Abstract: A method for joining a woven flexible ceramic fabric and a thin metal sheet creating an integral metal surfaced flexible thermal protection article, which method comprises:placing multiple dots of high temperature metallic or ceramic brazing material between the flexible ceramic fabric and the thin metal sheet in a random or organized pattern, with the proviso that the brazing material covers about 10% or less of the surface of one flat side of the metal sheet;heating the flexible ceramic fabric, brazing material and thin metal sheet for a predetermined period of time to integrally connect the same; andcooling the formed flexible article to ambient temperature. Preferably the flexible ceramic is selected from fibers comprising atoms of silicon, carbon, nitrogen, boron, oxygen or combinations thereof. The flexible thermal protection article produced is also part of the present invention. The thin metal sheet is comprised of titanium, aluminum, chromium, niobium or alloys or combinations thereof.

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.

Abstract: Composite flexible multilayer insulation systems (MLI) were evaluated for thermal performance and compared with currently used fibrous silica (baseline) insulation system. The systems described are multilayer insulations consisting of alternating layers of metal foil and scrim ceramic cloth or vacuum metallized polymeric films quilted together using ceramic thread. A silicon carbide thread for use in the quilting and the method of making it are also described. These systems are useful to provide lightweight thermal insulation for a variety of uses, particularly on the surface of aerospace vehicles subject to very high temperatures during flight.

Abstract: Composite flexible multilayer insulation systems (MLI) were evaluated for thermal performance and compared with currently used fibrous silica (baseline) insulation system. The systems described are multilayer insulations consisting of alternating layers of metal foil and scrim ceramic cloth or vacuum metallized polymeric films quilted together using ceramic thread. A silicon carbide thread for use in the quilting and the method of making it are also described. These systems are useful to provide lightweight thermal insulation for a variety of uses, particularly on the surface of aerospace vehicles subject to very high temperatures during flight.

Abstract: Structural wood paneling or other molded wood compositions consisting of finely divided wood chips, flour, or strands are bound together and hot pressed with a modified novolac resin which is the cured product of a prepolymer made from an aralkyl ether or halide with a phenol and a hardening agent such as hexamethylene tetramine. The fire resistance of these articles is further improved by incorporating in the binder certain inorganic fillers, especially a mixture of ammonium oxalate and ammonium phosphate.

Abstract: Flame and temperature resistant polyimide foams are prepared by the reaction of an aromatic dianhydride, e.g., pyromellitic dianhydride, with an aromatic polyisocyanate, e.g., polymethylene polyphenylisocyanate (PAPI) in the presence of an inorganic acid and a lower molecular weight alcohol, e.g., dilute sulfuric acid or phosphoric acid and furfuryl alcohol.The exothermic reaction between the acid and the alcohol provides the heat necessary for the other reactants to polymerize without the application of any external heat. Such mixtures, therefore, are ideally suited for in situ foam formation, especially where the application of heat is not practical or possible.

Abstract: Polyimide foam products having greatly improved burn-through and flame-spread resistance are prepared by the reaction of aromatic polyisocyanates with aromatic dianhydrides in the presence of metallic salts of octoic acid. The salts, for example stannous octoate, ferric octoate and aluminum octoate, favor the formation of imide linkages at the expense of other possible reactions.

Abstract: New, flexible intumescent protection sheeting of unusually uniform thickness have been prepared from epoxy-polysulfide compositions containing microfibers and the ammonium salt of 1,4-nitroaniline-2-sulfonic acid, as disclosed in U.S. Pat. No. 3,663,464, except that an ammonium salt particle size in the order of 5 to 8 microns and a fiber size of about 1/128th inch in length and 3 to 5 microns in diameter have been found critical to obtain the required density of 1.46 to 1.50 g/cc. The insulation sheeting is prepared by a continuous process involving vacuum mixing, calendering, and curing under very strict conditions which depend to some extent upon the thickness of the sheet produced.The resulting flexible sheet can be wrapped easily and tightly around small diameter missiles, thus affording them for the first time, protection from fire for at least 5 minutes.

Abstract: An intumescent-ablator coating composition which comprises an intumescent agent such as the ammonium salt of 1,4-nitroaniline-2-sulfonic acid or 4,4-dinitrosulfanilide, a polymeric binder system and about 5 to 30% by weight, based on the total weight of the intumescent agent and the binder, of an endothermic filler having a decomposition temperature about or within the exothermic region of the intumescent agent.

Abstract: An intumescent composition, which comprises a mixture of 4,4'-dinitrosulfanilide as the intumescent agent in a polymer binder mixture of a chlorinated polyolefin, a bisphenol A epoxy resin and a rubber-like amine hardener.