materials architectures and characterization for hypersonics (mach) · what is not cti in mach all...

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


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


• 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


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


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


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


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


• 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


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


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)

Distribution Statement “A” (Approved for Public Release, Distribution Unlimited)13

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


• 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)


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


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


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


• 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


• 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


mailto:[email protected]

http://www.darpa.mil/work-with-us/opportunities

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 - -


www.darpa.mil


DARPA BAA PROCESS

Susan Shean

DARPA Contract Management Office

MATERIALS ARCHITECTURES AND CHARACTERIZATION FOR HYPERSONICS (MACH)

BAA No. HR001119S0022

JANUARY 22, 2019


• 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


• 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


• 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


• 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


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


READ


THE


BAA!


www.darpa.mil


DSO 101

Dr. Mark Rosker

Deputy Director, Defense Sciences Office

January 22, 2018


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


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


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


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


http://www.google.com/url?sa=i&source=images&cd=&cad=rja&uact=8&ved=0CAgQjRw&url=http://www.economist.com/node/21553006&ei=RaUmVcedL8HYsAW_5IKgAg&psig=AFQjCNF1WOSfHZbMzCCGlGyVJ4l_DHajjw&ust=1428682437849758

Frontiers in Math, Computation & Design


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



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



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


http://www.google.com/url?sa=i&source=images&cd=&cad=rja&uact=8&ved=0CAgQjRw&url=http://www.economist.com/node/21553006&ei=RaUmVcedL8HYsAW_5IKgAg&psig=AFQjCNF1WOSfHZbMzCCGlGyVJ4l_DHajjw&ust=1428682437849758


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


www.darpa.mil


materials architectures and characterization for hypersonics (mach) · what is not cti in mach all...

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