Abstract: A metallized product includes a composite substrate or other substrate wherein at least a portion of the surface of the substrate is coated with an adhesion-promoting layer comprising resin and microballoons. A metallic coating is adhered to the adhesion promoting layer to produce the metallized surface. Methods for producing metallized products are also provided.

Abstract: A metallized product includes a composite substrate or other substrate wherein at least a portion of the surface of the substrate is coated with an adhesion-promoting layer comprising resin and microballoons. A metallic coating is adhered to the adhesion promoting layer to produce the metallized surface. Methods for producing metallized products are also provided.

Abstract: An apparatus and method for consolidating a composite workpiece are provided. The apparatus includes an electromagnetic field generator for inducing a current and thereby heating a susceptor in thermal communication with the workpiece. The workpiece is supported by one or more support tools, each of which transmits the electromagnetic field so that the support tools are not substantially heated by the electromagnetic field. Thus, the time and energy required for heating the workpiece are reduced relative to conventional consolidation techniques.

Abstract: An apparatus and method for consolidating a composite workpiece are provided. The apparatus includes an electromagnetic field generator for inducing a current and thereby heating a susceptor in thermal communication with the workpiece. The workpiece is supported by one or more support tools, each of which transmits the electromagnetic field so that the support tools are not substantially heated by the electromagnetic field. Thus, the time and energy required for heating the workpiece are reduced relative to conventional consolidation techniques.

Abstract: A process of waterproofing alumina-rich or silica-rich fibrous thermal insulation material, the process including the steps of:(a) providing an alumina-rich or a silica-rich fibrous material;(b) providing a waterproofing solution including:(1) a carrier solvent selected from the group consisting of aliphatic alcohols having from 1C to 6C, water, and mixtures thereof; and(2) an alkoxysilane defined by the formula R.sub.4-x -Si-(O-R').sub.x where x is 1-3 and R is selected from the group consisting of alkyl groups having from 1C to 10C, hydrogen, or fluorocarbon groups having from 1F to 15F; and where O-R' is an alkoxy group having from 1C to 5C, or a mixture of alkoxysilanes defined by the above formula R.sub.4-x -Si-(O-R').sub.x ; and optionally(3) modifiers including acids, such as acetic acid or nitric acid, or bases, such as ammonium hydroxide, RNH.sub.2, R.sub.2 NH, or R.sub.

Abstract: A coated ceramic has alumina as an amorphous residue from an alumina sol containing alumina powder or and, optionally, a high emittance powder. The alumina powder alters the rheology and wetting characteristics of the sol to aid in forming the residue and increases the alumina concentration (% solids) in the residue. The high emittance powder radiates heat out of the residue and away from the ceramic when the coated ceramic is heated, such as during orbital reentry.

Abstract: Ceria is used to assure release between a metal workpiece and associated forming tooling in forming operations conducted at temperatures of 1500.degree. F. (816.degree. C.) and above.

Abstract: The invention provides a thermal insulation blanket suitable for removable mounting on a structure such as the exterior of a reusable launch vehicle. In one embodiment, the invention include a batting layer with a rigid screen embedded within it. A cover layer is secured over the batting, and a plurality of fasteners are held by the screen in a position where they extend out from the blanket to be mounted on the exterior of the space craft. The blanket can include two layers of batting with the screen disposed therebetween. The structure would have corresponding mating fasteners on its exterior to which those extending out from the blanket cover would be joined for a secure mount. The blanket can be formed of a first and a second batting layer with the screen positioned therebetween. In a preferred embodiment, a cover would be positioned over the batting layers, and the blanket would be quilted to hold the layers and cover in close proximity.

Abstract: A passive thermal protection system that overcomes the disadvantages of the polyurethane "water wall" includes a fiberformed ceramic insulation, a plurality of electrodes embedded in the insulation to define a wick panel, and a gelled ceramic sol in the wick panel. The system can be prepared by introducing the sol into the wick panel with its subsequent gelling by applying a direct current across the electrodes. Cooling water is held in the gelled sol to provide passive cooling, yet the system easily achieves even distribution of the water (even when subject to accelerations) without the use of pre-gelled or viscous reagents.

Abstract: Expendable mandrels and methods of using such mandrels for forming voids within materials or surfaces on materials deposited onto the mandrels are described. The mandrels have a coefficient of thermal expansion that substantially matches that of the material to be deposited on the mandrel. Matching coefficients of thermal expansion reduces the likelihood of cracking of the base material when the mandrel and base material are cooled.

Abstract: A seal for preventing extremely hot gases from passing between a movable engine ramp and an engine splitter wall in a hypersonic aircraft. The seal moves with the engine ramp, in a direction parallel to the surface of the splitter wall. The seal includes a first flange which makes sliding contact with the outer engine ramp surface and is attached to a flexible sealing portion that fills the gap between the ramp and wall. The sealing portion maintains sliding contact with the wall as the gap changes dimension due to variations in the ramp's temperature. The attachment region can be a concave surface to radiate the seal's heat. In a second embodiment, the seal includes a second flange through which the seal is attached to the cooler side of the engine ramp.