Sandia Researchers Develop Faster Method to Evaluate Heat-Shield Materials

Engineers at Sandia National Laboratories have developed a method to more rapidly evaluate heat-shield materials used on hypersonic vehicles. The work was carried out as part of a three-year research project that combined computer modeling, laboratory testing, and flight experiments.

Heat shields, formally known as thermal protection systems, are used to protect vehicles from extreme heat and pressure during atmospheric reentry or hypersonic flight. Hypersonic vehicles travel at speeds of at least five times the speed of sound, or more than 3,800 miles per hour. At these speeds, vehicles are exposed to intense thermal loads that require specialized materials to prevent structural failure.

The Sandia project focused on understanding how heat-shield materials behave under these extreme conditions and on improving the speed at which their performance can be predicted. According to the researchers, traditional qualification approaches rely heavily on long-lead testing and access to specialized facilities, which can slow development timelines.

To address this, the team combined lower-cost laboratory experiments with refined computer models. Materials were tested using inductively coupled plasma torches to replicate hypersonic heating conditions on the ground. Data from these tests was then used to improve the accuracy of predictive models, reducing the need for repeated large-scale testing.

The research evaluated a wide range of materials, including graphite, carbon-based materials, and ceramic-based composites. Hundreds of material samples were produced and tested by Sandia’s materials science team, with additional contributions from Oak Ridge National Laboratory.

Unlike reusable spacecraft, thermal protection systems used on U.S. hypersonic missiles are designed for single use. These systems are intended to withstand extreme environments for the duration of a mission rather than repeated flights, placing different demands on material performance and testing approaches.

As part of the next phase of the project, the team plans to test a new heat-shield tile containing multiple material samples and embedded temperature sensors. The tile is scheduled to be mounted on the nose of a reentry capsule planned for launch in summer 2026. The materials used in the tile will include carbon-based and ceramic-based materials, according to the researchers.

Sandia stated that the project relied on close collaboration between material scientists, experimental engineers, flight-test specialists, and modeling experts. The goal of the work is to improve the speed and efficiency of predicting heat-shield performance in hypersonic environments.

Article & image source: Sandia National Laboratories