Carbon Fibre Reinforced Polymers suitable for secondary structures

As space exploration focuses more and more on mass and cost reduction targets, one possible way to improve stiffness and strength in materials while maintaining a low mass is by using Carbon Fiber Reinforced Polymer (CFRP) composites. A TDE activity has demonstrated which opportunities there are within space projects to use CFRP materials.

The activity, with Thales Alenia Space Italia S.p.A, focused on two structures where they replaced metallic parts with similar polymer composite versions – an ESPR (European Standard Payload Rack) from the International Space Station and a future proposed lightweight secondary structure (LSS) for use on human exploration missions beyond low Earth orbit (LEO).

The tests were conducted in three phases. First, the screening phase put the resins through a preliminary validation for the space compatibility. Second, the material and structures underwent a basic evaluation of mechanical and thermal capability. Third, two 2-3m long breadboards of the pultruded beams were produced with different design solutions.

The tests showed that pultruded technology is fully compatible for application on crewed structures, simultaneously giving significant mass savings and increased stiffness increasing in secondary structure components and could eventually be applied  to structures such as pressurised habitation modules.

Activity 4000119825/ T424-419QT closed in September 2019.