Advancement of Multifunctional support structure technologies (AMFSST)

The multifunctional support structure (MFSS) technology is promising a reduction of overall mass and packing volume for spacecraft (S/C) electronic components. This technology eliminates the electronic box chassis and the cabling between the boxes by integrating the electronics, thermal control and the structural support into one single element. The ultimate goal of the MFSS technology is to reduce size, weight, power consumption, cost and production time for future spacecraft components. The paper focus on the main challenges and solutions related to the thermal management within the MFSS technology based on the selected charge regulator (CR) application. Starting with the main set of thermal requirements for the CR the paper will include, conceptual and detailed design based on highconductivity carbon fibre CFRP, description and results of the thermal material sample test program ; parameter and results for the performed first thermal simulationComment: Submitted on behalf of TIMA Editions (http://irevues.inist.fr/tima-editions

IN-SERVICE INSPECTION OF AERONAUTICS PARTS PRODUCED BY ADDITIVE LAYER MANUFACTURING (ALM) - in the framework of Bionic Aircraft project (GA nº 690689)

Bionic Aircraft is a project founded under the H2020 Framework Program and it is a result of a need to reduce emissions due to the impact of the growth of the aviation industry. The introduction of Additive Laser Manufacturing (ALM) to produce some metal aircraft parts is considered as an opportunity to address this issue. This technology allows to produce ultra-lightweight and highly complex parts (so-called “bionic parts”). One of the actions to consider in the project is the development of new NDT strategies to inspect, in-service, parts produced by ALM made of Al-based alloys. This need arises because, ALM processes for these alloys are at low maturity level (TRL2) and hence, no proven and certified NDT methods are yet developed. Moreover, in-service inspection of aeronautic bionic parts involves challenges like the uncertainty of the inner inspection of a layered material, the lack of accessibility (the part is attached to the aircraft fuselage), and the expected defects under in-service conditions, something still under study. The objective of this work is to assess the inspection, in-service, of this kind of parts, by selecting and customizing the most suitable NDT methods, according to the type and maximum tolerable damage sizes estimated by a fatigue life prediction evaluation.H2020, 690689, Bionic Aircraf

RADIATION SHIELDING OF COMPOSITE SPACE ENCLOSURES

Space electronic systems employ enclosures to shield sensitive components from space radiation. The purpose of shielding is to attenuate the energy and the flux of ionizing radiation as they pass through the shield material, such that the energy per unit mass (or dose) absorbed in silicon is sufficiently below the maximum dose ratings of electronic components. The received radiation amount varies significantly depending on several variables that include mission parameters (orbit, altitude, inclination and duration), spacecraft design (spacecraft wall thickness and panel-enclosure location). To achieve the optimum shielding with the minimum weight, all these variables have to be considered in the design. Energetic particles, mainly electrons and protons, can destroy or cause malfunctions in spacecraft electronics. The standard practice in space hardware is the use of aluminium as both a radiation shield and structural enclosure. Composite structures show potential for significant mass savings. However, conventional graphite epoxy composites are not as efficient shielding materials as aluminium because of their lower density, that is, for the same mass, composites provide 30 to 40% less radiation attenuation than aluminium. A solution is to embed high density (atomic weight) material into the laminate. This material, typically metallic material, can be dispersed in the composite or used as layers in the laminate (foils). The main objective of the “Radiation Shielding of Composite Space Enclosures” (SIDER) project is the development of the technologies and tools required to obtain lightweight, safe, robust and reliable composite structures. Two different strategies are being analysed as alternatives for radiation shielding: and he incorporation of a high density material foil. This paper will present and analyse the radiation shielding obtained by the incorporation of nanomaterials in composite structures

Hot stamping of aerospace aluminium alloys: Automotive technologies for the aeronautics industry

This paper proposes the use of the hot stamping process that provides ready to use parts for the obtention of aircraft components as an alternative manufacturing technology to e.g. machined parts. The development has been focused on the study of the high temperature formability of aluminium alloys. The feasibility of hot forming the AA2198 aluminium lithium alloy into complex shapes component has been studied. A wide experimental campaign has been carried out to set up the optimum hot stamping process parameters. In addition, forming trials with different geometries (omega and B-pillar shapes) have also been performed and, after the corresponding heat treatment, material properties have been recovered. Simulations of the hot stamping process have been carried out with Pamstamp® 2G software. These results have been correlated with the ones obtained in the experimental campaign. As a final step of the development, a demonstrator corresponding to a wing rib has been successfully manufactured. Characterization carried out to the prototype indicate specifications are fulfilled.The study presented in this paper was carried out in the frame of OUTCOME project within Airframe ITD of Clean Sky 2 Programme. The project received funding from the Clean Sky 2 Joint Undertaking (JU) under ITD Airframe Grant Agreement for Members. The JU received support from the European Union's Horizon 2020 (H2020) research and innovation programme and the Clean Sky 2 JU members other than the Union. The authors want to acknowledge Airbus Defence and Space S.A.U for providing the design of the developed prototype, Aernnova Aero- space S.A.U for OUTCOME project coordination and facilitator and fruitful technical discussions and RIB-ON Consortium for developing and building the die and final manufacturing of the wing rib

PM Based Titanium Matrix Composites for Aerospace Applications: Processing, Mechanical Properties and Scale Up

The reinforcement of titanium with a hard phase is an efficient way to increase the stiffness and strength of conventional titanium alloys. The high reactivity of titanium is a critical challenge in the processing of Titanium Matrix Composites (TMCs). For this reason, Powder Metallurgy is considered a very promising route for the manufacturing of TMCs. In this work, a master alloy (Ti-TiC) was developed by combustion synthesis. This alloy was further blended with conventional titanium alloy and the final consolidation was performed by Spark Plasma Sintering. In addition to the processing details, microstructural and thermomechanical characterization is presented. Materials obtained present higher Young Modulus and strength than conventional Ti-6Al-4V, with higher thermal conductivity and maintaining similar thermal expansion coefficient (CTE). The good corrosion resistance of the material makes it a candidate for possible applications in aerospace. This work presents also the scale up of the process to obtain aerospace demonstrators.This work was carried out within the frame work of the projects: ‘‘Development and Characterization of Advanced Metal Matrix Composites (Hybrid-MMs)’’) and “Hybrid Titanium Matrix Composites (TMC) for aero engines applications (AIRTMC) both supported by ESA (European Space Agency

Development of Titanium Matrix Composites for Aerospace applications

Titanium Matrix Composites are very interesting for aerospace applications. These materials typically present higher Young Modulus and resistance than conventional titanium alloys. The ceramic reinforcement can be continuous or discontinuous (fibers or particles). Main advantages of discontinuously reinforced TMCs are the isotropic mechanical properties and the lower production costs. This work presents the development of discontinuously reinforced TMCs with TiC as reinforced particles. The reinforcement was obtained by Combustion Synthesis and the final consolidation by Spark Plasma Sintering. Main advantage of this PM process is the short processing time. Regarding the thermos-mechanical characterization, the material presents higher stiffness and resistance with higher thermal conductivity than conventional Ti-6Al-4V. This work also presents the scale-up of the SPS process to obtain aerospace demonstrators. Machining and joining issues are also considered

Fabrication and characterisation of Titanium Matrix Composites obtained using a combination of Self propagating High temperature Synthesis and Spark Plasma Sintering

This work presents a novel processing method for the fabrication of particle reinforced Titanium Matrix Composites (TMCs). TMCs are a promising alternative to improve the mechanical properties of titanium alloys. In the processing method, the reinforcement (TiC–Ti) was obtained by Self-propagating High-temperature Synthesis (SHS). The composition of the reinforcement was Ti1.3C. An excess of titanium compared to the equiatomic TiC was introduced in the reaction in order to control the size of the reinforcement and to improve the compatibility between reinforcement and matrix. This reinforcement was mixed with Ti–6Al–4V powder and the final consolidation of the TMC was performed by Spark Plasma Sintering (SPS). The microstructure and mechanical characterisation of the TMCs are presented. Comparing tensile properties with conventional Ti–6Al–4V alloys, the materials developed in this work present higher young modulus and tensile strength. In addition, in order to study the possible scale up of SPS process for the production of TMCs, the manufacturing of large samples was studied.This work was carried out within the frame work of the project with reference AO/1-7091/12/NL/EM, entitled “Development and Characterisation of Advanced Metal Matrix Composites (Hybrid-MMCs)” supported by ESA (European Space Agency)