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Distribution Statement “A” (Approved for Public Release, Distribution Unlimited)
Materials Architectures and Characterization for Hypersonics (MACH)
Dr. William (Bill) Carter
Program Manager
Defense Sciences Office
MACH Proposers Day
January 22, 2019
SETA SupportMs. Katie Shirey
Dr. Dick Cheng
Ms. Kristin Massaro 1
MACH Proposers Day Agenda
Time Topic Speaker Duration
12:00 Registration - 1:00
13:00 Defense Sciences Office Overview Rosker 0:30
13:30 Contracting Overview Shean 0:15
13:45 MACH Overview Carter 0:45
14:30 Leading edge development: Materials testing and validation Glass 0:30
15:00 Break – Submit question cards - 0:15
15:15 Poster Session & Networking - 1:15
16:30 FAQ Answers Carter 1:00
17:30 Adjourn - -
Distribution Statement “A” (Approved for Public Release, Distribution Unlimited) 2
Goals
1. Present BAA to community – convey expectations for program
2. Q&A for program clarification
• Collect questions (on note cards or through webex question module)
• Gov’t team will generate answers during break, poster session, and after meeting
• Review answers after the poster session
• Publish Q&As in a FAQ attached to the MACH site under www.darpa.mil/work-with-us/opportunities
3. Poster session – encourage collaboration and team forming
Proposer’s Day Welcome and Goals
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New leading edges for hypersonic vehicles with integrated thermal management
• Sharp and shape-stable at all stages during flight
• Enable performance well beyond current carbon-carbon (C-C) composites
Broad applicability to boost-glide and air-breathing scramjet vehicles
MACH Scope and Objectives
Perf
orm
ance (
e.g
. W
/cm
2)
2000 2010 2020 2030 2040
Year
High temperature
materials
Disruptive technology approach to hypersonic leading edges
High temperature materials +
thermal management
~5°~1mm
Distribution Statement “A” (Approved for Public Release, Distribution Unlimited) 4
• Evolutionary improvements to the existing state of practice
• e.g. Solid materials without significant added cooling
• Enhancements to composites composed principally of C-C
• e.g. Only utilizing coatings to enable higher temperature operation for C-C
• Approaches that rely principally on ablation as a thermal management method
• Shape change (e.g. recession) is not desired
• Techniques for enhancing heat transfer solely through solid conduction
• e.g. Utilizing highly conductive materials in C-C to increase emissive heat rejection
• Manufacturing techniques, computational development, new ways of testing, that are not focused on, and do not result in, a testable technology
What MACH is NOT about
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The MACH program has two technical areas:
• TA1: Integrated thermal management solutions (utilizing today’s materials)
• TA2: Next-generation materials research (new thermal and materials solutions)
Proposals and Awards:
• Separate proposals required for each TA
• Multiple awards anticipated for each TA
Two Program Phases
• Phase I, 27 months: Demonstrate feasibility through subscale ground test campaign
• Government sponsored arcjet testing at month 24
• Phase II decisions made at month 27
• Phase II, 21 months: Demonstrate manufacturability and performance through ground testing and potential flight testing
MACH Program Structure
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MACH is an UNCLASSIFED program that contains CLASSIFIED elements
• An U//FOUO security classification guide will be made available to program awardees at kickoff
It is expected that MACH performers will generate controlled unclassified information (CUI) and/or controlled technical information (CTI) as part of their research:
• CUI is defined as is information that requires safeguarding or dissemination controls pursuant to and consistent with applicable law, regulations, and government-wide policies but is not classified under Executive Order 13526 or the Atomic Energy Act, as amended, and all CUI shall be marked and safeguarded in accordance with DoDI 5200.01 Volume 4
• CTI is defined as technical information with military or space application that is subject to controls on its access, use, reproduction, modification, performance, display, release, disclosure, or dissemination
• Contractor information systems shall be subject to the security requirements in National Institute of Standards and Technology (NIST) Special Publication (SP) 800-171 “Protecting Controlled Unclassified Information in Nonfederal Information Systems and Organizations”
• NIST SP 800-171 implementation guidance can be found at: https://nvlpubs.nist.gov/nistpubs/specialpublications/nist.sp.800-171.pdf
MACH Security
Distribution Statement “A” (Approved for Public Release, Distribution Unlimited) 7
TA1 Integrated Thermal Management System Development and Demonstration
• All detailed design data (e.g. detailed CAD drawings, bill of materials, manufacturing workflow, performance simulations, etc.) of integrated TA1 solutions are considered CTI.
• All detailed performance data (e.g. thermal response, oxidation response, cooling capacity, geometric limitations, etc.) are CTI when tied to a specific operating environment (e.g. “cooling rate of X at operating temperature of Y”, “recession rate of X when exposed to ground testing conditions Y”, etc.).
• All leading edge integration details (joining, system resource requirements, etc.) are considered CTI when tied to a specific flight vehicle.
TA2 Next-Generation Leading Edge Solutions and Technologies
• Material properties at temperatures above 1500 °C generated from MACH.
• Oxidation response at temperatures above 1500 °C generated from MACH.
• Thermal management architectures with maximum cooling rates higher than 400 W/cm2.
• All detailed design data of materials, coatings, or thermal management architectures are considered CTI when tied to specific MACH program-provided geometries.
• All detailed performance data are CTI when tied to a specific hypersonic operating environment.
Definition of CTI for MACH
Performers uncertain about whether a given dataset contains CTI should request guidance from DARPA
Distribution Statement “A” (Approved for Public Release, Distribution Unlimited) 8
DARPA will segregate all Government furnished information into appropriately-marked CTI and non-CTI datasets. Service-specific and joint DoD planning doctrine publications that are available for download from the internet and are marked Distribution A are considered non-CTI datasets.
TA1 Integrated Thermal Management System Development and Demonstration
• Algorithms when realized in source code, executable formats, or documented in written reports.
TA2 Next-Generation Leading Edge Solutions and Technologies
• Fundamental material properties at temperatures below 1500 °C, or that already exists in public domain.
• Fundamental oxidation response at temperatures below 1500 °C, or that already exists in public domain.
• Thermal management architectures with maximum cooling rates lower than 400 W/cm2.
• Algorithms when realized in source code, executable formats or documented in written reports.
What is not CTI in MACH
ALL PUBLICATIONS resulting from MACH-funded R&D will have publication restrictions and must go
through the formal DARPA DISTAR process for pre-publication review in accordance with the contractual
requirements
Distribution Statement “A” (Approved for Public Release, Distribution Unlimited) 9
• MACH seeks to improve hypersonic leading edge performance
• Shape stable, higher heat flux capable leading edges enable increased lift-to-drag (L/D), higher aerothermal loads
• TA1: Integrated thermal management system development and demonstration
• Handle higher heat loads via thermal management with current materials
• TA2: Next generation hypersonic materials research
• Develop new materials and thermal management techniques for enhanced performance beyond achievable in TA1
MACH overview: Future hypersonic needs: greater range and speed
Sharp, high heat flux leading edges for hypersonic vehiclesDistribution Statement “A” (Approved for Public Release, Distribution Unlimited) 10
Current material architectures limit thermal performance
Carbon-carbon (C-C) is state of the art
• Uncoated C-C cools by ablation (~1500 W/cm2) which limits leading edge radius >1-2 cm
• Coated, sharp C-C edges cool by emissive cooling; Demonstrated for short flights (~2 min)
Sharp edges (~ mm) generally required for efficient flight but are difficult to embody (Fay-Riddell, 1968):
𝐻𝑒𝑎𝑡 𝑓𝑙𝑢𝑥, 𝑄 ∝ (𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑉)3 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒, 𝑃
𝐸𝑑𝑔𝑒 𝑟𝑎𝑑𝑖𝑢𝑠, 𝑅
A breakthrough in system level thermal management will enable leap-ahead platform performance
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Cooled leading edges have been studied since 1958.
• Can be effective, but rarely flown due to complexity, manufacturing difficulty
Materials Architectures to cool the leading edge (a long-standing dream)
MACH will advance new materials and architectures to meet future hypersonic performance goals
Historical example: Boost-Glide Reentry Vehicle, 26 Feb 1968,
MACH 8-18
Water transpiration cooling nosecone,
water blanket. Niobium casing
Example: D. Glass, 2005 NASA
What is different now?
• Advancements in thermal engineering & net-shape manufacturing pave the way to >1000 W/cm2 cooling
Available materials and thermal architectures to demonstrate integrated thermal solutions
• New emerging opportunities in materials, multiscale optimization for >1500 W/cm2
New thermal management architectures, materials & coating compositions to extend art of the possible
TA1
TA2
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TA1: Integrated LE thermal management system development and demonstration
Thermal Ground Plane (TGP)
performance ~300 W/cm2
World record (LANL): >20 kW/cm2
Hierarchical microchannel with
>1000W/cm2 cooling demonstrated
in MTO ICECool
MT
O IC
EC
ool
MT
O T
GP
Microelectronics cooling
Cooling requires architectural complexity
Biggest challenge is scalable manufacturing using high temperature materials
• Advances in turbine engine and microelectronics cooling demonstrate ~1000W/cm2 possible
• TA 1 objective: Demonstrating robust >1000 W/cm2 capable leading edges
• Meet form factor, thermo-mechanical and thermo-chemical requirements
• Component modeling and scalable manufacturing
Turbine engine cooling
1965 1975 1985 1995 2005 2015 2025 2035
Year
700
900
1100
1300
1500
Film cooling
Closed-loop cooling
Gas temperature
1700
1900 Heat pipe cooling
Te
mp
era
ture
(°
C)
200
+ W
/cm
2C
oo
lin
g
(H. Wadley, UVA)
(A. Bar-Cohen)
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TA2: Next generation thermal management, materials & coatings
Extend the art of the possible for future hypersonic systems
New metals and ceramics
• Examples include high entropy materials, ceramic
and metal composites
• Very large compositional spaces to search
New coatings
• Better oxidation barriers (particularly >1600°C)
• Intelligent coating - thermal response
• Robustness to point failure
• Manufacturability, bonding, robustness
• Aerothermal, chemical response
• Manufacturing
• Vehicle geometry
• Trajectory
Atomic scale Vehicle scale
Apply new computational materials methods
to hypersonics
• Multiphysics modeling
• Multidisciplinary optimization
• Microstructure & composition
• Uncertainty quantification
Higher performance leading edge thermal management
• Heat flux >> 1500 W/cm2
• Prefer passive but can be active
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• Performers should provide data that enable government assessment of leading edge performance as a function of:
• Design parameters (i.e. size, external and internal geometrical features, constituent materials)
• Aerothermal operating conditions (altitude, velocity, angle of attack)
• Government provided ground test opportunities and potential flight test
Modeling and testing
Month TA1 TA2
Phase I
12Coupon sized part, 400 W/cm2 at <0.1 atm air mixture (optional but encouraged)
18Subscale sample for manufacturing demo and thermal shock (optional but encouraged)Subscale sample for combined thermomechanical testing
Coupon sample for thermal shock (optional but encouraged)
24 Arcjet with subscale geometry, 1000W/cm2 at ~0.5 atm air mixture Coupon sized part, 1500 W/cm2 at <0.1 atm air mixture
Phase II
33Month 33: Wind tunnel with full scale geometry at >MACH 6 (optional but encouraged)
39 Arcjet with full scale geometry, 1000W/cm2 at ~0.8 atm air mixture Arcjet with subscale geometry, 1500W/cm2 at ~0.5 atm air mixture
45Flight testing (given opportunity & funding) Arcjet with full scale geometry, 1500W/cm2 at ~0.8 atm air mixture
(optional but encouraged)
Distribution Statement “A” (Approved for Public Release, Distribution Unlimited) 15
Phase I: 27 months Phase II: 21 months
TA1 TA2 TA1 TA2
Metr
ics
Leading edge geometry≤ 3 mm radius of curvature,
≤10° wedge angle≤ 1 mm radius of curvature,
≤10° wedge angle
Survive‡ transient heat flux in oxidative environment (≥2 cycles)
Subscale*, 30s, 1000 W/cm2, 0.5 atm air mixture
Coupon**, 30s, >1500 W/cm2, 0.02 atm air mixture
Full scale***, 120s, 1000 W/cm2, 0.8 atm air mixture
Subscale*, 120s, >1500 W/cm2, 0.5 atm air mixture
Thermal shock resistance Survive‡ ≥ 500°C/sec Survive‡ ≥1000°C/sec
Survive sustained heat flux ≥500 W/cm2 for 600 sec ≥500 W/cm2 for 1200 sec
Size≥5 cm span,
≥10 cm chordN/A
≥10 cm span, ≥20 cm chord
≥5 cm span, ≥5 cm chord
Scalability Rate and cost model N/A Manufacturing demo Rate and cost model
High G operation ≥10 g ≥20 g
Strength at maximum operating heat flux
≥100 MPa ≥100 MPa
Survivability ≥100 g shock ≥200 g shock
MACH Metrics
‡ Survive is defined as <1mm recession and no visible spallation, delamination, cracking or other obvious failure
* Subscale is a wedge with notional dimensions of 5cm span, 10cm chord, and 10º wedge angle
** Coupon is a button with notional dimensions of 3cm diameter, 1cm thickness
*** Full scale is a wedge with notional dimensions of 10cm span, 20cm chord, and 10º wedge angle
Distribution Statement “A” (Approved for Public Release, Distribution Unlimited) 16
Deliverables
• Phase I:
• TA1: Two (2) 5 cm (span) x 10 cm (chord) structures capable of meeting phase I metrics (with accompanying models, validation and test data)
• TA2: Laboratory test data and validated material/component model showing feasibility for exceeding phase I metrics
• Phase II:
• TA1: Two (2) 10 cm (span) x 20 cm (chord) structures capable of meeting phase II metrics (with accompanying models, validation and test data); manufacturing and cost models (with accompanying validation and test data)
• TA2: Two (2) 5 cm (span) x 5 cm (chord) structures capable of exceeding phase II metrics (with accompanying models, validation and test data); preliminary performance, manufacturing and cost models
• Quarterly technical reports & Monthly financial reports
• A phase completion report submitted within 30 days of the end of each phase, summarizing the research done
Distribution Statement “A” (Approved for Public Release, Distribution Unlimited) 17
Coupon, 1500
W/cm2, <0.1 atm
Full scale
wind tunnel
MACH program schedule, milestones, and deliverables
FY19 FY20 FY21 FY22 FY23
TA1: Integrated LE
solutions
addressing TM,
manuf. & scalability
TA2: Next Gen LE
architectures,
coatings, and
computational tools
Phase II: 21 Months
Coupon, 400
W/cm2, 0.02 atmSubscale arcjet
1000 W/cm2, 0.5 atm
IV&V &
government team
activities
Initial platform model
Future test definition
Phase II
decision
Phase II test
geometry release
Final report
Coupon
thermal shock
Potential TA2 to
TA1 on-ramp
Potential
flight testing
Phase I: 27 Months
Lab validation
Subscale
thermal shock
Full-scale arcjet
1000 W/cm2, 0.8 atm
Lab
validation
Subscale arcjet
1500 W/cm2, 0.5 atm
Full-scale arcjet
1500 W/cm2, 0.8 atm
Distribution Statement “A” (Approved for Public Release, Distribution Unlimited) 18
• Posting Date (PD): January 28,2019
• Proposers Day: January 22, 2019. See Section VIII.C.
• Abstract Due Date: February 11, 2019, 4:00 pm
• Abstract Feedback: No Later Than March 4,2019
• FAQ Submission Deadline: April 1, 2019, 4:00 p.m. See Section VIII.A.
• Full Proposal Due Date: April 11, 2019, 4:00 p.m.
Important MACH Dates
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• Please submit questions via webex module, or via notecard
• If questions arise after industry day, please submit questions to [email protected]
• Answers to most questions will be provided after the poster session
• All relevant questions and answers will be published as part of the official MACH FAQs located at www.darpa.mil/work-with-us/opportunities under MACH
Questions
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MACH Proposers Day Agenda
Time Topic Speaker Duration
12:00 Registration - 1:00
13:00 Defense Sciences Office Overview Rosker 0:30
13:30 Contracting Overview Shean 0:15
13:45 MACH Overview Carter 0:45
14:30 Leading edge development: Materials testing and validation Glass 0:30
15:00 Break – Submit question cards - 0:15
15:15 Poster Session & Networking - 1:15
16:30 FAQ Answers Carter 1:00
17:30 Adjourn - -
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DARPA BAA PROCESS
Susan Shean
DARPA Contract Management Office
MATERIALS ARCHITECTURES AND CHARACTERIZATION FOR HYPERSONICS (MACH)
BAA No. HR001119S0022
JANUARY 22, 2019
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• READ THE BAA• Words are Meaningful
• Should, must, encouraged
• Teaming is strongly encouraged, see Collaborative Efforts/Teaming (BAA Section VIII.B.)
• Abstracts are strongly encouraged (BAA Section IV). See the mandatory templates referenced in BAA Section IV.B.1.
• Full Proposal contains Technical, Cost and Administrative sections (See mandatory templates referenced in BAA Section IV.B.2)
• Technical sections lead to “Selectable” (described in BAA Section V.B.) - note particular requirements in BAA Sections I.C-I.H for the Program
• Technical and Management Proposal (Volume 1)
• Proposal Templates and Proposal Summary Slide Template
• Administrative sections lead to Award
• Cost Proposal (Proposal Volume 2)
• Cost Volume Template and Cost Breakdown template (procurement contracts or OTs) or SF 424 (cooperative agreements)
• Admin and National Policy Requirements (Proposal Volume 3)
• Admin Proposal Template
BAA PROCESS
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• PROPOSAL PREPARATION/SUBMISSION
• Instructions are detailed in the BAA and its attachments as posted on FBO.gov (Follow closely). Detailed proposals are requested for Phases I and II. Phase II is an option.
• There are two Technical Areas (TA). Proposers can propose to either or both TAs.Program Metrics are at Table 1 in Section I.F.
• ALL questions EMAILED to [email protected]
• FAQ (including today’s) available on the DARPA/DSO Opportunities website identified in Section VIII.A. of the BAA (Read Regularly)
• Funding instruments = procurement contracts, cooperative agreements and OTs
BAA PROCESS
Distribution Statement “A” (Approved for Public Release, Distribution Unlimited) 25
• Per BAA Section I.D., all proposals must contain a task for flight test in Phase II. This is not to be priced with your proposal submission. If selected as a candidate for flight test in Phase II, cost proposals will be requested at that time.
• BAA Sections I.H.1 and VI.B.4 address intellectual property. Assert rights to all technical data & computer software generated, developed, and/or delivered to which the Government will receive less than Unlimited Rights.
• Assertions apply to Prime and Subs
• Justify “Basis of Assertion”
• BAA Section III, Other, addresses security requirements. Personnel and facility clearances are not required at the time of proposal submission. Clearances will be addressed at the time of contract award.
BAA PROCESS
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• Abstracts are due no later than February 11, 2019 by 4:00 pm EST
• Proposals are due no later than April 11,2019 by 4:00 pm EST
BAA PROCESS
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BAA PROCESS
• EVALUATION/AWARD
• Read Evaluation Criteria Carefully (BAA Section V)
Criteria in Descending Order of Importance:Overall Scientific and Technical Merit
Potential Contribution and Relevance to the DARPA Mission
Cost Realism
• Government reserves the right to select for award all, one, some,
or none of the proposals received.
• Government anticipates making multiple awards
• No common Statement of Work - Proposal evaluated on individual
merit and relevance as it relates to the stated research
goals/objectives
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DSO 101
Dr. Mark Rosker
Deputy Director, Defense Sciences Office
January 22, 2018
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DARPA Technical Offices
BIOLOGICAL
TECHNOLOGIES
OFFICE
DEFENSE
SCIENCES
OFFICE
INFORMATION
INNOVATION
OFFICE
MICROSYSTEMS
TECHNOLOGY
OFFICE
TACTICAL
TECHNOLOGY
OFFICE
STRATEGIC
TECHNOLOGY
OFFICE
Biology for Security• Outpacing
Infectious Disease
• Neurotechnology
• Gene Editing & Synthetic Biology
• Frontiers in Math, Computation & Design
• Limits of Sensing & Sensors
• Complex Social Systems
• Anticipating Surprise
• Symbiosis: Partner with Machines
• Analytics: Understand the World
• Cyber: Deter Cyber Attack
• Electromagnetic Spectrum
• Tactical Information Extraction
• Globalization
Enterprise Disruption: Platforms, Systems, and Technologies that Enable New Warfighting Constructs
Crosscutting Themes• Eliminate High-
Value Assets
• Exploit Cross-Domain Seams
• Enable Decision-Making Asymmetry
Win In Any Environment via Adaptive Kill Webs• Sensing
• Comms, Command, Control
• Effects
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DARPA
• Founded in 1958 in the wake of Sputnik
• 60 years of supporting breakthrough technologies fornational security
DSO
• “DARPA’s DARPA”: Create opportunity from scientific discovery
• Invest in multiple, often disparate, scientific disciplines; reshape existing fields or create entirely new disciplines
• Harvest and accelerate the development of promising breakthroughs and technologies to address national security challenges
DARPA and the Defense Sciences Office
DSO: The Nation’s first line of defense against scientific surprise
DARPA: Create and prevent strategic surprise
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Program Managers
James GimlettPhysics
John MainSystem Frontiers
Alé LukaszewPhysics/Materials
Michael FiddyElectromagnetic waves, scattering & structures
John PaschkewitzSystems, Design, & Materials
Jan VandenbrandeMath, Design, & Production Automation
Adam RussellBehavioral/Social Sciences
Anne FischerChemical Systems
Vincent TangApplied Physics
MAJ David LewisPhysics
Bill CarterMaterials Science
Ted SenatorArtificial Intelligence
Tatjana CurcicQuantum Information Science
Jiangying ZhouArtificial Intelligence
Distribution Statement “A” (Approved for Public Release, Distribution Unlimited) 36
Current Areas of DSO Focus
Limits of Sensing & Sensors
Complex Social Systems
Anticipating Surprise
Frontiers in Math,
Computation & Design
© 2007 Ned Batchelder
The Economist, April 2012
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Frontiers in Math, Computation & Design
© 2007 Ned Batchelder
The increasingly complex, technologically sophisticated, fast-paced and dynamic military operational environment imposes fundamental challenges in how we design and plan for future military needs.
Topics of interest 1. Mathematical, computational, and design frameworks and tools that
provide robust solutions to challenging planning and optimization problems
2. Fundamental scientific underpinnings and limits of machine learning 3. Alternative computing models, architectures, and substrates for
faster, more robust decision making4. Advanced design tools
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© 2007 Ned Batchelder
Sensing and measurement of signals ranging across the spectrum are ubiquitous to military systems and missions. Surveillance, navigation, warfighter health monitoring, and target ID/tracking are examples of missions that rely on various sensing modalities.
Limits of Sensing & Sensors
Topics of interest 1. New sensing modalities 2. Fundamental sensing limits 3. Engineered materials that enable novel optics and imaging capabilities4. Fundamental & practical limits of quantum sensing and metrology
Distribution Statement “A” (Approved for Public Release, Distribution Unlimited) 39
© 2007 Ned Batchelder
Understanding social behavior and the dynamics of complex social networks is critically important for many military operations including stability, deterrence, compellence, counter terrorism, shaping the environment, training, and mission planning.
Complex Social Systems
Topics of interest 1. Scientifically validated models of the social dynamics underlying
different kinds of conflict2. Capabilities to improve understanding of causality in social systems3. Tools that enable human-machine symbiotic decision-making4. New concepts in war-gaming & conflict simulation5. Social media tools to expedite discovery
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© 2007 Ned Batchelder
The goal of DSO R&D investments is to ensure that U.S. warfighters have access to the most advanced technologies. This thrust area supports S&T discovery that leads to “leap ahead” capabilities forenhanced military readiness across multiple operational domains.
Anticipating Surprise
Topics of interest1. Functional & structural materials 2. Manufacturing processes3. Materials for harsh environments 4. Defense against WMD/WMT5. Exploitation of COTS technology to achieve increased lethality6. Energetic materials7. Concepts in ultra-rapid, high-magnitude energy transduction
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