Materials Architectures and Characterization for Hypersonics (MACH)

Materials Architectures and Characterization for Hypersonics (MACH) Dr. William (Bill) Carter Program Manager Defense Sciences Office MACH Proposers Day January 22, 2019 SETA Support Ms. Katie Shirey Dr. Dick Cheng Ms. Kristin Massaro Distribution Statement A (Approved for Public Release, Distribution Unlimited) 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

Proposer s Day Welcome and Goals 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/workwith-us/opportunities 3. Poster session encourage collaboration and team forming Distribution Statement A (Approved for Public Release, Distribution Unlimited) 3

Performance (e.g. W/cm 2 ) MACH Scope and Objectives New leading edges for hypersonic vehicles with integrated thermal management Sharp and shape-stable at all stages during flight Enable performance well beyond current carboncarbon (C-C) composites Broad applicability to boost-glide and air-breathing scramjet vehicles High temperature materials + thermal management High temperature materials 2000 2010 2020 2030 2040 Year ~5 ~1mm Disruptive technology approach to hypersonic leading edges Distribution Statement A (Approved for Public Release, Distribution Unlimited) 4

What MACH is NOT about 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 Distribution Statement A (Approved for Public Release, Distribution Unlimited) 5

MACH Program Structure 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 Distribution Statement A (Approved for Public Release, Distribution Unlimited) 6

MACH Security 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 Distribution Statement A (Approved for Public Release, Distribution Unlimited) 7

Definition of CTI for MACH 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/cm 2. 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. Performers uncertain about whether a given dataset contains CTI should request guidance from DARPA Distribution Statement A (Approved for Public Release, Distribution Unlimited) 8

What is not CTI in MACH 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/cm 2. Algorithms when realized in source code, executable formats or documented in written reports. 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 overview: Future hypersonic needs: greater range and speed 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 Sharp, high heat flux leading edges for hypersonic vehicles Distribution Statement A (Approved for Public Release, Distribution Unlimited) 10

Current material architectures limit thermal performance 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 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) A breakthrough in system level thermal management will enable leap-ahead platform performance Distribution Statement A (Approved for Public Release, Distribution Unlimited) 11

Materials Architectures to cool the leading edge (a long-standing dream) Cooled leading edges have been studied since 1958. Can be effective, but rarely flown due to complexity, manufacturing difficulty Example: D. Glass, 2005 NASA Water transpiration cooling nosecone, water blanket. Niobium casing What is different now? Historical example: Boost-Glide Reentry Vehicle, 26 Feb 1968, MACH 8-18 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 MACH will advance new materials and architectures to meet future hypersonic performance goals Distribution Statement A (Approved for Public Release, Distribution Unlimited) 12

MTO TGP Temperature ( C) 200+ W/cm 2 Cooling MTO ICECool TA1: Integrated LE thermal management system development and demonstration Advances in turbine engine and microelectronics cooling demonstrate ~1000W/cm 2 possible Turbine engine cooling 1900 Heat pipe cooling Microelectronics cooling 1700 1500 Gas temperature Closed-loop cooling Hierarchical microchannel with >1000W/cm 2 cooling demonstrated in MTO ICECool 1300 Film cooling 1100 900 (H. Wadley, UVA) 700 1965 1975 1985 1995 2005 2015 2025 2035 Year Thermal Ground Plane (TGP) performance ~300 W/cm 2 World record (LANL): >20 kw/cm 2 (A. Bar-Cohen) 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 Cooling requires architectural complexity Biggest challenge is scalable manufacturing using high temperature materials Distribution Statement A (Approved for Public Release, Distribution Unlimited) 13

TA2: Next generation thermal management, materials & coatings Higher performance leading edge thermal management Heat flux >> 1500 W/cm2 Prefer passive but can be active New metals and ceramics Examples include high entropy materials, ceramic and metal composites Very large compositional spaces to search Apply new computational materials methods to hypersonics New coatings Atomic scale Multiphysics modeling Multidisciplinary optimization Microstructure & composition Uncertainty quantification Vehicle scale Aerothermal, chemical response Manufacturing Vehicle geometry Trajectory Better oxidation barriers (particularly >1600 C) Intelligent coating - thermal response Robustness to point failure Manufacturability, bonding, robustness Extend the art of the possible for future hypersonic systems Distribution Statement A (Approved for Public Release, Distribution Unlimited) 14

Modeling and testing 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 Month TA1 TA2 12 Coupon sized part, 400 W/cm 2 at <0.1 atm air mixture (optional but encouraged) Phase I 18 Subscale 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/cm 2 at ~0.5 atm air mixture Coupon sized part, 1500 W/cm 2 at <0.1 atm air mixture Phase II 33 Month 33: Wind tunnel with full scale geometry at >MACH 6 (optional but encouraged) 39 Arcjet with full scale geometry, 1000W/cm 2 at ~0.8 atm air mixture Arcjet with subscale geometry, 1500W/cm 2 at ~0.5 atm air mixture 45 Flight testing (given opportunity & funding) Arcjet with full scale geometry, 1500W/cm 2 at ~0.8 atm air mixture (optional but encouraged) Distribution Statement A (Approved for Public Release, Distribution Unlimited) 15

Metrics MACH Metrics Phase I: 27 months Phase II: 21 months Leading edge geometry Survive transient heat flux in oxidative environment ( 2 cycles) TA1 TA2 TA1 TA2 3 mm radius of curvature, 10 wedge angle Subscale*, 30s, 1000 W/cm 2, 0.5 atm air mixture Coupon**, 30s, >1500 W/cm 2, 0.02 atm air mixture 1 mm radius of curvature, 10 wedge angle Full scale***, 120s, 1000 W/cm 2, 0.8 atm air mixture Subscale*, 120s, >1500 W/cm 2, 0.5 atm air mixture Thermal shock resistance Survive 500 C/sec Survive 1000 C/sec Survive sustained heat flux 500 W/cm 2 for 600 sec 500 W/cm 2 for 1200 sec Size 5 cm span, 10 cm chord N/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 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

MACH program schedule, milestones, and deliverables Phase I: 27 Months Phase II: 21 Months FY19 FY20 FY21 FY22 FY23 TA1: Integrated LE solutions addressing TM, manuf. & scalability Lab validation Coupon, 400 W/cm2, 0.02 atm Subscale thermal shock Subscale arcjet 1000 W/cm2, 0.5 atm Full scale wind tunnel Full-scale arcjet 1000 W/cm2, 0.8 atm Potential flight testing Potential TA2 to TA1 on-ramp TA2: Next Gen LE architectures, coatings, and computational tools Lab validation Coupon thermal shock Coupon, 1500 W/cm2, <0.1 atm Subscale arcjet 1500 W/cm2, 0.5 atm Full-scale arcjet 1500 W/cm2, 0.8 atm Initial platform model Phase II decision Final report IV&V & government team activities Future test definition Phase II test geometry release Distribution Statement A (Approved for Public Release, Distribution Unlimited) 18

Important MACH Dates 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. Distribution Statement A (Approved for Public Release, Distribution Unlimited) 19

Questions Please submit questions via webex module, or via notecard If questions arise after industry day, please submit questions to mach@darpa.mil 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 Distribution Statement A (Approved for Public Release, Distribution Unlimited) 20

www.darpa.mil Distribution Statement A (Approved for Public Release, Distribution Unlimited) 22

DARPA BAA PROCESS Susan Shean DARPA Contract Management Office MATERIALS ARCHITECTURES AND CHARACTERIZATION FOR HYPERSONICS (MACH) BAA No. HR001119S0022 JANUARY 22, 2019 Distribution Statement A (Approved for Public Release, Distribution Unlimited) 23

READ THE BAA BAA PROCESS 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 Distribution Statement A (Approved for Public Release, Distribution Unlimited) 24

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 MACH@darpa.mil 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 Distribution Statement A (Approved for Public Release, Distribution Unlimited) 25

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. Distribution Statement A (Approved for Public Release, Distribution Unlimited) 26

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 Distribution Statement A (Approved for Public Release, Distribution Unlimited) 27

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 Distribution Statement A (Approved for Public Release, Distribution Unlimited) 28

READ Distribution Statement A (Approved for Public Release, Distribution Unlimited) 29

THE Distribution Statement A (Approved for Public Release, Distribution Unlimited) 30

BAA! Distribution Statement A (Approved for Public Release, Distribution Unlimited) 31

www.darpa.mil Distribution Statement A (Approved for Public Release, Distribution Unlimited) 32

DSO 101 Dr. Mark Rosker Deputy Director, Defense Sciences Office January 22, 2018 Distribution Statement A (Approved for Public Release, Distribution Unlimited) 33

DARPA Technical Offices BIOLOGICAL TECHNOLOGIES OFFICE DEFENSE SCIENCES OFFICE INFORMATION INNOVATION OFFICE MICROSYSTEMS TECHNOLOGY OFFICE STRATEGIC TECHNOLOGY OFFICE TACTICAL 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 Win In Any Environment via Adaptive Kill Webs Sensing Comms, Command, Control Effects 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 Distribution Statement A (Approved for Public Release, Distribution Unlimited) 34

DARPA and the Defense Sciences Office DARPA Founded in 1958 in the wake of Sputnik 60 years of supporting breakthrough technologies for national security DSO DARPA: Create and prevent strategic surprise 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 DSO: The Nation s first line of defense against scientific surprise Distribution Statement A (Approved for Public Release, Distribution Unlimited) 35

Program Managers Anne Fischer Chemical Systems Jan Vandenbrande Math, Design, & Production Automation John Paschkewitz Systems, Design, & Materials Bill Carter Materials Science Michael Fiddy Electromagnetic waves, scattering & structures Tatjana Curcic Quantum Information Science Jiangying Zhou Artificial Intelligence James Gimlett Physics John Main System Frontiers Adam Russell Behavioral/Social Sciences Alé Lukaszew Physics/Materials MAJ David Lewis Ted Senator Vincent Tang Physics Artificial Intelligence Applied Physics Distribution Statement A (Approved for Public Release, Distribution Unlimited) 36

Current Areas of DSO Focus Limits of Sensing & Sensors 2007 Ned Batchelder Frontiers in Math, Computation & Design Complex Social Systems Anticipating Surprise The Economist, April 2012 Distribution Statement A (Approved for Public Release, Distribution Unlimited) 37

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. 2007 Ned Batchelder 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 making 4. Advanced design tools Distribution Statement A (Approved for Public Release, Distribution Unlimited) 38

Limits of Sensing & Sensors 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 2007 Ned Batchelder that rely on various sensing modalities. Topics of interest 1. New sensing modalities 2. Fundamental sensing limits 3. Engineered materials that enable novel optics and imaging capabilities 4. Fundamental & practical limits of quantum sensing and metrology Distribution Statement A (Approved for Public Release, Distribution Unlimited) 39

Complex Social Systems 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. 2007 Ned Batchelder Topics of interest 1. Scientifically validated models of the social dynamics underlying different kinds of conflict 2. Capabilities to improve understanding of causality in social systems 3. Tools that enable human-machine symbiotic decision-making 4. New concepts in war-gaming & conflict simulation 5. Social media tools to expedite discovery Distribution Statement A (Approved for Public Release, Distribution Unlimited) 40

Anticipating Surprise 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 for enhanced military readiness across multiple operational domains. 2007 Ned Batchelder Topics of interest 1. Functional & structural materials 2. Manufacturing processes 3. Materials for harsh environments 4. Defense against WMD/WMT 5. Exploitation of COTS technology to achieve increased lethality 6. Energetic materials 7. Concepts in ultra-rapid, high-magnitude energy transduction Distribution Statement A (Approved for Public Release, Distribution Unlimited) 41

www.darpa.mil Distribution Statement A (Approved for Public Release, Distribution Unlimited) 42