Abstract: A heat shield is disclosed. The heat shield may have a honeycomb core having a plurality of intersecting wall portions forming a plurality of cells. A strain compliant material may be applied to the wall portions of the honeycomb core prior to filling of the cells with an ablative material. An ablative material may be used that at least substantially fills the cells of the honeycomb core.

Abstract: A heat shield is disclosed. The heat shield may have a honeycomb core having a plurality of intersecting wall portions forming a plurality of cells. A strain compliant material may be applied to the wall portions of the honeycomb core prior to filling of the cells with an ablative material. An ablative material may be used that at least substantially fills the cells of the honeycomb core.

Abstract: A heat shield having a honeycomb core. The honeycomb core has a plurality of intersecting wall portions forming a plurality of cells. A strain compliant material is applied to the wall portions of the honeycomb core prior to filling of the cells with an ablative material. An ablative material at least substantially fills the cells of the honeycomb core.

Abstract: A heat shield having a honeycomb core. The honeycomb core has a plurality of intersecting wall portions forming a plurality of cells. A strain compliant material is applied to the wall portions of the honeycomb core prior to filling of the cells with an ablative material. An ablative material at least substantially fills the cells of the honeycomb core.

Abstract: A thermal protection paste as described herein can be used by itself, or impregnated into a high temperature resistant fabric to form a repair patch, to repair a thermal protection structure. The paste includes a ceramic composition that includes ceramic material having at least a first controlled particle size and a second controlled particle size that is larger than the first controlled particle size. The ceramic composition is mixed into a high temperature ceramic precursor resin to form the paste. The paste (or patch) is applied to the structure under repair and initially heated to cure the paste and to secure it in place. When the paste and/or patch is cured, it becomes a cross-linked polymer having high thermal protection characteristics. When the paste is exposed to very high temperature, e.g., spacecraft reentry temperatures, it pyrolizes and retains its high thermal protection characteristics.

Abstract: A process for joining solid compositions, comprising placing a first solid composition having a first joining zone and a second solid composition having a second joining zone in a chamber; positioning a first gas phase, which comprises a substance that decomposes to a material that adheres to the first and second solid compositions during the process, proximate the target area; directing an energy beam to the first and second joining zones to selectively deposit material from the first gas phase on the first joining zone and the second joining zone until a joint is formed between the first and second solid compositions wherein the joint adheres to the first and second compositions at the first and second joining zones.

Abstract: Methods and apparatus for selectively depositing a layer of material from a gas phase to produce a part comprising a plurality of deposited layers. The apparatus includes a computer controlling a directed energy beam, such as a laser, to direct the laser energy into an unheated chamber substantially containing the gas phase to preferably produce photodecomposition or thermal decomposition of the gas phase and selectively deposit material within the boundaries of the desired cross-sectional regions of the part. At least one component of the gas phase is a vapor which condenses at a temperature above the ambient temperature of the chamber. Each such component can exist at a partial pressure no higher than its equilibrium vapor pressure at the chamber ambient temperature. For each cross section, the aim of the laser beam is scanned over a target area and the beam is switched on to deposit material within the boundaries of the cross-section.