Abstract: A porous body of fibrous, low density silica-based insulation material is at least in part impregnated with a reactive boron oxide containing borosilicate glass frit, a silicon tetraboride fluxing agent and a molybdenum silicide emittance agent. The glass frit, fluxing agent and emittance agent are separately milled to reduce their particle size, then mixed together to produce a slurry in ethanol. The slurry is then applied to the insulation material and sintered to produce the porous body.

Abstract: The present invention discloses a ceramic reusable externally applied thermal protection system (TPS). The system functions by using the composite device created by combining an upper shell, thermal insulation and lower tile components shown in FIG. 2. The upper shell effectively separates its primary functions as a toughened outer-surface and load carrier. In a preferred embodiment, a structurally strong ceramic/ceramic upper shell is manufactured from ceramic cloth upon which additional ceramic material has been deposited and maintains the configuration of the upper shell. The lower tile is composed of lightweight ceramic normally acceptable in this application. One or more lightweight rigid or flexible insulation materials are used in the cavity created by combining the upper shell and lower tile. The assembly of the overall tile is facilitated by attachment means effective to withstand the temperature and stress conditions.

Abstract: A spray coating apparatus is provided for rotating a workpiece relative to a spray station to obtain a uniform coating of the workpiece. In a typical example, the workpiece comprises a ceramic tile which is to be coated with a ceramic coating and the tile is to be used as a reusable component of the thermal protection system for a space shuttle. The apparatus for rotating the workpiece includes a base support having a first rotatable stage for rotation in the horizontal plane and a second rotatable stage for rotation in a second plane inclined at an angle, such as 45 degrees, to the horizontal plane and the workpiece is supported on this second stage. Thus the workpiece is rotatable in both of two planes of rotation. The workpiece support is detachable from the first rotatable stage and the workpiece is readily detachable from the workpiece support to facilitate off loading of the spray coated workpiece.

Abstract: A flexible, adjustable refractory filler (1) is disclosed for filling gaps between ceramic tiles (10, 11) forming the heat shield of a space shuttle vehicle, to protect its aluminum skin (20) during atmospheric re-entry. The easily installed and replaced filler (1) consists essentially of a strip of ceramic cloth (3) coated, at least along both its longitudinal edges (4, 5), with a room temperature vulcanizable silicone rubber compound with a high emittance colored pigment. The filler may have one or more layers (2, 3), as the gap width requires. Preferred materials are basket-weave aluminoborosilicate cloth, and a rubber compounded with silicon tetraboride as the emittance agent and finely divided borosilicate glass containing about 7.5% B.sub.2 O.sub.3 as high temperature binder. The filler cloth strip or tape is cut to proper width and length, inserted into the gap, and fastened with previously applied drops of silicone rubber adhesive.

Abstract: A refractory composite insulating material prepared from silica fibers and aluminosilicate fibers in a weight ratio ranging from 1:19 to 19:1, and about 0.5 to 30% boron oxide, based on the total fiber weight. The aluminosilicate fiber and boron oxide requirements may be satisfied by using aluminoborosilicate fibers and, in such instances, additional free boron oxide may be incorporated in the mix up to the 30% limit. Small quanitites of refractory opacifiers, such as silicon carbide, may be also added. The composites just described are characterized by the absence of a nonfibrous matrix.

Abstract: A reusable silica surface insulation (RSI) material is provided by bonding amorphous silica fibers with colloidal silica at an elevated temperature. The surface insulation is ordinarily manufactured in the form of blocks (i.e., tiles).