Zirconium Carbide Coated Carbon Fiber Tip for Supersonic Flight

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Solution Overview

Problem

Current materials fail to simultaneously withstand aerodynamic heating, maintain shape stability, prevent thermal transfer, and balance weight for flying bodies traveling at supersonic speeds, as refractory metals oxidize, carbon fiber composites degrade, and ablators wear rapidly.

Innovation Solution

A heat-resistant structure featuring a three-layer configuration with a surface member made of zirconium carbide and zirconium oxide, an insulation member, and a base part with a lower melting point, thermally insulating the base from the surface member, and a manufacturing method involving immersion of carbon fiber reinforced carbon composite materials in molten zirconium to create a zirconium alloy surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If refractory metals such as tungsten are used for the tip part, then the melting point is sufficiently high, but the surface oxidizes and wears out during high-speed movement in the atmosphere

Engineering Contradiction:

Improvemelting pointVSAvoidoxidation resistance

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The invention uses a composite material consisting of carbon fiber reinforced carbon composite material as the base and zirconium carbide as the surface layer. This composite structure combines the high temperature resistance of carbon fiber with the oxidation resistance of zirconium carbide, resolving the contradiction between maintaining high melting point and preventing oxidation during atmospheric flight.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention changes the material parameters by selecting zirconium carbide with specific physical and chemical properties (high melting point of approximately 3500°C and excellent oxidation resistance). This parameter selection allows the surface layer to withstand both extreme temperatures and oxidative environments, solving the contradiction between temperature resistance and oxidation resistance.

Inventive Principle:

Principle #35Parameter changes

2Temperature

If refractory metals are used for the tip part, then the melting point is high, but the thermal conductivity is relatively high causing heat transfer to the body part

Engineering Contradiction:

Improvemelting pointVSAvoidheat transfer

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The invention applies local quality by creating a layered structure where the carbon fiber reinforced carbon composite material provides thermal insulation properties (low thermal conductivity) while the zirconium carbide surface layer provides heat resistance. This local differentiation of material properties allows the tip part to withstand high temperatures while minimizing heat transfer to the body part.

Inventive Principle:

Principle #3Local quality

3Temperature

If refractory metals are used for the tip part, then the melting point is high, but the specific gravity is relatively high affecting weight balance

Engineering Contradiction:

Improvemelting pointVSAvoidspecific gravity

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The invention uses a composite material structure where carbon fiber reinforced carbon composite material (low specific gravity) forms the base and zirconium carbide (high melting point) forms the surface layer. This composite approach allows the tip part to achieve high temperature resistance while maintaining low weight, resolving the contradiction between melting point and specific gravity.

Inventive Principle:

Principle #40Composite materials

4Strength

If carbon fiber reinforced carbon composite materials are used for the tip part, then the specific strength is high, but the material oxidizes in oxygen atmosphere of 400° C. or higher

Engineering Contradiction:

Improvespecific strengthVSAvoidoxidation resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The invention applies local quality by differentiating the functions of different layers: the carbon fiber reinforced carbon composite material provides structural strength while the zirconium carbide surface layer provides oxidation resistance. This local functional differentiation allows the material to maintain both high specific strength and excellent oxidation resistance in high-temperature oxygen environments.

Inventive Principle:

Principle #3Local quality

5Weight of moving object

If carbon fiber reinforced carbon composite materials are used for the tip part, then the specific gravity is low, but the thermal conductivity is relatively high causing heat transfer to the body part

Engineering Contradiction:

Improvespecific gravityVSAvoidheat transfer

Core Design Contradiction:

Weight of moving objectVSLoss of energy

Solution Approach 1:

The invention applies local quality by creating a layered structure where the carbon fiber reinforced carbon composite material provides thermal insulation (low thermal conductivity) and low weight, while the zirconium carbide surface layer provides heat resistance. This local differentiation allows the tip part to maintain low specific gravity while minimizing heat transfer to the body part.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The structure effectively withstands high-speed aerodynamic heating, maintains shape integrity, and prevents heat transfer to the body, ensuring stability and weight balance for flying bodies.

Implementation Method 1

immersing a carbon fiber reinforced carbon composite material in molten zirconium so that zirconium is impregnated on at least an outer surface of the carbon fiber reinforced carbon composite material and that a carbon of the carbon fiber reinforced carbon composite material as a base material and the zirconium react into a zirconium alloy

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 2

a carbon of the carbon fiber reinforced carbon composite material as a base material and the zirconium react into a zirconium alloy

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Implementation Method 3

the surface member is arranged on an outer surface of the tip part and has a melting point higher than a desired temperature

Methodology Applied

Scientific EffectThermal stability: Refractory Material

Implementation Method 4

The insulation member is arranged between the surface member and the base part and thermally insulates the base part from the surface member

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20230152070A1Heat resistant structure of flying body and manufacturing method of heat resistant structure of flying body

Publication Date: 2023.05.18 MITSUBISHI HEAVY IND LTD

AI summary

The heat resistant structure of the flying body is provided with a tip part and a body part. The tip part is arranged in a front end of the flying body with respect to a direction of travel of the flying body. The body part is arranged in a back direction from the tip part with respect to the direction of travel of the flying body. The tip part is provided with a surface member, a base part, and an insulation member. The surface member is arranged on an outer surface of the tip part and has a melting point higher than a desired temperature. The base part couples the surface member to the body part. The insulation member is arranged between the surface member and the base part., and thermally insulates the base part from the surface member.