8/13/2019 nebiolo

1/18

16/05/2013

Ref.:

83230913-DOC-TAS-EN-002

Composite Materials in Aerospace

Italian Association of Science andTechnology: XXI Conference

Catania, Italy 15th-17st May 2013

8/13/2019 nebiolo

2/18

This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed

to any third party without the prior written permission of Thales Alenia Space - 2013, Thales Alenia Space

16/05/2013

2

Ref.:

Aerospace Composites

Aerospace Main Design Drivers for Composites

A rough distinction can be made as follows:

Aeronautics: design primarily driven by strength &fatigue

Space: design primarily driven by stiffness to avoidcoupled resonant responses (e.g. between a satellite

and its launcher) and long term on-orbit environment

Common: mass optimization effort to maximize theembarked payload (aerospace), reduce fuelconsumption (aircrafts)

The different design needs address the choice of

different composite materials (fibers & resin systems) for

aircrafts and space structures

ENVISAT: a European Earthobservation satellite for environment

monitoring (8200 kg)

Boeing 787 50 % composite

8/13/2019 nebiolo

3/18

This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed

to any third party without the prior written permission of Thales Alenia Space - 2013, Thales Alenia Space

16/05/2013

3

Ref.:

Drawbacks

Material cost (recurring & nonrecurring,storage and expiring)

Low thermal & electrical conductivity

(solvable with use of conductive fibers)

Properties of structural laminates tendto deteriorate due to environmental

conditions (transportation, prelaunch,launch)

Strong concurrent design to

manufacturing & tooling required

NDI: more complex wrt metals, widevariety of defectology

Repair: complex to recover structuralintegrity, impact damage visibility

Advantages

Light Weight (Specific Strength/Stiffness)

Low Coefficient of Thermal Expansion

Low Thermal & Electrical Conductivity

Tailorable Thermo-Mechanical properties in

terms of:

Fibers (type, diameter, UD, fabrics)

Resin Systems Polymeric Matrix

Mix Resin/Fiber

Lay-up sequence & number of plies

Reduced machining (mostly limited tocutting & holing)

Aerospace Composites Main Pros & Cons

8/13/2019 nebiolo

4/18

This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed

to any third party without the prior written permission of Thales Alenia Space - 2013, Thales Alenia Space

16/05/2013

4

Ref.:

Aerospace Main Fiber Typologies for Composites

The composite materials fiber typologies:

7090

70

180

120

60

> 450

350 450

200 350

8/13/2019 nebiolo

5/18

This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed

to any third party without the prior written permission of Thales Alenia Space - 2013, Thales Alenia Space

16/05/2013

5

Ref.:

Aerospace Main Resin Typologies for Composites

The composite materials typologies vs temperatures:

Epoxy for normal use where high stability and release ofchemicals does not affect the performance, max workingtemperature of 150 C for 180 C curing systems

Cyanate Esters superior thermal stability, low out-gassing, low moisture absorption, radiation resistance

Bismaleimidic up to about 250 C due to high Mach orengines exhaust impingement (mostly aeronautic use: e.g.F22 Raptor Wings, C-17 Aft Flaps Hinge Fairing Structure,A330 Thrust Reversers, Formula 1 Racing Cars)

Polyimide up to about 330 C (e.g. aircrafts enginesnacelles)

Satellites & Aircrafts

Satellites

Aircrafts & Space Re-Entry

Vehicles

Aircrafts & Space Re-

Entry Vehicles

8/13/2019 nebiolo

6/18

This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed

to any third party without the prior written permission of Thales Alenia Space - 2013, Thales Alenia Space

16/05/2013

6

Ref.:

Composite Application in Space

Composite in Space Manned Applications

ISS Manned modules applications, limited to internal secondary structures & external

equipment

Equipment Racks in Manned Structures (Epoxy CFRP)

External Payloads (Epoxy CFRP)

Deployable Booms (Kevlar Epoxy)

8/13/2019 nebiolo

7/18

This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed

to any third party without the prior written permission of Thales Alenia Space - 2013, Thales Alenia Space

16/05/2013

7

Ref.:

Composite Application in Space

Composite in Space Manned Applications

Thermal Decoupling Washers (GFRP) for MDPS (Micro Meteoroids & DebrisProtection System) panels attachment points

GFRP Washer in MDPSpanels attachment points

8/13/2019 nebiolo

8/18

This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed

to any third party without the prior written permission of Thales Alenia Space - 2013, Thales Alenia Space

16/05/2013

8

Ref.:

Composite Application in Space

Composite in Space Unmanned Applications

Satellite Primary Structures & Structural Components

Launchers Inter-stage Structures, Engine Thrust Cones,

Fairing, Adapters

Platforms and Benches for Optical

Solar Arrays

Antenna Reflectors

Truss Structures

Overwrapped Tanks

Solar Arrays

Antenna Reflectors

Launcher Parts

Truss Structures

8/13/2019 nebiolo

9/18

This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed

to any third party without the prior written permission of Thales Alenia Space - 2013, Thales Alenia Space

16/05/2013

9

Ref.:

Aerospace Composite Configurations

Aerospace Composite Configurations

Typical configurations given by:

Solid Laminates (mostly for high strengthapplications e.g. wing panels, fuselage segmentsin aircrafts, corrugated panels, struts)

Sandwich (mostly for high stiffness applicationse.g. aircrafts floor panels & control surfaces,satellite primary structures)

B787 Composite Fuselage Segments

Sandwich in Satellite Primary Structures

CFRP Wing Panels

8/13/2019 nebiolo

10/18

This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed

to any third party without the prior written permission of Thales Alenia Space - 2013, Thales Alenia Space

16/05/2013

10

Ref.:

Satellite Structure Typical Configuration

The satellite structural configuration is here represented

and is typically based on a sandwich panels assembly with

Al or CFRP skins and Al Honeycomb:

Thrust Cone/Cylinder connected to the spacecraftadapter

Shear Panels

Lateral Panels

Top & Bottom Closure Panels

Satellite Primary Structure

Satellite with Subsystems

Satellite in Flight

Composite Application in Space

8/13/2019 nebiolo

11/18

This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed

to any third party without the prior written permission of Thales Alenia Space - 2013, Thales Alenia Space

16/05/2013

11

Ref.:

Versatility of Sandwich Panels Solution

Inserting & potting for equipment fixation

Brackets & machined parts under skin embedding

Heat pipes embedding

Connection of panels via angular shapes cleats

Perspective of high multi functional panels

Current Sandwich Solutions

Inserts in Composite Sandwich

Partial Potting Composite Sandwich

Full Potting Composite SandwichHeat Pipes Embedding

8/13/2019 nebiolo

12/18

This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed

to any third party without the prior written permission of Thales Alenia Space - 2013, Thales Alenia Space

16/05/2013

12

Ref.:

Towards Multifunctionality

Composite materials and sandwich panels are suitable elements forMulti-functionality due to the possible embedding or surface patchingsince the manufacturing phase of:

Wireless sensorsOptical fibersNeural networks for HMS & data transmissionActuators piezo-electric/ceramicElectrical CablingSolar cells

Heat pipesAntennas

Multi-functionality will work for:

Higher reliability of aerospace vehicles

Simultaneous satisfaction of multiple functional requirements

Mass optimization: through high integration degree ofdifferent functions, components miniaturization

Under Development Sandwich Solutions

Multifunctional Composite &

Sandwich Panels

8/13/2019 nebiolo

13/18

This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed

to any third party without the prior written permission of Thales Alenia Space - 2013, Thales Alenia Space

16/05/2013

13

Ref.:

TAS-I Composite Capabilities, Facilities & Equipment

TAS-I Composite Capabilities

Manufacturing of composite structures by handlay-up or filament winding plus autoclave cure

Bonding of Aluminum/FRP sandwich panels,insert potting, edge taping

TAS-I Facilities & Equipment

Clean rooms (100000 class, according to FED-STD-209) covering an area of 800 m2

Numerically-controlled 4-axis filament windingmachine (FWA1 Bolenz & Schaefer) for theautomatic manufacture of axis-symmetricalcomposite parts up to 1.8 m in diameter and 3 m

in length

Autoclave (dimensions diam. 4 m x 12 m length).

Filament Winding Plant

Autoclave

8/13/2019 nebiolo

14/18

This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed

to any third party without the prior written permission of Thales Alenia Space - 2013, Thales Alenia Space

16/05/2013

14

Ref.:

Design of a typical component: representative portion of a medium high

temperature structure (e.g. engine thrust, wing panel or fuselage for a RLV)

Component lay-up for MMC composite: basic skin layers (0,90,90,0), stringers layers

(0,0,0,0)

Panel breadboard size 200 x 500 mm

Sizing for compression/buckling

High Temp MMC Composites (target 700 C)

MMC Breadboard Design

8/13/2019 nebiolo

15/18

This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed

to any third party without the prior written permission of Thales Alenia Space - 2013, Thales Alenia Space

16/05/2013

15

Ref.:

Some panels breadboards (dim 200 x 500 mm) have been

developed based on Ti6Al4V matrix and SiC (SCS-6) long fibers

Target manufacturing processes:

Hot Isostatic Pressing (HIP) for composite material of basic

skin and half-stringers

Super Plastic Forming (SPF) for L-shaping of each half-

stringer

Diffusion Bonding (DB) for bonding of half-stiffeners and

fixation of stiffeners to the panel basic skin

MMC Composites Development

Stringers

Lay-up (0,0)

Basic Skin Panel

Lay-up (0,90,90,0)

DB Line 1

PureTi6Al4V Areas

DB Line 2

HIP Plant

Development Panel Full Ti6Al4V

Development Panel Parts Lay-Up

MMC Section View

8/13/2019 nebiolo

16/18

This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed

to any third party without the prior written permission of Thales Alenia Space - 2013, Thales Alenia Space

16/05/2013

16

Ref.:

2 breadboard panels have been successfully manufactured

Characterization samples have been water jet cut for testing from all the 2panels areas

MMC Composites Development

Sample cutting from the 2 panels BBs

8/13/2019 nebiolo

17/18

This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed

to any third party without the prior written permission of Thales Alenia Space - 2013, Thales Alenia Space

16/05/2013

17

Ref.:

Mechanical performances (tension, compression, fatigue creep) tested at both700 C and RT before and after thermal cycling (100 cycles: representative of aReusable Launch Vehicle operative life)

Tension properties at RT up to 1200 MPa

Tension properties at 700 C are still comparable w ith a good aerospace Alalloy (above 400 MPa)

Thermal cycling has not significantly affected the mechanical properties

MMC Composites Development

Sample ready for testing Final Panel Demo

8/13/2019 nebiolo

18/18

This document is not to be reproduced, modified, adapted, published, translated in any material form in whole or in part nor disclosed

to any third party without the prior written permission of Thales Alenia Space - 2013, Thales Alenia Space

16/05/2013

18

Ref.:

Thanks for Attention:

Any Question ?