Ultra High Temperature Resistance Coatings for Thermal Protection of Space Vehicles

One of the key technological issues for future space vehicles is the availability of advanced thermal protection systems, able to withstand very high temperature (up to 2000°C) in an oxidising environment. For this reason, thermal sprayed ceramic coatings have been developed and the results obtained up to know are presented. Several coating compositions, based on carbides particles dispersed in a ZrB₂ matrix, and engineering solutions were investigated; high temperature oxidation resistance and mechanical properties have been tested and compared with published data on bulk materials of similar composition. With the more promising among the investigated materials, demonstrative components were realised and tested by means of a Plasma Wind Tunnel in simulated operative conditions. Test results showed the good potentiality of the thermal sprayed ceramics to be used as thermal protection system in space re-entry vehicles.