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Hypersonics

Advanced materials have been an integral part of Battelle’s DNA for the entirety of our 90+ years. When materials are traveling upwards of 20 times the speed of sound, you want an agile organization that has the knowledge and capability to move as fast as the materials that we're developing.
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Materials and Technologies for Extreme Environments 


Developing solutions for hypersonic systems requires world-class expertise in materials and systems engineering. Battelle’s innovative edge in advanced materials development and system prototyping is unmatched. Our agile approach reduces development lead times and our ability to work in ITAR and classified environments, while maintaining the highest levels of security, makes Battelle the ideal partner in hypersonics.

Specialized Capabilities and Facilities



  • Graphitization Furnace (3,000 °C)
  • Autoclave (300 °C, 200 psi)
  • Pyrolysis Furnace
  • Oxidation Furnace (1,600 °C)
  • Finite Element Analysis (FEA)
  • Computational Fluid Dynamics (CFD)
  • Molecular Dynamics (MD)
  • Quantum Mechanics/Molecular Mechanics (QM/MM)
  • Dissipative Particle Dynamics (DPD)
  • Density Functional Theory (DFT)
  • Quantitative Structure Property Relationships (QSPR)
  • High-Performance Computing Center (HPC)
  • Thermogravimetric Analysis (TGA)
  • High Temperature/Pressure (HT/HP-TGA)
  • Differential Scanning Calorimetry (DSC)
  • High Pressure Differential Scanning Calorimetry (HP-DSC)
  • Dynamic Mechanical Analyzer (DMA)
  • Rheometer
  • Nuclear Magnetic Resonance (NMR) with Solid State Capability, Magic Angle Sample Spinning (MASS)
  • Micro-Raman System with In-House Deconvolution for Carbon
  • Laser Ablation Test System with In-Situ Thermal Measurement
  • High Resolution Scanning Electron Microscope (SEM) with Energy Dispersive Spectrometer (EDX) and Electron Backscatter Diffraction (EBSD)
  • Polarized Light Microscopy (PLM)
  • Focused Ion Beam Scanning Electron Microscope (FIB/SEM)
  • X-Ray Diffraction (XRD), Small Angle X-Ray Scattering (SAXS), Pole Figure (texture analysis)
  • Adsorption Surface Area and Pore Size (BET)
  • Rheometer
  • Multi-Purpose Facility Supports Ballistic and Static Tests, 25 pound Limit
  • Press, Cast-Cure and and Melt-Cast Loading of Explosives
  • HME Synthesis
  • High-Speed Photography
  • Flash Radiography
  • PDV

Our Products and Services

To support the national need, Battelle is making investments to develop and deploy technologies for hypersonic applications. This includes carbon-carbon composites, ceramic matrix composites and monolithic materials for structural, anti-ablation/oxidation and sensing applications. The solution to these complex problems lies not in just the materials, but in the system built from these materials. Battelle is developing the supporting technologies and infrastructure for system level modelling, design, development and testing.
Designed for use in extreme environments, Battelle’s carbon-carbon composites have exceptional thermal protection.  From selective laser carbonizing of materials, where the benefits of refractory carbon-carbon composites are combined with structural capability of polymer matrix composites, to traditional carbon-carbon processing, Battelle supports the industry with state-of-the-art prototyping capability.
An IR window must remain both structurally sound and IR transparent. Battelle technology is leading to new approaches to this high-temperature thermal shock problem. We see it as a system problem where the window must interact synergistically with the structure to maintain integrity throughout the mission. 
Integrated Computational Materials Engineering approaches at Battelle enable digital prototypes at early development stages to develop alongside experimental prototypes. Our modeling approach for carbon-carbon begins with detailed process modeling including simulations of reactive flowing media, resin infusion and thermally-activated densification steps. Models of thermal stress, strain, fractures and ablation follow to determine their performance metrics.
Battelle’s High Energy Research Laboratory Area (HERLA) provides extensive energetic and hazardous material RDT&E services to address the most challenging problems facing the country. The HERLA is well suited for the design, development, prototyping, evaluation and scale-up of primary and secondary explosives, EFI initiators, propellants, pyrotechnics, high-voltage, reactive-gas and other energetic related systems. Battelle’s indoor detonation facilities can accommodate detonation experiments from the gram-scale up to 50 pounds of TNT. High-speed data acquisition, including photon Doppler velocimetry (PDV), thin-film pressure and time of arrival gauges, high-speed imaging, and flash radiography are available along with numerous other specialized instrumentation and sensors.

Related Expertise

Our Experts


Brent Carey

Oct 20, 2021, 07:59 AM
Title : Brent Carey
Name : Brent Carey
Position : Campaign Lead
Brent leads Battelle's Hypersonics campaign and serves as the principal investigator for the Air Force Research Laboratory’s MOC3HA program,  strengthening the C/C composite industrial base for hypersonic systems.
Brent Carey, Battelle hypersonics lead
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