The world of aerospace increasingly relies on carbon fiber-reinforced polymer composites to build the structures of satellites, rockets, and jet aircraft. But the life of those materials is limited by how they handle heat. Researchers have developed a heat shield that better protects those extremely fast machines.

The team used carbon nanotubes, which are linked hexagons of carbon atoms in the shape of a cylinder, to build the heat shields. Sheets of those nanotubes are also known as “buckypaper” — a material with incredible abilities to conduct heat and electricity. By soaking the buckypaper in a resin made of a compound called phenol, the researchers were able to create a lightweight, flexible material that is also durable enough to potentially protect the body of a rocket or jet from the intense heat it faces while flying.

Existing heat shields are often very thick compared to the base they protect. The new design lets engineers build a very thin shield, like a sort of skin that protects the aircraft and helps support its structure. After building heat shields of varying thicknesses, the researchers put them to the test.

One test involved applying a flame to the samples to see how they prevented heat from reaching the carbon fiber layer they were meant to protect. After that, the researchers bent the samples to see how strong they remained. They found the samples with sheets of buckypaper were better than control samples at dispersing heat and keeping it from reaching the base layer. They also stayed strong and flexible compared to control samples made without protective layers of nanotubes.

Because of their flexibility, the nanotubes are less vulnerable to cracking at high temperatures compared to ceramics, a typical heat shield material. They are also lightweight, which is helpful for engineers who want to reduce the weight of anything on an aircraft that doesn't help the way it flies.

For more information, contact Bill Wellock at This email address is being protected from spambots. You need JavaScript enabled to view it..


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This article first appeared in the January, 2020 issue of Tech Briefs Magazine.

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