Space Structures: Prof. Alessandro Airoldi

SPACE STRUCTURES
Prof. Alessandro Airoldi
INTRODUCTION TO THE COURSE

Introduction to the course
 Objectives of the course

 Stressed skin constructions in
aircraft structures
 Loads in space structures
 Examples of space structures
 Contents and organisation of the
course
Space Structures - Prof. Alessandro Airoldi 2

Objectives of the course
Approaches to the analysis of

structures in aerospace
constructions


Aerospace constructions Aerospace structures
AERODYNAMIC
AERODYNAMIC
LOADS
LOADS Structure works to
transfer the applied
loads
INERTIAL LOAD
INERTIAL LOAD Force equilibrium

(D’Alembert principle)
Such considerations apply to all type of

structures (not only aerospace structure)
THRUST


Requirements: Stiffness
Limitation to the relative displacements
AERODYNAMIC due to functional requirements (e.g.
LOADS AERODYNAMIC
LOADS aerodynamics)
Avoid frequency coupling (resonance)
Strength
Avoid permanent deformation and the
collapse of the structures under
operative load
INERTIAL LOAD
INERTIAL LOAD
Shape Constraints
AERODYNAMICS, INTERNAL
VOLUMES FOR PAYLOADS
OBJECTIVE: perform structural functions,

fullfilling requirements, respect constraints with
THRUST MINIMUM WEIGHT

Why analysis ?
Analysis of existing structures

helps understanding the functions
of structural elements, critical
issues in design, the available
solution for design (synthesis)
Design is an iterative process,

which involve analysis of design
hypothesis at different level of
detail


 Enhance the capability to apply the approaches of structural
mechanics to the structural types that are employed in
aerospace structure. Given the applied loads:
-methods for the evaluation of internal stress and strain states
-methods for the evaluation of stiffness, displacements, natural frequencies
 Learn the main features of aerospace structures:

comprehension of structural roles, capability to critically
analyse a structure
 Achieve the bases for a proper use of structural calculation
software: knowledge of principles, technologies, limitations

Stressed skin constructions in aircraft structures

The peculiar and severe requirements
for aircraft structures led to the
development of a very effective
structural typology:
Thin load bearing skin (stressed skin),

reinforced by longitudinal stringers
and internal frames
SEMI-MONOCOQUE STRUCTURES
They still represent the basic
structural concept in aerospace
structures, together with
TRUSS
STRUCTURES

FABRIC
COVER
TRUSS
STRUCTURE
INTERNAL
Biplane (1916) FRAMES
(RIBS) AND
LONGITUDINAL
REINFORCEME
NT (SPARS)
Motivations for the development of stressed skin constructions can be traced to

the beginning of flight
Q 1
= C p ρV 2
S 2
Torsional stiffness: critical issue
in wing design
High pitch angle
Low pitch angle
WING TORSION

Torsional stiffness of biplane wings


Hurricane had originally a fabric cover (1935)
All metal
stressed skin
provided in
1939
Load bearing skin provides a closed high-

stiffness path for shear stress, contribute to
bending stress and stiffness

Thin load bearing skin

(stressed skin),
reinforced by
longitudinal stringers
and internal frames
Semi-monocoque structure (1943)


Modern airliner structure
CLOSELY
SPACED FRAME
COMPOSITE AND RIBS
VERTICAL TAIL (internal
WITH SEMI- diaphragm in
MONOCOQUE fuselage and wing
MORPHOLOGY


Wing box and ribs
REAR FWD
SPAR SPAR
Integrally stiffened composite skin


TRUSS
STRUCTURES
Type of
diaphragms and
instability
C – SHAPED
BEAMS WITH
VARIABLE
SECTION AND
CUTOUTS
CLOSED LOOP OF
BEAMS WITH L, C, Z
or other shape
SECTIONS


Tail structure and bulkheads
AIRBUS A 300 TAIL

BULKHEAD WORKING
UNDER PRESSURE LOADS
A380 COMPOSITE BULKHEAD


Supersonic fighters
FUSELAGE FRAMES ARE MORE

SPACED DUE TO NEED OF LARGE
CUT-OUTS (Cockpit, cut-out
inspections of engines, air inlets)
WINGS BECOME VERY THIN AND STRINGERS ARE

MERGED IN A SERIES OF SPARS

Loads in space structures

Natural environment: climatic, thermal, chemical and vacuum conditions,
required cleanliness, levels of radiation and the meteoroid and space debris
environment.
Mechanical and thermal loads that are induced by operation of spacecraft:
 ground handling
 launch
 manoeuvres and disturbances
 re-entry
 descent and landing
 Additional induced loads, which include static pressure within the payload
volume, temperature and thermal flux variations


Ground handling and transportation loads


Ground handling and transportation loads
<<
Ra
Rb
Rc Rd
-ρ l a
1 ma inertia forces a
mg ∫
ρl a =
L
mg
=
weigth
=
g


Launch
MODIFIED ICBM LAUNCHER
SATURN V
7g
3.7g
INERTIAL LOAD
4.2 g
Launch phase corresponds to the

most severe loads
Launcher structure is heavily
compressed
THRUST
ARIANE V


Loads are typically transient loads, vibration loads
When load are applied for an extended period of time they can be
considered static (g loading / steady state accelerations)
The design load factors are represented by Quasi Static Loads,
which are the most sever combination of dynamic and steady
Lateral g loads
state acceleration
COMPRESSIVE LOADS ARE THE HIGHEST
LATERAL LOADS BEND THE STRUCTURE AND CAN NOT BE NEGLECTED
Axial g loads
<<
Ariane V QSL


Internal forces in a launcher (first stage for
the application of a beam model )
Generation of oscillatory axial

tensile at engine shut down


Launch loads also act on spacecraft, which represent the launcher
payload. Spacecraft are constrained to launchers by means of
structures called adapter (or dispenser). Ariane IV QSL AT PAYLOAD
-ma
THE TYPE OF LAUNCHER DEFINES THE LOAD
CONDITIONS FOR THE SPACECRAFT
QSL are the design loads for launcher structure, adapters

and spacecrafts. Strength requirements imply a margin of
safety > 1


For spacecraft a fundamental (stiffness) requirement is avoiding
resonant coupling with vibrations by launcher
THE TYPE OF LAUNCHER DEFINES THE

STIFFNESS REQUIREMENTS FOR THE
SPACECRAFT
Dynamic decoupling must be attained: spacecraft structure must exhibit

natural frequency higher than the ones of launcher induced vibrations


Other loads:
 Pressure fluctuation due to engine operations and unsteady aeordynamic
phenomena
 Shock (e.g. during jettison of stages)
 Thermo-elastic actions due to thermal flux
 Collision with meteoroids and space debris

Examples of space structures: SPACE SHUTTLE
Unique combination of semi-

monocoque, pressure vessels, truss
structures structural concepts
Orbiter
Many different materials used:
-Aluminium alloy
- high strength steel
SRB External -Titanium
tank -Boron/aluminium composite
-Carbon/epoxy composites
-Fibreglass
-Ceramics


Solid busters
MAIN STRUCTURE:
SEGMENTED STRUCTURE (11 SEGMENT)
HIGH STRENGTH STEEL 13 mm THICK
JOINED BY STEEL PINS

JUNCTIONS WRAPPED BY
FIBERGLASS
SEALED WITH RUBBER BANDS
SUCH MAIN STRUCTURE IS

CLOSED BY THE FWD AND AFT
SEGMENT DOMES
IT IS THE EXTERNAL
STRUCTURE BETWEEN THE
FORWARD AND THE AFT
SKIRT
EXTERNAL COVER, SUCH AS

NOSE CAP AND SKIRTS ARE
MADE OF WELDED ALUMINUN

External Tank
TWO TANKS: OXYGEN AND HYDROGEN
PRE-FORMED ALUMINUM
ELEMENTS (PANELS,
MACHINED THICK ELEMENTS)
PRESENCE OF INTEGRALLY
MACHINED STRINGERS AND RING
FRAMES
RING FRAMES STABILIZE THE TANK

AT HIGH COMPRESSIVE LOADS
INTERTANK STRUCTURE IS A MORE

CONVENTIONAL SEMIMONOCOQUE
STRUCTURE (PANELS-SKIN-FRAMES
MECHANICALLY JOINTED)


Orbiter
BASED ON SEMIMONOCOQUE
PRINCIPLES
LARGE PARTS MADE OF
ALUMINUM ALLOY
PECULIAR ASPECTS
 CONVENTIONAL FORWARD
FUSELAGE STRUCTURE HOSTS
WELDED PRESSURISED CREW
MODULE
 CENTRAL SECTION FRAMES MADE
OF BORON/ALUMINUM TRUSS
STRUCTURE
 THRUST BEARING TRUSS
STRUCTURE WITH BORON/EPOXY
REINFORCEMENTS
 WINGS WITH HONEYCOMB SKIN
COVER


Orbiter
FORWARD FUSELAGE: EXTERNAL
SHELL STRUCTURE (SEMIMONOCOQUE
CONCEPT)
INTERNAL PRESSURIZED VESSEL


Orbiter
CENTRAL SECTION
LONGHERON CARRY
BENDING LOADS
HIGH STIFFNESS-
STRENGTH REQUIRMENT
FOR FRAMES: TRUSS WITH
BORON/ALUMINUM TUBES
CONCEPTS OF STRESSED
SKIN CONSTRUCTION
LARGELY EMPLOYED


Orbiter
GRAPHITE\EPOXY
PAYLOAD BAY DOORS
REINFORCED BY FRAMES
AND END TORQUE BOXES
HIGH STRENGTH 3D TRUSS

STRUCTURE TO SUSTAIN
THE THRUST LOAD OF
MAIN ENGINES


Orbiter
CONVENTIONAL ALUMINUM
STRUCTURE WITH MULTI
SPAR AND RIB
ARRANGEMENT
HONEYCOMB SKIN
REINFORCED BY
ALUMINUM HAT-SHAPED
STRINGERS

Examples of space structures: SATURN V

First Stage
Separate serial tanks within
semimonocque structure
SEMI-MONOCOQUE AL 7075
INTERTANKS AND SKIRTS
AL 2219 – T87 TANK WITH

ANTI-SLOSH BAFFLES
(diaphragms that reduces fuel
movements)


Second Stage
Integral serial tanks with
common bulkhead
INTEGRALLY
STIFFENED TANKS
MADE OF DIFFUSION-
WELDED AL 2014
PARTS
COMMON BULKHEAD:
AL 2014 SHEET +
FIBERGLASS/
PHENOLIC
HONEYCOMB CORE
SKIRTS,
INTERSTAGES,
THRUST
STRUCTURE:
AL7075
SEMIMONOCOQUE


Third Stage
Serial tanks with
common bulkhead
VERY SIMILAR TO
2° STAGE
STRUCTURE
INTEGRALLY
STIFFENED TANKS
AND
SEMIMONOCOQUE
STRUCTURES

Examples of space structures: SPACECRAFTS
Experimental spacecraft designed at John Hopkins University:

multisensor platform including a Spatial Infrared Telescope
IN SPACECRAFTS THE DISTINCTION BETWEEN
PRIMARY AND SECONDARY STRUCTURES IS
IMPORTANT:
PRIMARY STRUCTURES
 TRANSMIT LOADS TO THE BASE OF THE SATELLITE
THROUGH SPECIFICALLY DESIGN COMPONENTS
(CENTRAL TUBE, HONEYCOMB PLATFORM, BAR
TRUSS, ETC.).
 PROVIDE THE ATTACHEMENT POINTS FOR THE
PAYLOAD AND THE ASSOCIATED EQUIPMENTS.
 FAILURE OF THE PRIMARY STRUCTURE LEADS TO
COLLAPSE OF SATELLITE
SECONDARY STRUCTURES
BAFFLE, THERMAL BLANKET SUPPORT AND SOLAR PANELS
 MUST ONLY SUPPORT THEMSELVES AND ARE ATTACHED TO
THE PRIMARY STRUCTURE WHICH GUARANTEE THE OVERALL
STRUCTURAL INTEGRITY.

SEVERAL DIFFERENT STRUCTURAL TYPES:

-TRUSS (ALSO IN HIGH STIFFNESS/STRENGTH COMPOSITE
MATERIAL)
- HONEYCOMB PANELS (OFTEN USED FOR ELECTRONIC
SUPPORT AND SOLAR CELL SUPPORT)
-MACHINED BEAMS AND PLATES

MANNED SPACECRAF INCLUDES

-TRUSS STRUCTURES
-SEMI-MONOCOQUE CONCEPTS (THIN WALLED
STRUCTURES WITH STIFFENERS AND FRAMES)
-STIFFENED PRESSURE VESSELS

Introductory lessons
Examples of space structures:

Structural concepts
• Central role of two different but very effective structural types: semi-
monocoque and truss structures
• pressure vessels design concepts and honeycomb structures
Basic structural elements (models)

Beam models can be applied at level of the vehicle structure, for the analyses
of truss systems, for the analyses of ribs and frames
Plate theory is required to understand the behavior of panels and covers
Required skills in aerospace structures

Extensive knowledge of
- different structural typologies and engineering solutions
- different theoretical models and analysis approaches to meet severe
requirements in a multiplicity of conditions
Course Content and Organisation:

Lectures (theory)
1. MECHANICS OF DEFORMABLE BODIES

2. BEAM MODELS AND BEAM SYSTEMS
3. SEMI-MONOCOQUE STRUCTURES
4. STIFFNESS APPROACHES AND RITZ METHOD
5. PLATES
6. FE METHOD
7. NON-LINEAR PROBLEMS AND INSTABILITY


Course Material & Textbooks
Slides of the lectures will be provided during the course
MALVERN, MECHANICS OF CONTINUOUS MEDIUM

Continuum mechanics, general principles
T.H. MEGSON, AIRCRAFT STRUCTURES FOR ENGINEERING STUDENTS, BUTTERWORTH-
HEINEMANN, 1972
Semi-monocoque structures, force and displacement approach to beam systems
J.N. REDDY, ENERGY PRINCIPLES AND VARIATIONAL METHODS IN APPLIED MECHANICS, WILEY
2002
Energy methods, Ritz Method, Plate Theory
K.J. BATHE, FINITE ELEMENT PROCEDURES, PRENTICE HALL 1982

Finite elements
V. GIAVOTTO, STRUTTURE AERONATICHE CITTA’ STUDI

Covers several parts of the course


Exercise classes
1. MECHANICS OF DEFORMABLE
1. STRESS AND STRAIN MEASURES BODIES
2. BEAM MODELS AND BEAM SYSTEMS
2. 3D BEAM SYSTEMS 3. SEMIMONOCOQUE STRUCTURES
4. PLATES (THIN & THICK PLATES,
3. SEMIMONOCOQUE STRUCTURES LAMINATES, PRESSURE VESSELS
HONEYCOMB)
5. STIFFNESS APPROACH AND
4. STIFFNESS APPROACHES AND APPROXIMATE METHODS
APPROXIMATE METHODS 6. FE METHOD

7. NON-LINEAR PROBLEMS AND
INSTABILITY
The exercises that will be proposed during the classes will

be all available on-line


Written Examination
Based on the same type of exercises that have been presented, solved and
discussed during classes
Capability to critically apply concepts as well as to organize and carry out
calculations
Admission to oral examination is possible only if the
written text will obtain a positive mark
Oral Examination
Comprehension of structural concepts, analytical and
numerical approach
Will include proofs of main theorems and formulation
development

Space Structures: Prof. Alessandro Airoldi

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SPACE STRUCTURES

Prof. Alessandro Airoldi

INTRODUCTION TO THE COURSE

 Objectives of the course

Space Structures - Prof. Alessandro Airoldi 2

Objectives of the course

Approaches to the analysis of

Space Structures - Prof. Alessandro Airoldi 3

Objectives of the course

INERTIAL LOAD Force equilibrium

Such considerations apply to all type of

Space Structures - Prof. Alessandro Airoldi 4

Objectives of the course

OBJECTIVE: perform structural functions,

Objectives of the course

Analysis of existing structures

Design is an iterative process,

Space Structures - Prof. Alessandro Airoldi 6

Objectives of the course

 Learn the main features of aerospace structures:

Space Structures - Prof. Alessandro Airoldi 7

Stressed skin constructions in aircraft structures

Thin load bearing skin (stressed skin),

Space Structures - Prof. Alessandro Airoldi 8

Stressed skin constructions in aircraft structures

Motivations for the development of stressed skin constructions can be traced to

Stressed skin constructions in aircraft structures

High pitch angle

Low pitch angle

Space Structures - Prof. Alessandro Airoldi 10

Stressed skin constructions in aircraft structures

Torsional stiffness of biplane wings

Space Structures - Prof. Alessandro Airoldi 11

Stressed skin constructions in aircraft structures

Load bearing skin provides a closed high-

Space Structures - Prof. Alessandro Airoldi 12

Stressed skin constructions in aircraft structures

Thin load bearing skin

Semi-monocoque structure (1943)

Space Structures - Prof. Alessandro Airoldi 13

Stressed skin constructions in aircraft structures

Space Structures - Prof. Alessandro Airoldi 14

Stressed skin constructions in aircraft structures

Integrally stiffened composite skin

Space Structures - Prof. Alessandro Airoldi 15

Stressed skin constructions in aircraft structures

Space Structures - Prof. Alessandro Airoldi 16

Stressed skin constructions in aircraft structures

AIRBUS A 300 TAIL

A380 COMPOSITE BULKHEAD

Space Structures - Prof. Alessandro Airoldi 17

Stressed skin constructions in aircraft structures

FUSELAGE FRAMES ARE MORE

WINGS BECOME VERY THIN AND STRINGERS ARE

Space Structures - Prof. Alessandro Airoldi 18

Loads in space structures

Space Structures - Prof. Alessandro Airoldi 19

Loads in space structures

Space Structures - Prof. Alessandro Airoldi 20

Loads in space structures

Space Structures - Prof. Alessandro Airoldi 21

Loads in space structures