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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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Technical and Programmatic Consequences of a Hypersonic Vehicle Flight Test Ban

The hypersonic vehicle (HV) is defined as any vehicle capable of traveling at or above five times the local speed of sound (Mach 5). Development of hypersonic flight has been pursued since the late 1950s, especially for reentry of missile warheads and returning orbiting spacecraft. Although considerable progress has been made since then, air- breathing and gliding hypersonic flight remains in the development and testing phase. Concerns have been raised, however, about continued HV flight tests because of HV's potential military use, which has the potential to encourage hair-trigger tactics that would increase crisis instability. In recent years, non-governmental organizations have called for a ban on HV flight testing for the primary purpose of halting continued development of the HV as a weapon. The emphasis on banning flight tests is due to its vital role in aerospace programs. Without it, significant technical uncertainties remain, creating safety and reliability issues that would discourage commercial development. Although the cost and time involved in flight tests have already spurred the use of other test methods, none can completely reproduce the flight test environment. Flight tests are important for reasons such as generating data unique to flight test environments to use in validating models and verifying ground test data, identifying unanticipated problems, and reducing risk. Commercial HV technology development today depends on advancements in four areas: propulsion; aerodynamics; critical guidance, navigation and control; and thermal management. This report summarizes the ramifications on HV technology development if flight tests were banned.

42 ENGINEERING↗

Chemical and morphological evolution of hybrid conversion coatings in low-Earth orbit space environment

Understanding how protective coatings respond to the harsh low-Earth orbit (LEO) environment is essential for ensuring the safety, longevity, and cost-effectiveness of spacecraft. In particular, identifying environmentally friendly, non-chromate alternatives that can maintain performance under such conditions has both technological and regulatory significance. This study investigates the environmental stability of zirconium-based hybrid conversion coatings with Cu additives (Cu10 and Cu20) applied to cold-rolled steel, tested in the Materials International Space Station Experiment (MISSE) outside the International Space Station (ISS). Chemical and morphological analyses were carried out using a combination of electron microscopy and X-ray spectroscopy techniques, including scanning electron microscopy (SEM), scanning transmission electron microscopy with energy-dispersive X-ray spectroscopy (STEM-EDS), X-ray photoelectron spectroscopy (XPS), and X-ray absorption near-edge structure (XANES) spectroscopy. After exposure outside the ISS, all coatings remained structurally intact, with all exhibiting a uniform Zr-rich matrix and embedded Cu-rich clusters, while a thin Si-rich surface layer developed from interaction with space environments. Depth-resolved XPS showed a layered structure with CuO on the surface, Cu 2 O, and partial Zr(IV) reduction near Cu-rich sites, evidence of Atomic Oxygen (AO)-driven surface oxidation. These results demonstrate that Cu–Zr coatings maintain their chemical integrity and microstructure in harsh space environments, offering a non-chromate alternative for long-term aerospace protection. These insights provide valuable guidance for developing next-generation protective coatings that combine environmental sustainability with the reliability required for future aerospace and orbital applications.

36 MATERIALS SCIENCE↗