Advanced Composite Materials for LEO Space Application Background

Broad use of polymer matrix composites in space

9 Light weight and extraordinary optical, thermal, electrical & mechanical characteristics

Special Environments

Hazardous LEO space environment effects on composites

9 Damage on composite structures and components

LEO resistant composites is to be developed

Objective and Scope

Space structures operating in LEO

Development of Advanced Composite Materials for Space Application

LEO space environment simulation facility f Development of nano-sized fillers reinforced nanocomposites Selection of LEO resistant nano-fillers Understanding of the LEO space p environment effects on typical composites Investigation of LEO space environment characteristics after LEO exposure

- 30 -

LEO Space Environment Simulation LEO space environment simulation facility

6 Torr) Ultra-High Ultra High Vacuum (~10-6

Special Environments

UV radiation (< 200nm) Thermal cycling (-70 ( 70 C C to 100 C) C) AO exposure (AO flux = 4.5x10-16 atoms/cm2s)
4.2x10
14

120
gas flow rate : 5 sccm O2 : Ar = 0.9 : 0.1

Neutral density ( (atoms/cm )

100 80
Mass Flow Controller RF Power Supply Ar Orifice UV Lamp Plasma Chamber O2

4.0x10

14

Temperature( C) )

3.8x10

14

4.0x10 2.0x10

13

O3 O O2 O2* O* Ar Ar*

60 40 20 0 -20 -40 -60

Quartz

Halogen Lamp Refrigerator

13

0.0 150 200 250 300 350 400

upper side lower side

0 20 40 60 80 100 120

specimen Copper plate

-80
Main Vacuum Chamber

RF power (Watt)

Time(min)

AO flux analysis

Thermal cycling

LEO Space Environment Simulation Facility, KAIST

- 31 -

LEO Space Environment Characteristics of Nano-Composites Fabrication of nano-fillers reinforced composites

MWNT/epoxy and Al2O3 nanotubes/epoxy composites

Special Environments

LEO environment characteristics of nano-composites

Enhancement in LEO resistant characteristics by reinforcement of LEO resistant nano-fillers
100 90 80

MWNTs

Al2O3 50nm nanotubes

Nano-fillers used

10
unexposed exposed

Tensile Strength (MPa)

70 60 50 40 30 20 10 0 0.0 0.2 0.5 1.0

Total Mass Lo oss (%)

MWNT concentration (wt.%)

Epoxy

0.2 wt %

0.5 wt %

1.0 wt %

MWNT concentration

Enhancement of tensile strength by MWNT reinforcement after LEO exposure

Mass loss reduction by MWNT addition after LEO exposure

- 32 -

Development of Composite Materials for Cryotanks Background

Special Environments

Light weight structure is a primary concern for the storages of launch vehicles There are some dramatic changes in composite properties and their performances under cryogenic environments Cryogenic characteristics of composites must be evaluated under cryotank conditions such as cycling/aging process

Objective j & Scopes p

Development of CFRP composite material systems Selection of adhesive for cryogenic use Consideration of manufacturing processes Investigation on the actual problems in cryotank

Cryotank structures using CFRP composites

<cryotank>

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Evaluation of Composite Properties at Cryogenic temperature

Development of CFRP composite material system for cryogenic use Bonding characteristics of adhesives between composite and metal liner for TYPE-III tanks
220 200 180 160 CU125NS (Baseline) Type A Type B Type D Type E Type C Type F
1.1% 2.1% 2.3% 8.3%5.9% 2.9% 5.5% 3.8% 0.8%2.0% 6.2%

Special Environments

4000 3500 3000

CU125NS (Baseline) Type A Type B Type D Type E

5.9% -3.1% -9.3% -4.0% -11.4% -10.7%

Type C Type F
7.1% -1.6% -2.4% 5.0% -0.3%

Stiffness(GPa)

Strengt th(MPa)

140 120 100 80 60 40 20 0

-5.4%

2500 2000 1500 1000 500 0

-13.6%

<tensile test at cryogenic temperature>

6-cycled at RT 6-cycled to -150 C
o

6-cycled y at RT

6-cycled y to -150 C

80 70 60 Strength (MPa)
Strength (MPa)

Bondex606 EA9696 FM73

at RT

80 70 60 50 40 30 20 10 0 Bulk Joint Bulk Joint Bulk Joint Bondex606 EA9696 FM73

at -150 C

50 0 40 30 20 10 0 Bulk Joint Bulk Joint Bulk Joint

<3-jaw 3 j tensile t il grip i for f CT-cycling> CT li

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Cryogenic Behaviors of Composite/Aluminum Ring Specimen

Special Environments

Tensile response of ring specimen at -150oC using split-disk test method Different stiffness around the composite ring due to friction and bending effects Residual strain in ring with aluminum-liner after first cycles
240 220 200 180

60

at RT o at -150 C

50

Stiffness (G GPa)

160 140 120 100 80 60 40 20 0 0 10 20 30 40 50 60 70

40

Load (kN N)

1st cycle 2nd cycle 3rd cycle 4th cycle 5th cycle 6th cycle Burst curve

30

20

80 90

10

0 0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

Degree from split line ()

Strain (%)

<stiffness around the composite ring specimen>

- 35 -

<load-strain characteristics of ring with Al.-liner at -150 oC>

LN2 Storage and Pressurization Test of Prototype Cryotank

Experimental procedure
Strain ()

Special Environments
<Test results w w.r.t. r t elapsed time>
0

GN2 pressurization (250psi) leak test

-500

-1000
ESG 1 ESG 2 ESG 3 ESG 4

-1500

LN2 storing g
-2000 0 10 20 30 40
Time (min)

50

60

70

80

GN2 pressurization (250psi)

0.00 -0.05 -0.10

Strain (%)

Strain behavior

-0.15 -0.20 -0.25 -0.30 -80

Temperature distrubution

-60

-40

-20

0
X (mm)

20

40

60

<LN2 storage test>

<Thermo-elastic analysis for the cryotank>

- 36 -

Carbon Nanotube(CNT)-Reinforced Composites Background

Application A li ti of f CNT
3 ELECTRICAL 3 MECHANICAL

Special Environments

Electrically Conductive Composite - Electrostatic Dissipation - Shielding - Conductive sealants

Energy Storage - Super Capacitors F l cells ll - Fuel Electronic Materials & Devices - Conductive inks and adhesives - Electronic packaging - Device and microcircuit components p

High performance composites Coatings wear wear-resistant and low low-friction High performance fibers Reinforced ceramic composites
3 THERMAL ThermallyThermally -conductive polymer composites ThermallyThermally -conductive paints & coatings 3 FIELD EMISSION Flat Panel Displays Electron device cathodes Lighting

C b nanotube Carbon t b

Objective & Scope

Investigation of properties of CNT/polymer nanocomposites and CNT-added fiberreinforced composites. Application A li ti of f th the d developed l d composites it t to various i structures. t t
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CNT/Epoxy Composites : Mechanical Properties

Special Environments

MWNT-added glass/epoxy fabric composites : mechanical properties

9 MWNTs were localized in matrix rich region g and interfaces between warps & fills. 9 Mechanical properties increased due to MWNT addition.

Glass fiber (warp) Glass fiber (fill) MWNT

Microstructure of 1.0 wt% MWNT-added fabric composites

Mechanical Test Tensile stiffness Tensile strength ILSS SS

MWNT contents MWNT0.4 MWNT0.4 MWNT0 7 MWNT0.7

Change (%) 9.3 % 12.2 % 38 0 % 38.0

Mechanical Test Compressive strength Shear stiffness Shear strength

MWNT contents MWNT1.3 MWNT0.7 MWNT0.7

Change (%) 11.5 % 7.6 % 4.9 %

- 38 -

Cryogenic Use : Improvement of Crack Resistance

Thermal stress induced at fiber/matrix interface and between laminae micro-crack under cryogenic environment Carbon nanotube (CNT)
Improvement of crack resistance through interlocking and bridging effect
Cryogenic fractures
10 Microcrack den nsity(microcracks s / cm) 8 6 4 2 0

Special Environments

1200 1100 1000 900 800 700 600 Microcrack density Fracture toughness 500 0

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

wt% of MWNT

<Microcracks>

<Delamination>

MWNT (wt%) 0.0 0.2 0.7

Fracture toughness 30% 32%

Crack density 18% 28%

CNT effects

<CNT interlocking>

<CNT bridging>

<Effect of MWNT addition on fracture toughness and crack density>

- 39 -

Fracture tou ughness, GI(J / m )