Refractory Coatings on Mechanically Resilient Insulators-Phase I demonstrated that ceramic coatings on plastic insulators raised the breakdown voltage, reduced the amount of damage, and improved the recovery after a breakdown event. The main goals of Phase II are to (1) coat actual insulators for the Shiva and HPM devices for testing (2) to optimize the existing ceramic coatings by increasing their thickness to (3) improve the performance of the existing coatings by testing multilayer coating systems and to (4) continue our commercialization efforts.

Diamond-like Carbon Coatings on Polymers-Phase I demonstrated a 10x improvement in abrasion resistance, excellent optical matching to the polycarbonate, and improved ballistic performance relative to industry-standard siloxane. The coating consists of a unique plasma pretreatment of the polycarbonate to improve adhesion, and a combination of layers forming a grading in the mechanical properties from the soft polycarbonate to a hard overcoat. Phase-II optimized the coating process and design, refining the grading of the mechanical properties and introducing surface modifications of the polycarbonate for improved hardness. The coatings were evaluated per MilSpec standards for ballistic performance, abrasion resistance, chemical exposure, and environmental durability. The goal is a manufacturing process capable of supplying low cost, highly abrasion resistant coatings on polycarbonate lenses and visors with significantly improved ballistic protection.

High Temperature Sensor Materials Optimization and Fabrication Methods-This project demonstrates the feasibility of using a nanoparticle inkjet process for directly writing high temperature health monitoring sensors on turbine engine and thermal protection system components, which eliminates the need for expensive sputtering, CVD, clean room, or photolithography equipment. The inkjet process allows sophisticated sensor geometries and material combinations to be produced on the component in a matter of minutes as opposed to the hours needed to produce the sensors using the conventional clean room/sputtering approach. The nanoparticle inkjet process is capable of applying a wide variety of ceramic and refractory metal materials. BENEFIT: The development of low cost robust high temperature sensors will allow: 1) measuring the operating parameters in extremely hot environments such as the compressor and turbine sections to validate computer modeling codes 2) allow active control of pressure surges in turbine engines 3) allow the ability to diagnose turbine engine and thermal protection system health and estimate component capability for future missions 4) and help reduce the significant costs of testing and qualifying turbine engines.

Advanced Canopy and Window Materials for Improved Helicopter and Aircrew Survivability-This project demonstrates the feasibility of applying an advanced multifunctional coating system to aircraft window materials to increase their resistance to electromagnetic interference (EMI) and to improve eye protection from low-power laser exposure. The project studies the control of transmission at selected laser hazard wavelengths and the reduction of solar effects from IR and UV wavelengths. The multifunctional coatings will be designed to produce laser absorption/reflection profiles suitable for a wide variety of window requirements. In addition the coating system will have an increased resistance to abrasion and scratching and an increased resistance to ballistic fragment impact.

Infrared-Transparent, Millimeter-Wave Bandpass, Missile Dome Design-This project develops an infrared-transparent millimeter- wave bandpass filter for use on tri-mode seeker domes for the next generation Joint Air-to-Ground Missile. The filters simultaneously have a pass-band insertion loss 20dB and IR transparency greater than 90% to 5ìm. The filters are characterized by optical transmission scans electrical measurements and EMI shielding measurements from 26.5 to 40 GHz. The coatings are tested to greater than 500°C, as well as abrasion and sand erosion tested. This data assesses the suitability of different designs for use in the tri-mode seeker domes.

Miniaturization of Sensors on Flexible Substrates-This project demonstrates nanoink printing processes for making function specific active sensors and electronics on flexible substrates. The goal is to demonstrate ink formulations and recipes for depositing conductor and semiconductor materials on various flexible polymer and polyimide substrates for use in smart munitions sensors. In this project active sensor electronic systems for intelligent munitions will be developed with an emphasis on antenna and GPS electronics for Medium Range Munitions (MRM).

Passive, Wireless Sensors for Extreme Turbine Conditions-This project develops and demonstrates innovative wireless sensor materials and concepts that can be used on turbine engine components for Engine Health Monitoring (EHM) at temperatures up to and exceeding 1260° C. The state of the wireless sensor circuit is determined by the resonant response from an outside transmitter/receiver. The sensors are constructed from proven high-temperature materials that meet the project goal of stable material properties up to 1260° C (2300° F). BENEFIT: The development of low cost, robust high temperature sensors will allow: 1) measuring the operating parameters in extremely hot environments such as the compressor and turbine sections to validate computer modeling 2) active control of pressure surges in turbine engines 3) the ability to diagnose turbine engine system health and estimate component capability for future missions thereby reducing the cost of ownership 4) provide inputs for diagnostic and life prediction models and will allow engine inspection and maintenance to be performed on accurate need-based schedules removing the inefficiencies and guesswork from aircraft maintenance. This is expected to lead to significant depot and maintenance cost savings and a significant reduction in aircraft downtime.