US' new computer model rapidly tests hypersonic heat shield materials

A team of engineers at Sandia National Laboratories has developed a new computer modeling approach to rapidly test and predict the performance of thermal protection systems (heat shields) for hypersonic vehicles. These heat shields are crucial for protecting spacecraft and high-speed vehicles from extreme heat during atmospheric reentry or supersonic travel. The project, spanning three years, combined computer simulations, ground-based experiments, and flight tests to better understand material behavior under severe heat and stress conditions typical of hypersonic speeds—defined as traveling faster than Mach 5 (over 3,800 mph). Unlike reusable spacecraft heat shields, those for US hypersonic missiles are designed for single use, making rapid and accurate material assessment essential. The researchers examined a wide range of materials, from common graphite to advanced carbon-based and ceramic composites, producing hundreds of samples with support from Oak Ridge National Laboratory. They employed specialized facilities such as an inductively coupled plasma torch at the University of Texas to simulate plasma hotter than the sun’s surface and