Abstract: In a first example, a radome includes a shell including a ceramic matrix composite, the shell forming a first hole at a forward end of the shell and a second hole at an aft end of the shell. The radome also includes a fluid impervious coating on the shell. In a second example, a vehicle includes a main body, the radome, and an attachment assembly that couples the radome to the main body. In a third example, a method includes forming a shell comprising a ceramic matrix composite using a wet layup process, applying a fluid impervious coating onto the shell, and curing the shell and the fluid impervious coating.

Abstract: In a first example, a radome includes a shell including a ceramic matrix composite, the shell forming a first hole at a forward end of the shell and a second hole at an aft end of the shell. The radome also includes a fluid impervious coating on the shell. In a second example, a vehicle includes a main body, the radome, and an attachment assembly that couples the radome to the main body. In a third example, a method includes forming a shell comprising a ceramic matrix composite using a wet layup process, applying a fluid impervious coating onto the shell, and curing the shell and the fluid impervious coating.

Abstract: An extruder includes a receptacle for containing material to be extruded. The extruder further includes a dispersion blade positioned within the receptacle and a nozzle secured to the receptacle. The nozzle defines a first opening positioned within an interior of the receptacle, defines a second opening positioned outside of the receptacle and defines a channel which extends from the first opening through the nozzle to the second opening defining a flow path which extends from the first opening, through the channel and to the second opening. The nozzle extends through a wall of the receptacle and into the interior of the receptacle such that the first opening is positioned spaced apart from the wall.

Abstract: An extruder includes a receptacle for containing material to be extruded. The extruder further includes a dispersion blade positioned within the receptacle and a nozzle secured to the receptacle. The nozzle defines a first opening positioned within an interior of the receptacle, defines a second opening positioned outside of the receptacle and defines a channel which extends from the first opening through the nozzle to the second opening defining a flow path which extends from the first opening, through the channel and to the second opening. The nozzle extends through a wall of the receptacle and into the interior of the receptacle such that the first opening is positioned spaced apart from the wall.

Abstract: A thermal protection system is provided for a vehicle substructure. The thermal protection system comprises an outer layer for protecting the vehicle substructure. The thermal protection system further comprises an inner layer for conforming to the vehicle substructure. The thermal protection system also comprises an insulation layer sandwiched between the inner and outer layers. The insulation layer includes a porous low-density ceramic insulating material having a densified portion that covers an inner surface of the outer layer to strengthen adhesion.

Abstract: A precursor material is provided for additive manufacturing of a low-density, high-porosity ceramic part. The precursor material includes a body of refractory fibers and a binder in admixture with the body of refractory fibers. The precursor material further includes a viscosity control additive in admixture with the binder and the body of refractory fibers to provide an overall mixture with a viscosity between about 0.3 centipoise and about 150,000 centipoise.

Abstract: A precursor material is provided for additive manufacturing of a low-density, high-porosity ceramic part. The precursor material includes a body of refractory fibers and a binder in admixture with the body of refractory fibers. The precursor material further includes a viscosity control additive in admixture with the binder and the body of refractory fibers to provide an overall mixture with a viscosity between about 0.3 centipoise and about 150,000 centipoise.

Abstract: A thermal protection system is provided for a vehicle substructure. The thermal protection system comprises an outer layer for protecting the vehicle substructure. The thermal protection system further comprises an inner layer for conforming to the vehicle substructure. The thermal protection system also comprises an insulation layer sandwiched between the inner and outer layers. The insulation layer includes a porous low-density ceramic insulating material having a densified portion that covers an inner surface of the outer layer to strengthen adhesion.

Abstract: An extruder includes a receptacle for containing material to be extruded. The extruder further includes a dispersion blade positioned within the receptacle and a nozzle secured to the receptacle. The nozzle defines a first opening positioned within an interior of the receptacle, defines a second opening positioned outside of the receptacle and defines a channel which extends from the first opening through the nozzle to the second opening defining a flow path which extends from the first opening, through the channel and to the second opening. The nozzle extends through a wall of the receptacle and into the interior of the receptacle such that the first opening is positioned spaced apart from the wall.

Abstract: A precursor material is provided for additive manufacturing of a low-density, high-porosity ceramic part. The precursor material comprises a body of refractory fibers and a binder in admixture with the body of refractory fibers. The precursor material further comprises a viscosity control additive in admixture with the binder and the body of refractory fibers to provide an overall mixture with a viscosity between about 0.3 centipoise and about 150,000 centipoise. The overall mixture can be extruded through a nozzle to manufacture the low-density, high porosity ceramic part. The precursor material is produced by obtaining a refractory fiber slurry, and adding a viscosity control additive to the slurry to provide the slurry with a viscosity that is suitable for extrusion through a nozzle to manufacture a low-density, high-porosity ceramic part.

Abstract: A precursor material is provided for additive manufacturing of a low-density, high-porosity ceramic part. The precursor material comprises a body of refractory fibers and a binder in admixture with the body of refractory fibers. The precursor material further comprises a viscosity control additive in admixture with the binder and the body of refractory fibers to provide an overall mixture with a viscosity between about 0.3 centipoise and about 150,000 centipoise. The overall mixture can be extruded through a nozzle to manufacture the low-density, high porosity ceramic part. The precursor material is produced by obtaining a refractory fiber slurry, and adding a viscosity control additive to the slurry to provide the slurry with a viscosity that is suitable for extrusion through a nozzle to manufacture a low-density, high-porosity ceramic part.

Abstract: High-temperature fabrics with a coatings to provide oxidation protection at high temperatures, and capable of being formed into a variety of softgoods parts, and methods for their manufacture are disclosed.

Abstract: A method for adding insulation or bulk absorbers into high temperature sandwich structures following fabrication is presented. A slurry of ceramic fibers and/or particles, opacified particles, fugitive fibers, organic binders and inorganic binders is prepared as an aqueous solution. The slurry is cast within a prepared sandwich structure, dried, and heated to form a low density ceramic core material to provide insulation or noise absorption. Following incorporation of the ceramic material, aerogels or phase change materials may also be added to provide additional thermal management benefits.

Abstract: A thermal protection system for a vehicle may include a substantially rigid, relatively thin outer aeroshell, a relatively low density insulation layer, and a resiliently compressible conformal layer. The vehicle may include a substructure. The aeroshell may be configured to be fastened to the substructure. The insulation layer may be disposed against the aeroshell. The conformal layer may be disposable against the insulation layer. The conformal layer may be compressively preloaded against the substructure when the aeroshell is fastened to the substructure.

Abstract: High-temperature fabrics with a coatings to provide oxidation protection at high temperatures, and capable of being formed into a variety of softgoods parts, and methods for their manufacture are disclosed.

Abstract: Thermal insulation assemblies, methods for fabricating thermal insulation assemblies, and thermally insulated structures are provided. In an exemplary embodiment, a thermally insulated structure is disclosed that includes a thermal insulation assembly comprises a ceramic tile having a surface coated with an alumina-mullite slurry. A ceramic matrix composite is disposed on the coated surface. The ceramic matrix composite comprises a first ply of a ceramic fiber impregnated with a ceramic matrix.

Abstract: A method for reworking a ceramic structure. A number of holes are formed in a portion of the ceramic structure in which a rework of the ceramic structure is desired. The ceramic structure has a plurality of layers in the portion in which the rework is desired. A ceramic bonding material is introduced into the number of holes formed in the portion of the ceramic structure. The ceramic bonding material is cured in the portion of the ceramic structure.

Abstract: Thermal insulation assemblies, methods for fabricating thermal insulation assemblies, and thermally insulated structures are provided. In an exemplary embodiment, a thermally insulated structure is disclosed that includes a thermal insulation assembly comprises a ceramic tile having a surface coated with an alumina-mullite slurry. A ceramic matrix composite is disposed on the coated surface. The ceramic matrix composite comprises a first ply of a ceramic fiber impregnated with a ceramic matrix.

Abstract: Thermal insulation assemblies and methods for fabricating thermal insulation assemblies are provided. In an exemplary embodiment, a thermal insulation assembly comprises a ceramic tile having a surface coated with an alumina-mullite slurry. A ceramic matrix composite is disposed on the coated surface. The ceramic matrix composite comprises a first ply of a ceramic fiber impregnated with a ceramic matrix.

Abstract: A method for reworking a ceramic structure. A number of holes are formed in a portion of the ceramic structure in which a rework of the ceramic structure is desired. The ceramic structure has a plurality of layers in the portion in which the rework is desired. A ceramic bonding material is introduced into the number of holes formed in the portion of the ceramic structure. The ceramic bonding material is cured in the portion of the ceramic structure.