Cerablak Composites for Next Generation Radomes

Applied Thin Films Inc

1801 Maple Ave
Evanston, IL 60201

INSERT IMAGE HERE

Contact: Benjamin Mangrich

Phone: (847) 287-6292
Fax: (847) 491-3997
Email: bmangrich@atfinet.com
Website: www.atfinet.com
Command: NAVSEA
Topic: N03-080

PROBLEM STATEMENT
Continuous development of high speed missiles and vehicles is required to keep pace with
ever increasing global threats. Next-generation hypersonic missiles and unmanned
vehicles, capable of Mach 5+ speeds, will provide the desired reach and ability for rapid
deployment. One critical component of such aircraft is the radome that provides structural
and thermal protection to the guidance system without disrupting signal. Due to the high
speeds during flight, extreme thermal and structural effects of aerothermal heating
(>1300C), are anticipated, as well as particulate and rain erosion. There are few materials
that can withstand this kind of abuse while maintaining electromagnetic transparency to
high temperatures. While there are many high-temperature structural materials, most suffer
from significant dielectric loss at high temperatures, disrupting accurate guidance.
The most common current radome material used is Pyroceram, but it is being phased out of
production, and it does not meet the dielectric property requirements for next generation
radomes. Other materials such as fused silica and silicon nitride are being developed for
radome applications, but they all have significant downfalls. Fused silica has good electrical
and thermal properties, but poor mechanical properties, while silicon nitride-based
materials offer high strength, but lack the necessary electrical and thermal properties.
Applied Thin Films Inc (ATFI) is developing advanced ceramic materials based on a
technology called Cerablak which has shown exceptional electrical properties at high
temperature due to its unique, stable amorphous structure. Cerablak -based composites
can offer the right combination of electrical, thermal, and mechanical properties to meet the
need for next generation missiles.

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WHO CAN BENEFIT?

There are many potential benefactors of new high temperature materials. For radome
applications, The US Navy, Army, Air Force and Missile Defense Agency are all seeking
improved capability for hypersonic missiles (i.e. SM-3, PAC-3, AIM-120, SM-6), which
require better materials. In addition, unmanned guided vehicles have similar requirements
for electromagnetic windows (radomes), broadening the horizon for Cerablak
technology. In addition to the defense sector, the commercial aerospace industry is
constantly seeking new, cutting-edge, high temperature materials that combine highstrength and electromagnetic transparency. Thus, the maturation of Cerablak composite
materials will be of considerable benefit to both defense and the commercial aerospace
industry for a many potential applications.
BASELINE TECHNOLOGY
There is no currently available material for hypersonic radomes, which is why this is such
an important technology to develop. There are, however, radome materials used on existing,
lower speed missiles that can be treated as a baseline. The most common missile radome
material is Pyroceram, a glass-ceramic material made by Corning. Production for this
material has been terminated and much of the effort is going into development of new
materials. The key challenge for this development is the requirement for a combination of
electrical, mechanical and thermal properties, as well as low density, which is always a
concern for flight-based applications. Electrical property requirements stem from the need
for radar transparency, and include low dielectric permittivity and loss tangent. Mechanical
property requirements are due to the need for structural integrity to withstand the severe
thermal gradients experienced during flight/aerothermal heating and protection of the
guidance system, with a key metric being flexure strength. Good thermal properties are
required due to the high temperatures during flight (up to 1350C), and extreme
temperature changes (high thermal shock). Table 1 below compares the radome material
property requirements with the properties of the baseline material (Pyroceram), as well as
other materials under consideration (fused silica and silicon nitride), and highlighted in
yellow are the properties for Cerablak composites.
Properties of baseline and potential radome materials, along with requirements
Properties
Density (g/cc)
Dielectric
Permittivity
(e)
Loss Tangent
Flexural
Strength

Performance Pyroceram
Cerablak
Requirement (Baseline)
<3
2.6
2.1

Fused
Silica
3.2

Silicon
Nitride
2.5- 3.2

<5

8.1

3-5

3.3

6-8

< 0.002

.001

.001

.003

.002

> 150

240

180

43

100-800

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(MPa)
CTE
(ppm/C)
Conductivity
(W/m K)

>1 and < 10

0.7

3.2

<5

3.3

<1

0.8

6-25

TECHNOLOGY DESCRIPTION
Cerablak, a platform material technology, is a new nano-scale designed ceramic material
that represents a revolutionary development in ceramics. Much of the commercialization
efforts are focused toward a thin film product form which is pin-hole free, hermetic, and
transparent and can be deposited on wide range of substrates. Such films have use in
providing electrical insulation, high temperature protection of components used in
aerospace and energy industries, and as a diffusion barrier in electronic and other industrial
applications. Cerablaks attributes are well suited for radome applications and
unmatched by any other advanced ceramic material under consideration for radome
applications. In particular, the exceptional dielectric properties of Cerablak enable
excellent electromagnetic transparency and can thus accommodate a wide variety of radome
designs.
Cerablak is based on amorphous aluminum phosphate composition with a glass structure
that is stable to > 1400C. This unique structure enables properties such as low dielectric
loss, as well as low moisture and gas diffusivity, and chemical inertness. A summary of the
salient features, advantages and benefits of Cerablak for radome applications given in the
table below.
Key features, advantages and benefits of Cerablak
Features
Advantages
Benefits
Low Dielectric
Electromagnetic
Uninterrupted guidance signal
Permittivity and Loss
transparency
High Flexure Strength and Provides structural
Protects guidance system from
Fracture Toughness
integrity
damage
Low Thermal
Insulates embedded
Prevents guidance system from getting
Conductivity
electronics
too hot
3
Low density (2.2 g/cm )
Weight savings
Maximizes fuel efficiency
Will not corrode or
Survives extreme environmental
Chemically Inert
oxidize
conditions

Cerablak is made by a low cost, solution derived process, involving a environmentallyfriendly precursor solution (alcohol or aqueous based) and does not contain any heavy
metals or environmental pollutants. It was originally developed as a protective thin film to
protect surfaces from oxidation and corrosion at high temperatures. It can now be made into
bulk solids such as monolithic ceramics, or ceramic matrix composites (which offer
additional advantages such as higher toughness and strength), as well as thermally stable

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solid or hollow glass microspheres. All of these product forms are shown in the figure
below.
Product forms of Cerablak

Microspheres

Composites

Nextel 720
Cerablak CMC

20 m

Bulk Ceramics

Thin Film

CURRENT STATE OF DEVELOPMENT

Under the current SBIR program, a new Cerablak based composite material has been
developed using a scalable process that has demonstrated properties desired for radome
applications. Critical property requirements have been met, including adequate flexure
strength and low dielectric permittivity. This opportunity to develop bulk Cerablak
ceramic materials have significant implications for its broad use in other applications
including refractories, aerospace, and space vehicles.
In addition to the advancements of Cerablak composite materials, a wide range of other
product forms based on Cerablak technology (shown in the previous figure) have been
developed under other programs at ATFI. For example, ultra-lightweight hollow
microspheres made from Cerablak are now available that offer excellent thermal stability
and chemical compatibility with other ceramic constituents. These microspheres may be
useful to improve upon the good results for making Cerablak composites.

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TECHNOLOGY AVAILABILITY
The path towards maturation of this important technology involves developing innovative
and efficient manufacturing processes, along with continued testing and product
qualification along the way. CerablakTM advanced ceramics and composites will become a
robust and mature technology able to solve critical problems for the military as well as
various commercial needs. The specific steps necessary to mature this technology are
primarily related to developing component manufacturing processes, as well as testing and
qualification of prototype materials.
To build off of the excellent progress towards materials developing for radome applications
to date, the next steps for this project will include a) continued optimization of
microstructure and material properties, b) processing scale up (fabrication of composite
panels using optimized, near-net shape processing, b) performance testing of panels under
simulated environments, including rain erosion and c) fabrication of full-size prototype
radome and subsequent flight testing. A technology readiness level of TRL5 is expected to
be achieved by the end of the current Phase II program, as well as a demonstrated
preliminary manufacturing process. The momentum for transition toward full-scale
production after the Phase II can be enhanced significantly by program office and
commercial participation through FY09. ATFI will be seeking partners to fund prototype
flight testing, which will increase the TRL to level 8, and enable the technology to be ready
for acquisition by FY09.
Technology development timeline Includes current SBIR effort and beyond:
Expected Required
Timeline
Milestone
TRL Measure of Success
date
Funding
Phase IICoupon fabrication
Electrical and
4
09/2006
$250K
Year 1
and testing
Mechanical Properties
Phase IISub-scale Prototype
End - shape
5
09/2007
$500K
Year 2
Fabrication
component
Phase III - Full Scale Prototype
Working Prototype
6
09/2008
$1.5M
Year 1,2
Development
with desired properties
Phase III Simulated
7
Testing Results
09/2009
$500K
Year 2
Operational Testing
Phase III
Flight Testing
8
Testing Results
09/2010
$1M
Year 3
Phase III
Production
Production Capability
8-9
12/2010
$3M
Year 3,4
Readiness
(1000 Units)
REFERENCES
Dr. Sankar Sambasivan, the Founder and President of ATFI has over 15 years experience
developing solution based ceramics for composites and has served as lead advisor for the
current project. Dr. Cutis Martin at the Naval Surface Warfare Center (NSWC) has been
developing ceramic materials for radomes for over 10 years, and has provided critical
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technical guidance throughout this initiative. Andy Facciano of Raytheon Missile Systems
(Tucson, AZ) is an active partner in the Phase II project and has provided critical technical
support.

Dr. Curtis Martin

Andy Facciano

Dr. Sankar Sambasivan

Ceramic Science Group

Senior Principle Engineer

President and CEO

NSWCCD, Code 617

9500 MacArthur Boulevard
Bethesda, MD 20817-5700
curtis.a.martin@navy.mil
301-227-4501 (tel)
301-227-4732 (fax)

Raytheon Missile Systems,

1151 E. Hermans Rd.
Tucson AZ, 85734
abfacciano@raytheon.com
520-794-9532 (tel)

Applied Thin Films, Inc.

1801 Maple Ave, Suite 5316
Evanston IL, 60201
sankar@atfinet.com
847-287-6291 (tel)
847-491-3997 (fax)

ABOUT THE COMPANY

Founded in 1998, Applied Thin Films, Inc. (ATFI) is a leader in the development of
nanoscale-designed novel thin film and ceramic technologies to serve defense, energy,
aerospace, and other industrial needs. With a highly qualified team including chemical and
material science engineers and chemists (3 PhDs, 3 BS Engineers, 2 BS Chemists), at the
core, ATFI is a specialty chemicals company offering unique solutions to enhance
performance of metals, glass, ceramics, and plastics in various applications exposed to
harsh environmental conditions. ATFI is poised to exploit its patented (two US patents
issued and several pending) flagship product, Cerablak, across several military and
commercial applications. ATFI intends to commercialize these products through strategic
partnerships/licensing and generate revenue through sale of raw materials and know-how.
Cerablak, which was cited as one of the top ten new advanced materials in the market in
a recent study by Frost & Sullivan, is a platform material technology offering various
product forms including thin film, microspheres, and bulk material structures. Thin films of
Cerablak are the current focus of our commercialization efforts that promises a
sustainable competitive advantage for our customers. Cerablaks unique footprint can be
attributed to the high quality films derived on a large-scale on complex-shaped substrates
that offer excellent thermal stability.
Due to the versatility and ease of applicability of Cerablak, ATFI has attracted significant
interest across wide range of in military and commercial customers. Over $5M in R&D
funds have been received from sponsors including MDA, AF Navy, Army, NASA, NSF
and DOE to enable the development of Cerablak as a validated product with a
comprehensive intellectual property portfolio.
DoD applications currently under
development via SBIR funding include protection of engine components for the JSF
program, development of next-generation hypersonic missile radome materials for the US
Navy, protection of magnesium used in IR flares, and thermal protection systems for
hypersonic vehicles and missiles. ATFI is closely engaged with a number of DoD prime
contractors including Raytheon, Boeing, GE, Pratt & Whitney, and Lockheed Martin, thus
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poised to explore Phase III transition in 2007. ATFIs industrial customers include several
Fortune 500 companies interested in a broad range of applications including aerospace
(protection of turbine components), metal casting (protection against molten metal),
electronic displays (enabling use of lower-cost substrates), appliances (protection of
cooking ranges), and many other proprietary applications.

Applied Thin Films Inc

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