Revolutionizing Hypersonic Flight: Breakthroughs in 3D Printing of High-Temperature Ceramics
In the realm of aerospace engineering, the pursuit of high-temperature ceramics has been a long-standing challenge. The development of such materials is crucial for the creation of hypersonic aircraft, which can withstand the extreme conditions of flight at speeds in excess of Mach 5. Researchers from the Purdue of Applied Research Institute (PRI) have made a groundbreaking breakthrough in this arena, using 3D printing to create high-temperature ceramics in complex shapes for hypersonic aircraft components. This innovative approach not only enables the mass production of these components but also improves efficiency and performance.
Overcoming the Challenges of 3D Printing with Black Ceramics
The development of black ceramics presents a unique challenge. Unlike traditional ceramics, which reflect and disperse light, black ceramics absorb UV light, hindering the layer-by-layer hardening process. This is particularly problematic, as thicker layers cannot be formed due to the absorption of UV light. “We cannot form thicker layers because the dark powder absorbs the UV light necessary to cure the material,” explains Professor Rodney Trice, head of ceramic machining at the Hypersonic Advanced Manufacturing Technology Center (HAMTC). “Thus, the depth of hardening we obtain is too thin, which negatively affects the time needed to build each part.”
To address this issue, Trice, along with his team, including doctoral student Matthew Thompson and ceramic research engineer Dylan Crump, explored novel systems, surface treatments, and methods to increase the depth of hardening. “We mainly worked as a test bench for these materials,” Thompson notes. “We set up surface performance and changes to improve their performance and improve the printing process.”
Eliminating Post-Processing Challenges
As the printed part increases in size, the post-processing phase becomes more complex, with risks of stratification or cracking becoming more pronounced. Trice, Thompson, and Crump are working to eliminate these issues, ensuring that the printed parts meet the required standards. “We are trying to find solutions and see how we can build a process that produces these parts, or find strategies that real stakeholders can use,” says Thompson. “This offers people a starting point to save time to develop a new system.”
Government Funding and Partnerships
This groundbreaking research is one of five projects funded by the Department of Defense’s Science and Technology Program, in collaboration with the Navy Surface Operations Center, the Crane Division, and the National Accelerator for the Strategic and Tactical Mission.
Breaking Barriers in 3D Printing
The development of high-temperature ceramics using 3D printing paves the way for the creation of complex shapes and geometries with precision at the micrometric level. The potential applications are vast, from military aircraft to commercial spacecraft. This innovative approach has the potential to revolutionize the field of aerospace engineering, enabling the rapid production of high-temperature ceramics with improved efficiency and performance.
Conclusion
The breakthrough in 3D printing of high-temperature ceramics is a significant step forward for the development of hypersonic aircraft. The challenges posed by black ceramics have been overcome, and the potential for mass production of these components has been realized. As researchers continue to push the boundaries of this technology, we can expect to see significant advancements in the field of aerospace engineering, leading to the creation of faster, more efficient, and more effective hypersonic aircraft.
