An exterior panel is formed of superplastic materials, including an exterior skin of titanium to accommodate high thermal stresses imposed on hypersonic transport vehicles during hypersonic flight. The exterior skin is fixed to an underlying reinforcing skeletal structure consisting of a superplastic formable reinforcement (SFR) layer, for example a titanium, zirconium, and molybdenum (TZM) alloy, which supports the exterior skin whenever the latter may be heated to temperatures exceeding 1200 degrees Fahrenheit. The exterior panel includes a separate interior skin configured for attachment to a frame member such as a rib, stringer, or spar of the hypersonic transport vehicle. A multicellular core is sandwiched between the exterior and interior skins to impart tensile and compressive strength to the exterior panel. In one disclosed method, the core is superplastic formed and diffusion bonded to the exterior and interior skins.

A hypersonic aircraft includes one or more leading edge assemblies that are designed to manage thermal loads experienced at the leading edges during high speed or hypersonic operation. The leading edge assembly includes a plurality of structural layers and a plurality compliant layers alternately stacked with each other to facilitate thermal expansion and movement between the plurality of structural layers, while also providing a thermal break between the plurality of structural layers.

A hypersonic aircraft includes one or more leading edge assemblies that are designed to manage thermal loads experienced at the leading edges during high speed or hypersonic operation. The leading edge assembly includes a plurality of structural layers and a plurality compliant layers alternately stacked with each other to facilitate thermal expansion and movement between the plurality of structural layers, while also providing a thermal break between the plurality of structural layers.

A hypersonic aircraft includes one or more leading edge assemblies that are designed to cool the leading edge of certain portions of the hypersonic aircraft that are exposed to high thermal loads, such as extremely high temperatures and/or thermal gradients. Specifically, the leading edge assemblies may include an outer wall tapered to a leading edge or stagnation point. A coolant supply provides a flow of cooling fluid to a porous tip that is joined to the forward end of the outer wall and defines variable porosity and/or internal barriers to direct a flow of cooling fluid to the regions of the leading edge experiencing the highest thermal loading.

A hypersonic aircraft includes one or more leading edge assemblies that are designed to cool the leading edge of certain portions of the hypersonic aircraft that are exposed to high thermal loads, such as extremely high temperatures and/or thermal gradients. Specifically, the leading edge assemblies may include an outer wall tapered to a leading edge or stagnation point. A coolant supply provides a flow of cooling fluid to a porous tip that is joined to the forward end of the outer wall and defines variable porosity and/or internal barriers to direct a flow of cooling fluid to the regions of the leading edge experiencing the highest thermal loading.

Methods, apparatus, systems and articles of manufacture are disclosed to prepare an aircraft surface, including depositing a first solution on a substrate on the aircraft surface, the substrate having a first charge, the first solution having a second charge opposite the first charge, the first solution including a carrier fluid, removing a first amount of the first solution deposited on the substrate to form a first layer on the substrate, depositing a second solution on the first layer, the second solution having the first charge, the second solution including the carrier fluid, and removing a second amount of the second solution deposited on the first layer to form a second layer on the first layer to prepare the aircraft surface.

A thermal insulation system for an aircraft is provided. The thermal insulation system includes a carrier and a container. The carrier has an interior surface including a first plurality of magnets that generate a first magnetic field, and an exterior surface that is thermally coupled to at least one high temperature component. The container is surrounded by the interior surface of the carrier, has an exterior surface including a second plurality of magnets that generate a second magnetic field oriented opposite the first magnetic field, and has an interior surface that is thermally coupled to at least one temperature sensitive component. The first magnetic field and the second magnetic field generate a gap between the carrier and the container to reduce a heat transfer from the at least one high temperature component to the at least one temperature sensitive component during operation of the aircraft.

Cable retainer apparatuses for retaining a cable, and aircraft and methods including such apparatuses are provided. In one example, a cable retainer for retaining a cable proximate a surface of an aircraft includes a cable retainer. The cable retainer is configured to retain the cable. A fairing is disposed about the cable retainer and is configured to couple to the aircraft to support the cable retainer adjacent to the surface of the aircraft.

An aircraft structure including a heat shield. A heat shield including an interior; a skin enclosing the interior; a plurality of barriers attached in the interior to the skin, each of the barriers spaced to separate a plurality of thermal insulation layers disposed in the interior; and wherein the barriers suppress heat flow between the thermal insulation layers.

An aircraft structure including a heat shield. A heat shield including an interior; a skin enclosing the interior; a plurality of barriers attached in the interior to the skin, each of the barriers spaced to separate a plurality of thermal insulation layers disposed in the interior; and wherein the barriers suppress heat flow between the thermal insulation layers.