Materials

Mission — Materials for Structures, Propulsion, and Subsystems source

This project develops and transitions materials and processing technologies to enhance the affordability, maintainability, and performance of current and future Air Force weapon systems. A key focus is affordable, lightweight materials for aircraft, spacecraft, missiles, and propulsion systems. These materials include metals, polymers, ceramics, metallic and nonmetallic composites, and hybrid materials, designed to improve the structural and performance of existing systems and to address future system needs. Key features of the materials and structures being developed are that they have improved ablation and oxidation resistance, structural integrity, thermal management capabilities, and strength to weight ratios. These attributes enable expanded mission capability for missile and aircraft systems. New processes are developed to provide more affordable solutions while maintaining the performance of fielded and future operational systems. To maintain the performance of fielded systems, the project develops alternative or replacement materials that address obsolescence challenges. The project develops advanced processing methods to enable adaptive manufacturing of aerospace materials.

Mission — Materials source

The Air Force Research Laboratory (AFRL) is focused on high-impact, multi-domain science & technology (S&T) solutions that drive innovation now while laying the groundwork for the Air and Space Force to win the future fight. AFRL effectively synchronizes the Department of the Air Force (DAF) S&T enterprise and workforce to align towards the most consequential DAF priorities and accelerate the delivery of game-changing S&T. This program develops advanced materials, processing, and inspection technologies to reduce life cycle costs and improve performance, sustainability, availability, affordability, supportability, reliability, and survivability of current and future Department of the Air Force systems and operations. The program has three projects that develop: structural, propulsion, and sub-systems materials and processes technologies; electronic, optical, and survivability materials and processes technologies; and sustainment materials, processes technologies, and advanced non-destructive inspection methodologies. Efforts in the program have been coordinated through the Department of Defense Science and Technology Executive Committee process to harmonize efforts and eliminate duplication. Funds in this PE may be used to investigate specified technology advancements in air, space and/or cyber domains. This program includes funding for the requisite DAF Science & Engineering (S&E) and mission enabling civilian workforce with the necessary technical competencies to develop, manage, and deliver science & technology capabilities. The use of program funds in this program element is in conjunction with the civilian pay expenses budgeted in the following program elements: 1206601SF, 1206616SF, 0601102F, 0602020, 0602202F, 0602203F, 0602204F, 0602298F, 0602336F, 0602602F, 0602605F, 0602788F, and 0603680F. In FY 2026, $68.328 million is budgeted in this program for 333 direct Full-Time Equivalent (FTE) civilians. The Air Force Research Laboratory (AFRL) utilizes 10 USC 4091, "Authorities for certain positions at science and technology reinvention laboratories” to manage the workforce strength, structure, positions, and compensation. This program element may include necessary expenses to support the operation and maintenance of facilities to manage, execute, and deliver science and technology capabilities. This program is in Budget Activity 2, Applied Research because this budget activity includes studies, investigations, and non-system specific technology efforts directed toward general military needs with a view toward developing and evaluating the feasibility and practicality of proposed solutions and determining their parameters.

Mission — Materials for Electronics, Optics, and Survivability source

This project develops materials technologies for the Department of the Air Force's Intelligence, Surveillance, and Reconnaissance (ISR), situational awareness, and specialty coatings for aerospace platforms and munitions. This includes sensors for microwave, short, mid, and long-wave infrared (SWIR, MWIR, LWIR) detection and countermeasures devices used for targeting, electronic warfare, and active aircraft protection. Electronic and optical materials are being developed to enable surveillance and situational awareness with faster operating speeds, greater tunability, higher power output, improved thermal management (including higher operating temperatures), greater sensitivity, and extended dynamic range. This project develops materials for protection of aircrews, sensors, and aerospace structures from directed energy threats without impairing mission effectiveness. Nanostructured and biological materials are being developed for aerospace structures, munitions, aerospace vehicle subsystems, and personnel.

Mission — Materials Technology for Sustainment source

This project develops materials and processing technologies to support operational Department of the Air Force mission areas by providing the ability to inspect the quality of delivered systems, transition more reliable and maintainable materials, establish a capability to detect and characterize performance threatening defects, characterize materials processes and properties necessary for materials transition, and provide quick reaction support and failure analysis to the operational commands and repair centers. Repair techniques and nondestructive inspection/evaluation (NDI/E) methods are developed that are needed for metallic and non-metallic structures, coatings, corrosion control processes, and to support integration of composite structures for aerospace systems. Various NDI/E methods are essential to ensure optimum quality in the design and production of aircraft, propulsion, and missile systems. These NDI/E methods are also essential to monitor and detect the onset of any service-initiated damage and/or deterioration due to aging of operational systems.

Accomplishments & Planned Programs (11)