The Role of Nanomaterials in Aerospace Heat Management Systems

By Ibtisam AbbasiReviewed by Lexie CornerJan 24 2025

Thermal management is essential for both civil and military aerospace systems to ensure high performance and extended operational durability of aircraft and spacecraft components.¹

Image Credit: Thiago B Trevisan/Shutterstock.com

At higher speeds, aircraft parts are exposed to elevated temperatures and exceptional thermal loads, making efficient heat management a critical requirement. In this context, nanomaterials are becoming increasingly important as they possess superior thermal properties and help maintain temperatures within safe limits.

Nanomaterial-Based Aerogels for Thermal Insulation

Aerogels developed using nanomaterials are extensively utilized for fabricating highly efficient lightweight insulation, especially for aircraft systems. Carbon nanotubes (CNTs), nanofibers, graphene, silver nanoparticles, and other 1D and 2D nanomaterials are being used to produce aerogels with superior mechanical and thermal properties.²

SiO₂ Aerogels

SiO₂ aerogels are a highly popular choice for thermal insulation due to their exceptional porosity and low specific gravity. However, at temperatures exceeding 700 °C, their internal bonds weaken, making reinforcement essential. Reinforcing SiO₂ insulations with polymeric or fiber composites is a common industrial practice.

A research study by Han et al. explored the use of 3D network modifier dimethyl-dimethoxy silane to reinforce SiO₂-based aerogel via a sol-gel process. This modification increased the pore volume by 100 % and reduced thermal conductivity from 0.3013 Wm⁻¹K⁻¹ to 0.02332 Wm⁻¹K⁻¹. During high-temperature testing over extended periods, the aerogel maintained its structural integrity at temperatures over 1000 °C,³ making it suitable for aerospace systems.³

Al₂O₃ Aerogels

Al₂O₃ aerogels are among the most important insulation materials for supersonic and hypersonic aerospace vehicles due to their excellent thermal stability.

Recently, researchers from China have developed an elastic aerogel with superior insulating properties by combining Al₂O₃ nano-rods with graphene sheets. This modern aerogel not only possesses improved thermal properties but also overcomes the brittleness typically observed in conventional Al₂O₃ aerogels.

During experimental testing, these aerogels demonstrated ultra-low thermal conductivity values of 0.0196 Wm⁻¹K⁻¹ at 25 °C and 0.0702 Wm⁻¹K⁻¹ at 100 °C.⁴ Al₂O₃ lightweight aerogels are, therefore, the preferred insulating material for high-speed aerospace systems.

Nano-Enhanced Phase Change Materials

Nano-enhanced phase change materials (PCMs) are widely used in space suits and deep-space exploration spacecraft as part of automatic thermal regulation systems. These nanomaterials ensure that operational temperatures remain within safe limits. In aerospace thermal control systems, phase-change nanomaterials play a critical role in managing electronics' thermal performance, storing thermal energy, functioning as thermal capacitors, and regulating temperatures in cargo containers.⁵

To develop nano-enhanced PCMs for aerospace applications, various types of nanoparticles are incorporated into PCMs. For instance, researchers have integrated alumina nanoparticles into tricosane PCM to cool electronic equipment aboard spacecraft. This innovation resulted in a 29 % reduction in temperature and approximately 45 % power savings on a modern spacecraft.⁶

Nanomaterial Applications for Aerospace Coatings

Ice-Repellant Coatings

Icing on aircraft surfaces poses a major hazard, significantly impacting safety and flight performance. With advancements in nanomaterials, the properties of icephobic coatings have improved drastically, substantially reducing ice adhesion on aircraft and spacecraft structures.

Experts have developed anti-icing coatings for aerospace structures by integrating silver nanoparticles with Zonyl 8740. Experimental ice adhesion testing results revealed that the incorporation of silver nanoparticles slowed the icing process by approximately six times compared to pure Zonyl coatings. Furthermore, for space stations, polydimethylsiloxane coatings incorporated with silica nanoparticles significantly reduce ice accumulation on power line insulation.⁷

Thermal Barrier Coatings

Thermal barrier coatings (TBCs) are essential for protecting metallic components operating at extremely high temperatures. They are crucial for ensuring durability and boosting the efficiency of gas turbine engines, such as jet engines, and their components, including turbines. TBCs play a vital role in preventing material damage due to extreme temperatures and thermal loadings, particularly on jet engine turbine blades, thus allowing for high energy conversion efficiency.⁸

An important method for depositing TBCs on aero-engine components is the Solution Precursor Plasma Spraying (SPPS) process. This technique involves the use of yttrium and zirconium salts, and by carefully regulating the parameters, the desired nanostructure for the coatings can be obtained. Similarly, another process called Suspension Plasma Spraying (SPS) has also been used for developing nano-TBCs. However, the SPS process is highly complex, and these nano-coatings have been found to exhibit micro-cracks in some cases.⁹

Nanomaterials for Heat Shields and Nano-Fluids

Heat Shields for Atmospheric Re-Entry

When space vehicles re-enter Earth's atmosphere, they experience intense aerodynamic heating due to their extremely high speeds. In this context, Thermal Protection Systems (TPS) play a vital role in safeguarding the spacecraft's surface and components. These systems incorporate nanomaterials within the matrix of carbon fibers to enhance their thermal properties.

In early 2024, researchers utilized nano-silica to develop high-quality, lightweight carbon fiber/phenolic ablators (CFPAs) to protect spacecraft from heating upon atmospheric re-entry. The incorporation of this nano-filler reduced the fracture strain from 31 % to 14 %.

Moreover, the addition of nano-silica significantly improved the thermal stability of the CFPA, especially under highly oxidizing conditions. The rate of thermal degradation decreased by 24 % after incorporating nano-silica, demonstrating its effectiveness in enhancing the CFPA's ability to function as a heat shield for aerospace systems during atmospheric re-entry.¹⁰

Nano-Fluids for Enhanced Thermal Conductivity

Researchers at NASA have found that adding metallic nanoparticles to aerospace TPSs improves their performance. These nanofluids significantly reduce the TPS's pumping power, thus contributing to energy-efficient operations and sustainability.

NASA experts have also incorporated aluminum oxide and copper oxide nanoparticles into the cooling fluid in the Orion spacecraft's cooling system.¹¹ The incorporation of nanofluids in aerospace systems allows for superior thermal conductivity, which is useful for extremely high temperatures, enhancing the durability of aerospace components.

Graphene in Aerospace Thermal Management

Graphene is an excellent choice for thermal management systems in aerospace applications, enabling efficient heat spreading and preventing electronic components and batteries from deteriorating under high operating temperatures.¹²

Researchers have found that graphene films exhibit outstanding thermal conductivity and remarkable flexibility. In a study by Peng et al., graphene, and polyimide (PI) were utilized to fabricate graphene films. The Young's modulus of the film was 15.1 GPa, while the film also demonstrated a superior tensile strength of 142 MPa. The thermal and electrical conductivity of the graphene films were found to be 1467 Wm^-1K^-1 and 1.8 × 105 Sm-1, respectively. 

These properties make graphene-carbon composite films a great choice for thermal management in modern aerospace vehicles and for regulating the operational temperature of avionics equipment.¹³

Challenges and Future Outlook: Refining Nanomaterials for Aerospace Innovation

Nanomaterials play a crucial role in modern industries, but several challenges still limit their widespread adoption, particularly in the aerospace sector. Developing nanomaterials often involves expensive processes and highly specialized equipment, making their use in complex industries like aerospace both costly and unsustainable.

Another significant hurdle is the lack of standardized methods for defining the technical specifications and integration of nanomaterials into existing materials. Additionally, environmental concerns associated with producing certain nanomaterials, such as graphene oxide nanosheets, further complicate their broader application. These obstacles collectively constrain the potential of nanomaterials to drive advancements in sustainable aerospace systems.

Despite these challenges, experts recognize the critical role nanomaterials can play in thermal management for aerospace applications. As a result, research into nanotechnology and nanomaterials continues to grow, with an emphasis on developing cost-effective and sustainable manufacturing methods that facilitate seamless integration with modern aerospace systems.

AI and advanced algorithms are proving to be valuable tools in this effort. For example, neural networks have been used by Khan et al. to analyze the performance of novel ferromagnetic nanofluids.¹⁴

Progress in manufacturing techniques, the development of standardization protocols, and the application of AI-driven methods are expanding the opportunities for nanomaterials in aerospace cooling systems. 2D nanomaterials like graphene are highly efficient and are now being produced using more cost-effective processes, making them a strong candidate for future heat management applications.

With ongoing advancements in technology, nanomaterials are expected to play an increasingly significant role in aerospace systems. To learn more about The Role of Nanotechnology in Modern Industry, please visit the following:

• Carbon Nanotubes for Energy Storage Applications
• Graphene Batteries: Market Trends and Growth Potential
• Advances in Thin-Film Electrolyte Membranes for Solid Oxide Fuel Cells

References and Further Reading

1. van Heerden, A., et al. (2022). Aircraft thermal management: Practices, technology, system architectures, future challenges, and opportunities. Progress in Aerospace Sciences. Available at: https://doi.org/10.1016/j.paerosci.2021.100767
2. Barrios, E., et al. (2019). Nanomaterials in Advanced, High-Performance Aerogel Composites: A Review. Polymers. https://doi.org/10.3390/polym11040726
3. Han, Y., et al. (2023). A three-dimensional network modifier (dimethyldiethoxysilane) makes ZrO2-SiO2 aerogel with excellent thermal insulation performance and high-temperature stability. Colloids and Surfaces A: Physicochemical and Engineering Aspects. https://doi.org/10.1016/j.colsurfa.2023.131716
4. Liu, F., et al. (2023). Ultralight elastic Al 2 O 3 nanorod-graphene aerogel for pressure sensing and thermal superinsulation. RSC advances. https://www.doi.org/10.1039/d3ra01070h
5. Diaconu, B., et al. (2024). Phase change materials in space systems. Fundamental applications, materials and special requirements–A review. Acta Astronautica. https://doi.org/10.1016/j.actaastro.2023.12.040
6. Nobrega, G., et al. (2024). A Review of Novel Heat Transfer Materials and Fluids for Aerospace Applications. Aerospace. https://doi.org/10.3390/aerospace11040275
7. Huang, X., et al. (2019). A survey of icephobic coatings and their potential use in a hybrid coating/active ice protection system for aerospace applications. Progress in Aerospace Sciences. https://doi.org/10.1016/j.paerosci.2019.01.002
8. Indhumathi, E. (2017). Synthesis of Nano Thermal Barrier Coating For Turbines In Aircraft Engines. International journal of scientific progress and research (ijspr). https://www.ijspr.com/citations/v24n4/IJSPR_2404_915.pdf
9. Li, Z., et al. (2021). Thermal barrier coating for aerial and aerospace engine. Inorganic and Organic Thin Films: Fundamentals, Fabrication and Applications. https://doi.org/10.1002/9783527344987.ch19
10. Xu, W., et. al. (2024). Nano-silica modified lightweight and high-toughness carbon fiber/phenolic ablator with excellent thermal insulation and ablation performance. Defence Technology. https://doi.org/10.1016/j.dt.2023.07.014
11. Ungar, E., et al. NASA/Johnson Space Center. Assessment of the Use of Nanofluids in Spacecraft Active Thermal Control Systems. [Online] American Institute of Aeronautics and Astronautics. Available at: https://ntrs.nasa.gov/api/citations/20110002800/downloads/20110002800.pdf [Accessed on: December 20, 2024].
12. Aftab, S., et al. (2019). Aerospace applications of graphene nanomaterials. In AIP conference proceedings. AIP Publishing. https://doi.org/10.1063/1.5094312
13. Zhu, Y., et al. (2021). Graphene–Carbon Composite Films as Thermal Management Materials. ACS Applied Nano Materials. https://doi.org/10.1021/acsanm.0c01754
14. Khan, S., et al. (2024). Innovative thermal management in the presence of ferromagnetic hybrid nanoparticles. Sci Rep. https://doi.org/10.1038/s41598-024-68830-9

Disclaimer: The views expressed here are those of the author expressed in their private capacity and do not necessarily represent the views of AZoM.com Limited T/A AZoNetwork the owner and operator of this website. This disclaimer forms part of the Terms and conditions of use of this website.