required—while also considering trade-offs in cost, manufacturability, and operational constraints—will be a major hurdle in transitioning this research into practical use.