The hypersonic environment: Required operating conditions and design challenges

Hypersonic flight powered by airbreathing engines offers the potential for faster response time at long ranges, and reduced cost for access-to-space. In the present paper the operating environment of typical hypersonic vehicles are discussed, including results for the radiation equilibrium wall temperature of external vehicle surfaces and the flow properties through three sample engines spanning the range of hydrocarbon-fueled Mach 4-8 flight and hydrogen-fueled flight at speeds up to Mach 17. Flow conditions at several locations through the sample engines were calculated to provide indications of the required operating flow environment. Additional system consideration such a seals, joints, vehicle integration and in-service engineering are addressed.     

High speed propulsion: Performance advantage of advanced materials

High-speed air breathing propulsion systems have many attractive military and civil applications. The high propulsive efficiency of these systems allows the exploitation of speed, distance, and bigger payloads, or any combination of the three. The severe operating conditions of these systems require particular attention to overall thermal management of the engine/air-frame. Fuel-cooling the engine structure is a viable way of maintaining thermal balance over a range of flight conditions. Air Force applications have focused on using endothermic hydrocarbon fuels to address this issue because of their compatibility with the military operations. Recent ground tests of scramjet engines have demonstrated adequate performance utilizing state-of-the-art technology in materials. This progress has paved the way for an expendable flight test vehicle in the near future. In order to take full advantage of the capabilities of this propulsion system, advances in fuel-cooled structures, high temperature un-cooled materials, and increased heat capacity of hydrocarbon fuels will be needed to enable expendable systems to reach higher Mach numbers. An additional benefit would be realized in future reusable systems.     

An in situ TEM study of phase formation in gold-aluminum couples

In the gold wire bonding of aluminum in microelectronic devices the presence of aluminum oxide on the metallization surface may be expected. Electron transparent couples containing an oxide layer at the interface were heated in a TEM to determine the effects of a passivation layer on intermetallic formation. Intermetallic phases were evidenced by changes in sample appearance and their structure was determined by electron diffraction. The presence of an oxide at the interface hindered second phase formation at temperatures at which they were usually expected to form. In aluminum rich couples, the formation of the AuAl₂ intermetallic was not observed to form until about 350°C with the oxide present. In a reverse configuration involving a gold rich couple, an amorphous oxide phase was observed between the Al and the advancing Au₂Al front. The movement of the reaction front appeared to be controlled by surface diffusion across this phase.     

The mechanochemical processing of aerospace metals

The status of mechanochemical processing of aerospace metals (aluminum and titanium) is reviewed. It is demonstrated that the activation of chemical reactions by mechanical energy can lead to many interesting applications including production of advanced materials with novel constitutional and microstructural effects leading to enhanced mechanical properties.