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Composite Materials for Unmanned Systems

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Composites are a natural fit for unmanned systems, writes David Cooper, who explains how the
materials are made and used.

(https://www.unmannedsystemstechnology.com/technical-article/composite-materials-for-unmanned-
systems/nasa-global-hawk-uav/)

The Global Hawk UAV is constructed with a composite airframe. (Photo: NASA/ Tony Landis)
A composite is essentially a material or structure formed of two (possibly more) distinct elements, the
principle being of course to counter the disadvantages of the one with the advantages of the other(s), and
vice versa. In unmanned systems, the functional engineering objective is most typically to achieve the best
possible mechanical properties for the least weight, balanced against other factors such as transparency to
communication/ sensor frequencies, overall cost to manufacture/maintain, and durability. The use of
composites to achieve these objectives is a natural solution, as they often provide superior specific
properties – that is, the strength or stiffness per unit weight of material – compared to those of non-
composites.

The composites used in unmanned vehicles

(https://www.unmannedsystemstechnology.com/category/supplier-directory/materials-
manufacturing/composites/) can be divided into two basic groups – metal matrix composites (MMCs) or
polymer matrix composites (PMCs) – which are then reinforced with fibres or particles of another material
that is typically more brittle but far stronger and stiffer than the matrix. In such a combination, the reinforcing
material carries the loading, while the softer matrix serves to protect the fibres and transfer the load
effectively as well as holding the required geometry.

Of the two, PMCs are more widely used in unmanned systems, given their excellent strength-to-weight
properties and perhaps easier manufacturing than MMCs.

Polymer composites
The most popularly known PMC is of course carbon fibre, or more properly carbon fibre reinforced polymer
(CFRP). However, there are many alternative reinforcing fibres available, and each has its own advantages
depending on the application. The most commonly available reinforcements besides carbon fibres are
aramid-based, glass, quartz or thermoplastic fibres.

The carbon fibres themselves can be manufactured from

petroleum-derived pitch as a base material, or more often from a
polyacrylonitrile (PAN) polymer. PAN fibres are heated (oxidised
and carbonised) to burn off other elements and leave the desired
carbon, after which further heat treatments can be applied to the
strength and stiffness of the material as required.

Aramid fibres are based on an aromatic polyamide, with a wide

(https://www.unmannedsystemstechnology.com/com
range of materials more often known by trade names such as
0-90-side_web/)
Nomex (a meta-aramid) or Kevlar (a para-aramid). Meta-aramid
Spread-tow carbon fibre (Courtesy of TeXtreme
fibres typically have high temperature resistance, while para-
(https://www.unmannedsystemstechnology.com/com
aramid fibres have excellent mechanical properties for a given
weight. Glass fibres may not provide the same strength-to-weight
performance as carbon fibres, but they are comparatively ductile and cheaper. Quartz fibres are most often
used for housings such as radomes, given their high-frequency radio wave transparency.

The reinforcement fibres are then combined with a polymer matrix, most often an epoxy resin. Pre-
impregnated woven fabrics or unidirectional tapes (termed pre-preg) already contain the matrix resin before
lay-up into a component, and the resins contain latent hardeners that are activated by elevated temperatures
to fully cure the material. The curing process cross-links molecules, and this can be an exothermic reaction,
so care must be taken in controlling the process temperatures, particularly in thick components. To stop the
resin curing at room temperature, refrigerated storage is required, and pre-preg composites have a finite shelf
life.

(https://www.highpowermedia.com/p/1189/unmanned_systems_technology_-_issue_001)

This is an excerpt from a five page dossier featured in Unmanned Systems Technology Magazine Issue 1.

To read the rest of this article and many more technical engineering-based articles on unmanned vehicles get
your copy of Unmanned Systems Technology Magazine Issue #01
(https://www.highpowermedia.com/p/1189/unmanned_systems_technology_-_issue_001), or subscribe to
Unmanned Systems Technology magazine
(https://www.highpowermedia.com/p/1176/1_year_of_unmanned_systems_technology) to make sure you
receive every issue going forward.

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