Abstract: A method of producing a three dimensional angle interlock ceramic fiber which is stable to high aeroacoustic noise of about 170 decibels and to high temperatures of about 2500 degrees F. is disclosed. The method uses multiple separate strands of a ceramic fiber or ceramic tow suitable for weaving having multiple warp fibers and multiple fill fibers woven with a modified fly-shuttle loom or rapier shuttleless loom which has nip rolls, a modified fabric advancement mechanism and at least eight harnesses in connection with a Dobby pattern chain utilizing sufficient heddles for each warp fiber and a reed which accommodates at least 168 ends per inch. The method produces a multilayered top fabric, rib fabric and single-layered bottom fabric.

Abstract: Sewn, quilted ceramic blankets (AFRSI) and integrally woven core insulation systems (TABI) were examined in a 170 decibel aeroacoustic environment under oscillating air loads. Preconditioning in a radiant heat source was done at both 2000.degree. F. and 2500.degree. F. before testing. A multi-layer ceramic weave construction based on an angle interlock weave architecture is superior over all other TPS systems examined. These configurations do not require a surface coating to enhance survivability. Single-ply TABI fabric surfaces using an insulated integrally woven core structure survive up to 2000.degree. F. without the use of a ceramic coating to toughen the surface to the aeroacoustic noise level. AFRSI blankets of the art require a ceramic coating in order to demonstrate comparable performance after exposure to a 2000.degree. F. radiant heat temperature.