Aerospace and Defense
What we do for the Aerospace and Defense Industries
Plasma Processes offers engineered materials solutions meeting demanding performance criteria, stringent quality requirements, and challenging schedules to our aerospace and defense customers. We strive to reduce the total cost of ownership through implementation of novel materials and unique processes. Plasma delivers prototype through high-rate production quantities (>10,000 piece parts per month). We have been certified to manned, space, and other types of aerospace processes for our services and products.
Plasma is set up to be a leader in engineered high-performing material solutions for products in extreme environments as it relates to aerospace and defense products. We help transition these technologies through product development into commercialization and high-rate production. We strive to save our customers time and money by having thorough engineering reviews focused on design for manufacturability (DFM) which has led to us producing some products at rates up to >10,000 piece parts per month. We also are proud to support DOD, academia, research institutions, and our partners in coatings, fabrication of components, and more. Our customer base consists of Lockheed Martin, Aerojet Rocketdyne (L3Harris), Northrop Grumman, Raytheon, and even agencies such as USAF, Army, Navy, and NASA. Our efforts serve initiatives such as Long-Range Precision Fires (LRPF), SDA, Golden Dome, Green Propulsion (including dual mode), and more. We are certified to AS9100, ISO9001, obtaining NADCAP, and follow all customer specifications and requirements.
Propulsion Components
Plasma has a history of fabricating components for different types of engines and vehicles over its 30+ years where we can suggest the right materials, processes, and designs in order to best meet our customers performance and quality requirements.
Liquid Rocket Engine Subcomponents and Coatings
- Radiation Cooled Combustion Chambers
- Non-toxic Green Propellant Combustion Chambers
- Regeneratively Cooled Combustion Chambers
- Injector and Faceplate Coatings
- Catalyst Beds and Igniters
- Nozzle Extension Coatings
Solid Rocket Motor (SRM) Subcomponents and Coatings
- Refractory Metal Subcomponents
- Ultra-High Temperature Ceramic (UHTC) Subcomponents
- Composite Material Subcomponents
- Solid Divert and Attitude Control System Subcomponents
- Hot Gas Valve Components
- Pintles, Throats, Non-Eroding Throats, Thrust Chambers, Nozzles, and more
Commercial Aerospace
- Machining: Plasma has acquired more machining capabilities to produce commercial and DOD focused components
- El-Form® and 3D Printing: Plasma provides unique additive manufacturing (AM) capabilities to build propulsion components using our in-house El-Form® process along with standard laser powder bed fusion (LPBF) 3D-printing services. We build things like electrodes, ignitors, brackets, and more, sometimes up to quantities of >10,000 piece parts per month, using our El-Form process and can provide both small and large products
Protective Coatings
Plasma Processes provides radiation shields for protection against galactic cosmic rays, solar energetic particles and secondary neutrons. Durability samples, mounted for passive exposure on the International Space Station, have been tested on Materials International Space Station Experiments (MISSE) 6.
Thermal Protection Systems (TPS)
Plasma Processes offers Thermal Protection Systems (TPS) for space vehicles to protect them from aerodynamic heating. Our TPS solutions feature high-temperature capability in combination with underlying thermal insulation to inhibit the conduction of heat to the interior of the vehicle
Thermal Barrier Coatings (TBC)
Plasma Processes applies thermal barrier coating systems designed to insulate components from prolonged heat loads. These coatings allow for higher operating temperatures while limiting thermal exposure, oxidation and thermal fatigue
Corrosion / Erosion Protection
The U.S. General Accounting Office estimates the cost of corrosion to the Department of Defense between $9 billion and $20 billion annually. In some agencies, corrosion maintenance represents 20% of the entire budget. Plasma Processes offers commercial, off-the-shelf solutions to combat a wide variety of corrosion issues. We also tailor programs to investigate, apply and validate corrosion solutions for metals, plastics, polymers and other substrates
Emissive Coatings
Plasma Processes provides emissive coating solutions to properly dissipate thermal energy from the component. Emissive coatings are tailored to the substrate and environment, are able to withstand combustion by-products and the hard vacuum of space, and avoid distortion commonly associated with high-temperature heat treatments that can oxidize the surface
Environmental Barrier Coatings (EBC)
We offer protection for products going to high temperatures, through or long-standing in rain, sand, cold, oxidation, and/or other extreme scenarios
High-Speed Materials
Plasma Processes provides leading edge, nosetip, and engine thermal management materials solutions for hypersonic RAMJET/SCRAMJET, RDE, space travel, and other types of vehicle components and projectiles operating at speeds above Mach 5, 10, and even 20 while also traveling through extreme environments
Ablative, Abrasive, Durability, and Other
Plasma possesses expertise in delivering advanced solutions for critical components such as turbine blades, engines, motors, and more. We leverage a range of protective technologies including ceramic, silicone, carbides, nitrides, and other ablative materials to mitigate wear and extend the life of parts operating in extreme environments. These solutions are designed to safeguard components subjected to high cycles, intense stresses, and other demanding conditions where durability and reliability are essential.
Advanced Surface Aircraft Component
Aircraft engine manufacturers such as General Electric, Pratt & Whitney and Rolls Royce are the largest users of thermal spray coatings. Plasma Processes is able to meet the stringent coating specifications of these manufacturers.
Thermal Management
Emissive Coatings
Plasma Processes provides emissive coating solutions to properly dissipate thermal energy from the component. Emissive coatings are tailored to the substrate and environment, are able to withstand combustion by-products and the hard vacuum of space, and avoid distortion commonly associated with high-temperature heat treatments to oxidize the surface
Hypersonic Materials
Plasma Processes provides leading edge and nosetip thermal management materials solutions for hypersonic vehicle components and projectiles operating at speeds above Mach 5, 10, and even 20.
Thermal Barrier CoatingsÂ
Plasma Processes applies thermal barrier coating systems designed to insulate components from prolonged heat loads. These coatings allow for higher operating temperatures while limiting thermal exposure, oxidation and thermal fatigue.
Thermal Protection Systems
Plasma Processes offers Thermal Protection Systems (TPS) for space vehicles to protect them from aerodynamic heating. Our TPS solutions feature high-temperature capability in combination with underlying thermal insulation to inhibit the conduction of heat to the interior of the vehicle.
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Lastest Articles
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SAN FRANCISCO – Rubicon Space Systems won a NASA contract to develop a 110-newton
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Plasma Processes’ green propellant technology was showcased in the Missile Defense Agency’s Tech Update,