DTU SpaceCarbon Fiber Reinforced Plastic and CFRP projects

Niels Christian Jessen Hans Ulrik Nørgaard-Nielsen

January 31 2013NCJE HUNN

2 DTU Space, Technical University of Denmark

Why CFRP

+ Material properties can be designed

+ High Specific Stiffness Young's module / Density

+ High Thermal StabilityThermal Conductivity / Coefficient of Thermal expansion

+ High StrengthUltimate strength / Density

- Moisture sensitive

- Radiation

- Outgassing

January 31 2013NCJE HUNN

3 DTU Space, Technical University of Denmark

CFRP Manufacturing methods

Filament Winding

Prepreg

Woven mesh

Prepreg

Injector molding

January 31 2013NCJE HUNN

4 DTU Space, Technical University of Denmark

Micro Mechanics

Variables ofLaminaUD UniDirectionalLayer

• Fiber type• Matrix• Fiber Volume

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5 DTU Space, Technical University of Denmark

Macro Mechanics

• Fiber lay upo Angleso Number of layerso Combination of

Lamina layers

• Laminate program

• FEM

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6 DTU Space, Technical University of Denmark

Symmetric Lay Up

• Symmetric around center of Laminate avoids out of plane effects for plates.

• Tubes are special case

Post Curing shapes of

Unsymmetrical Laminates

January 31 2013NCJE HUNN

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Behavior of lay up in Laminate

Bending: stiff

Torsion: soft

Bending: soft

Torsion: Stiff

January 31 2013NCJE HUNN

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Quasi isostropic Lay up

• In Plane:o Equal mechanical

properties in all directions.

• Out of Plane:o Different properties

since dominates by matrix material

Layers

1 -60⁰

2 0⁰

3 60⁰

Remember symmetry for plates

Layers

1 45⁰

2 0⁰

3 -45⁰

4 90⁰

Remember symmetry for plates

January 31 2013NCJE HUNN

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Space environments• Ultra high Vacuum

• Cooling only by radiation• Cavities must be avoided• Outgassing

• Extreme temperature• Cryo to very high temperatures• Dimensional Stability

• Radiation

• Static electricity

• Reliable• No possibilities for repair and adjustments

• Extreme launch loads• High g-loads (20 g and more not unusual in vibrations)

January 31 2013NCJE HUNN

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Planck

•Mapping the Cosmic Microwave Background anisotropies with improved sensitivity and angular resolution

January 31 2013NCJE HUNN

11 DTU Space, Technical University of Denmark

Planck Satellite

January 31 2013NCJE HUNN

12 DTU Space, Technical University of Denmark

Planck Satellite Reflectors

ESA Project:

DTU Space:Principal Investigator for the Reflector system.

74 detectors.

9 frequencies.

30 – 857 GHz.

Launch: May 14 2009.

January 31 2013NCJE HUNN

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PlanckCFRP-Reflectors

Qualification Model Secondary Reflector in 3D measurement machine.Dimensions 1051mm x 1104mm.Weight 13.6 Kg.

Flight Model Primary Reflector Shown in aluminizing plant.Dimensions 1556mm x 1887mm.Weight 29.2 Kg.

January 31 2013NCJE HUNN

14 DTU Space, Technical University of Denmark

Design af reflektorer til Planck

Skin.

Honeycomb.

January 31 2013NCJE HUNN

15 DTU Space, Technical University of Denmark

PlanckDimpling, Sandwich

666932 Nodes.486024 Elements.

January 31 2013NCJE HUNN

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PlanckInfluence from adhesive. Main expected Dimpling due to cool-down from Room Temperature to 41 K.

L20/SL, Aerosil Quarts Powder.Dimpling 2.4 µm.Original adhesive.

2216 Gray.Dimpling 0.4 µm.New adhesive.

January 31 2013NCJE HUNN

17 DTU Space, Technical University of Denmark

PlanckLift Of

Lift OfMay 14 2009Kl. 10:12:07KourouFrench Guiana

January 31 2013NCJE HUNN

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James Web Space TelescopeMIRI

6.5 m Space telescope.

NASA/ESA Project.

L2.

3 Instruments.

Launch 2017.

January 31 2013NCJE HUNN

19 DTU Space, Technical University of Denmark

MIRI/JWSTInfrared spectrograph

MIRI

A combined mid infrared camera and spectrograph covering wavelengths 5-27 µm.

DTU Space:Responsible of the Primary Support Structure.

January 31 2013NCJE HUNN

20 DTU Space, Technical University of Denmark

MIRI/JWSTPrimary Support Structure

Design drivers:

Low thermal conductivity between the 7K cold instrument and the 35 K ’hot’ telescope.

Lowest Eigenfrequency above 60 Hz with a 103 Kg instrument.

Max g-load 20.

January 31 2013NCJE HUNN

21 DTU Space, Technical University of Denmark

MIRI/JWSTPrimary Support Structure Tests:

Thermal cycling from Room Temperature to 7 K.

Strength Test.

Vibration.

Material properties:

Young's module.

Coefficient of thermal expansion.

Coefficient of moisture expansion.

Thermal conductivity.

Out gassing.