What sealing materials, methods, and technologies are available for hypersonic vehicles?

A Diagram of Elevons That May Be Used on Hypersonic Weapon Systems
A Diagram of Elevons That May Be Used on Hypersonic Weapon Systems (Source: D. Motes).

Posted on June 25, 2025 | Completed on April 30, 2025 | By: Doyle T. Motes III

What sealing materials, methods, and technologies are available for hypersonic vehicles?

The Defense Systems Information Analysis Center (DSIAC) received an inquiry regarding the state of materials and methods available for sealing the external joints in the outer mold line and the engines of U.S. Department of Defense hypersonic weapon systems. In this technical inquiry response report, DSIAC subject matter experts provide a discussion of the needs for the seals and what materials and methods are available based on publicly available information and references.

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