DS-JUL24-PG55_Layout 1 02/08/2024 15:41 Page 1


MATERIALS IN DESIGN & PROTOTYPING WITHOUT GETTING BURNED


HYPERSONIC FLIGHT: TAKING THE HEAT


The race for hypersonic flight is heating up,


however a significant challenge lies in crafting materials that can withstand the extreme conditions of hypersonic travel. Dr Pradyumna Gupta, founder and CEO of Infinita Lab, comments


technology. The current market is valued at $7.2 billion, with an estimated annual growth rate of around 9.3%. However, as a highly technical industry, this growth doesn’t come without its share of challenges. One of its significant issues lies in crafting


H


materials that can withstand the extreme conditions of hypersonic travel, which include temperatures reaching thousands of degrees Celsius and immense aerodynamic stress. Alongside this barrier, engineering and design teams are also contending with limited access to laboratory and testing facilities to ensure aircraft are safe and fit for flight. Here’s a breakdown of the design challenges that engineering teams face and how the industry as a whole can overcome them:


BRAVING EXTREME CONDITIONS TO EXPLORE NEW FRONTIERS When something is moving faster than the speed of sound, even the smallest hits can cause devastating damage. A clear example of this is the tragic Space Shuttle Columbia disaster, where loose debris destroyed the integrity of the aircraft. So, materials’ ability to resist thermal stress


and distribute heat is vital. Usually, materials contain a ceramic outside that can withstand temperatures upwards of 1300°C. To illustrate, Space Shuttle Columbia’s Thermal Protection System (TPS) materials had to withstand temperatures from -121˚C to 1,649˚C. Air pressure is another key consideration that


manufacturing teams must account for. However, the challenges of heat and pressure also need to be balanced against the factor of weight – hypersonic aircraft need to be lightweight enough to fly. Moreover, there are three types of hypersonic flight materials: refractory metals, composites, and ceramics. Each comes with its own set of benefits and challenges – such variety enhances difficulties surrounding the standardisation of processing and testing materials, making weight an even trickier issue.


ypersonic flight research is taking off as nations and private enterprises compete to develop this transformative


Dr Pradyumna Gupta


pressure capabilities of the materials should always be prioritised when experimenting because they play a vital part in determining product safety. Unfortunately, this is where scientists and engineers encounter the most roadblocks. Due to the degree of specificity needed for the simulations, there are many currently unavailable testing methods that are imperative to sufficient testing standards. All these obstacles boil down to the fact that these simulations have such unique requirements that custom-built facilities are necessary to prove if designs are sound. Again, researchers also have to contend with the fact that they’re constantly exploring new frontiers.


“One of the significant issues lies in crafting materials that can


withstand the extreme


conditions of hypersonic travel, which include temperatures reaching thousands of degrees Celsius and immense aerodynamic stress”


This plethora of risks means constant


testing is absolutely non-negotiable. Hypersonic flight is at the frontier of scientific advancements, and so new solutions and technologies are continuously being explored. Therefore, experiments need to push the boundaries – requirements are always five steps ahead of what is available. For instance, a simulation model may be available for a speed of 500mph, while a new requirement may ask for testing at 1000mph speed. In hypersonic flight, real-world testing feeds simulation models, not the other way around. Testing the thermal, mechanical, and air


COLLABORATION There are two types of challenges when researching hypersonic flight. First, academic research approaches a problem primarily at a fundamental level. Second, industry exploration primarily focuses on immediate or practical needs – and pressing deadlines guide the research agenda. Striking a balance between these two areas


of research is imperative. Thankfully, there is a complex and somewhat effective web of collaboration between academic and industry research institutions. Governments and universities alike are majorly


increasing research initiatives into hypersonic flight. For example, the Defense Advanced Research Projects Agency (DARPA) is onboarding academics and universities to align research initiatives. Hypersonic technologies are also crucial for governments as they develop defense weapons like high-speed aircraft and missiles. So, they actively invest in research among universities and industries – SpaceX is a renowned example. Cross-collaboration in research is a democratic


process. A variety of platforms and conferences facilitate knowledge sharing on an annual basis. However, access to conducting field research and testing is highly limited, even though connecting researchers with lab facilities is crucial. Opening up access to testing facilities is key


to paving the way for stronger collaboration in researching materials for hypersonic flight. That’s why companies like Infinita Lab are facilitating knowledge sharing to unlock new opportunities in hypersonic flight by connecting scientists and researchers with laboratory and testing facilities that they otherwise would not have access to or knowledge of. Accessible testing facilities are at the heart of resolving the industry-wide challenges researchers constantly face.


InfinitaLab https://infinitalab.com/


JULY/AUGUST 2024 DESIGN SOLUTIONS 55


FEATURE


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52  |  Page 53  |  Page 54  |  Page 55  |  Page 56  |  Page 57  |  Page 58  |  Page 59  |  Page 60  |  Page 61  |  Page 62  |  Page 63  |  Page 64