The presentation is about the various types of composites used in the space shuttle program. The history of the STS program was elucidated and the further developments were discussed. The presentation discussed about the various types of the composites used in various parts of the shuttle. The presentation was made in PowerPoint 2016, theme STEM Pitch Dark. Authors: Adarsh Agrawal, Gunjan Javaria, Vaibhav Mahawar

1. COMPOSITESIN
SPACESHUTTLE
A DISPOSITION
Space Shuttle Atlantis at Cape Canaveral, Florida
Courtesy: NASA

2. page 2
• Introduction
• History of the STS and facts
• Comprehensive list of composites
• Application and reasons
• Pros and Cons
• Conclusion
OBJECTIVE
To elucidate the usage of various
composites used in space
shuttles over the years..
FLOWOF
DISCUSSION

3. page 3
SPACE
TRANSPORTATION
SYSTEM
FORMER GATEWAY TO LOW EARTH ORBITS
• Partially reusable launch vehicle
• First Flight:April 12, 1981 & Last Flight:
July 21, 2011
• A total of 135 successful missions (with
only 2 failures)
• Established the major chunk of
technology in space at status quo

4. page 4
Courtesy: NASA

5. • A Total Of Six Space Shuttles Were Built,
Five Were Launched: Columbia,
Challenger, Discovery, Atlantis And
Endeavour
• The Shuttle Enterprise; Only For
Approach And Landing Tests.
FACTSABOUT
THESPACE
SHUTTLE
page 5
Courtesy: NASA

6. page 6
• Enterprise – Replacement To
Challenger Disaster In 1986.
• 73 Seconds Into Flight;
Challenger Broke Apart. All On
Board Perished
The L.A.Times front page the day of the shuttle explosion.
Sharon Christa McAuliffe, first civilian and educator to fly in
space

7. • In 2003, Space Shuttle Columbia
Disintegrated Upon Reentering Earth’s
Atmosphere
• A piece of foam insulation broke off from
the Space Shuttle, struck the left wing of
the orbiter.
COLUMBIA
ACCIDENT
page 7
TIME© magazine featuring the Columbia disaster
Courtesy: content.time.com

8. page 8

9. page 9

10. page 10
CostTradeoffStudy
• Cost trade off study between the
Development cost and the cost
per flight
• Rectangular hyperbola obtained
• Higher the initial investment
(development cost) lesser the
future per flight cost
• Lesser investment yield higher
cost per flight
Courtesy: GSFC,NASA

11. LightWeight
Composites weigh
less than metals used
for the same
purposes
Strength
Composites provide
high strength to
weight ratio
Trustworthy
Flight proven; easy to
maintain, durable and
reliable
Cost
Comparably cheaper
to maintain
Good conductors
Generally good
conductors of heat
and electricity
page 11
Whycomposites

12. page 12
AnOverview!
Courtesy: McGillCorporation

13. COMPOSITES
USED
DISCUSSION OF VARIOUS TYPES OF
COMPOSITES, THEIR AREA OF USAGE FOLLOWS
page 13
LI 900 Silica tiles (in black),
Space ShuttleAtlantis.
Courtesy: NASA

14. • Space Shuttle endure temperature
range of -1210C to 16490C
• Variety of thermal control
techniques implied to withstand the
high temperatures
• Materials like RCC withstand such
temperature ranges
THERMAL
PROTECTION

15. <
Temperaturedecidesmaterial
page 15
12600C : Rigid SilicaTiles/Fibrous
Insulation.
> 12600C : RCC
(Reinforced Carbon- Carbon)

16. • Based on the work of Lockheed
Missiles and Space Company
• Reusable ceramic fibres for
reentry
• reusable insulation bonded to a
lightweight aluminium airframe
• Large portions comprised of RSI
• On LRSI:
• White coating, possessing optical
properties
• Max temp reached: 649oC
I)RigidSilicaTiles/FibrousInstallation
Reusable
Surface
Insulation
Low –
Temperature
RSI
High-
Temperature
RSI
• On HRSI:
• Black borosilicate glass coating to
protect areas reaching up to
1260C
1-3 micron diameter pure silica glass fibers.
6 % solid phase and 94 % air by volume

17. HRSI Tiles

18. • withstand high temperatures and
protect areas > 1260°C
• Parts made of RCC:
• nose cap
• the area from nose cap to nose landing
gear doors
• arrowhead aft of the nose landing gear
door and
• the outer edges of the wings
• ability to reject heat: external radiation
and cross radiation;
• cross radiation from lower surface to
cooler upper surface
Large Impact hole
during test on RCC
panel, when hit with
foam piece
II)RCC
Courtesy: Southwest Research Institute

19. • This replaced the LI-2200
tiles located around door
penetrations
• Helped reduce the overall
weight of the space shuttle
• Nextel fiber, an amorphous
alumino-boro-silicate fiber
• Blankets ; pure silica felt
sandwiched between a layer
of silica fabric (the hot side)
and S – glass fabric
 ARSI provided with
• Durability
• Reduced installation times
• Reduced cost of the shuttle
• Reduced weight of Atlantis
and Discovery
Replacementmadetotilesandothermaterials
page 19
Fibrous Refractory
Composite Insulation
FRCI-12
Felt Reusable Surface
Insulation
FRSI
Advanced fiber reusable
surface Insulation
AFRSI
• Parts experience
temperatures below 371°C
including the upper payload
bay doors, sections of the
mid-fuselage and the aft
fuselage sides.
• felt like material made
from needled polyaramid
fibers
• Naturally water resistant

20. page 20
Courtesy: NASA

21. Courtesy: NASA

22. page 22
Courtesy: CAIB

23. 01
02
0503
04
Polymermatrix
composite
Metalmatrix
composite
Elastomers
Elasticmemory
composite
Graphitefibre
composite
Othercomposites(&futurescope)

24. PolymerMatrixComposite
• Use of PMC began in 1940;
• First used to fabricate aircraft radome
via glass/polyester PMC
• Carbon/epoxy materials were used
fighter aircrafts in 1969
• Other commonly used PMC's are :
• Aramid- Kevlar/epoxy (1971),
• Carbon/ polyimide (1974),
• Carbon/ thermoplastic (1988)

25. Graphite-fibreComposite
• Most commonly used type of composite
• Light weight, high stiffness, and thermo-
dimensional stability
• Negative coefficient of thermal
expansion(CTE)
• Best suitable to build trusses as negative CTE
can be used to offset the positive CTE of
metal end fittings and hinges
• Manufacture by pultrusion mechanism

26. ElasticMemoryComposites
• Similar to traditional fibre-reinforced
composites but uses thermoset shape
memory resin
• Can achieve much higher failure strains than
traditional composites when exercised
through a very specific thermo-mechanical
load cycle.
• These high strains are induced by raising the
temperature of resin above critical glass
temperature(Tg) and applying the
mechanical load

27. MetalMatrixComposites
• MMCs possess high specific strength and
stiffness, good thermal and electrical
conductivity, and moderate coefficients of
thermal expansion.
• MMCs such as B/Al, Gr/Al, Gr/Mg, and Gr/Cu
have been manufactured by diffusion
bonding.
• Used for spacecraft components such as
tubes, plates, and panels.
• Have stable mechanical properties up to
510°C and high thermal conductivity
Elastomers
• Polymer with rubber like elasticity
(viscoelasticity).
• Made from materials like thermoplastic
polyurethanes, copolyester elastomer, and
woven materials made from elastane yarns.
• Best used for making aircraft and spacecraft
skins
• Have high strain capability, lower degree of
risk due to their passive operation, elastic
recovery with nominal strain values and a
smooth aerodynamic surface characteristics

28. page 28
Applications Material Satellites/SpaceVehicles
Antenna, reflectors, horns,
platforms
Graphite/epoxy and aramid/epoxy Anik B- first use of GRE in Space
(1972)
Synthetic aperture radar antennas Graphite/epoxy ERS-1
Antenna feeds, waveguides and
microwave filters
Graphite/epoxy IntelsatV
Central tube cylinder Graphite/epoxy sandwich NAVSTAR GPS GOESWeather
satellites
Solar arrays(telephonic cylindrical
arrays)
Graphite/epoxy tubes and skins TDF-1
Tubular truss structures and towers Graphite/epoxy SPAS, Eureca
Payload bay doors
pressure vessels
thermal protection tiles
Graphite/epoxy sandwich
Aramid/epoxy
Carbon/carbon
Space shuttle
Space shuttle
Space shuttle
Launch vehicle structures Graphite/epoxy Ariane
Optical structures Graphite/epoxy Hubble telescope
Space robot systems Graphite and aramid/epoxy sandwich
Graphite/peek
Canadarm
Space shuttle
Mobile Service Facility/Space Station

29. page 29
OtherAreasofApplication(Spin-Offs)
Robust Material Building, better
thermal control, employment
and opprtunities
Research and Innovation
Fire resistant materials; chemically
treated fabric for sheets; uniform
for hazardous material handling
Fire Fighting
Improved passive thermal
control
Satellite Building
Engine efficiency
Icarbon-carbon pistons lighter
than Al, increase of mechanical
& thermal efficiency

30. page 30
• Composites usage was best decision for
shuttle making
• Composites can and will be used in future
space missions
• Composites are getting better, lighter,
stronger and reliable
• Huge opportunity of innovation and research
lies ahead!
CONCLUSION
Future seems bright!

31. Adarsh Agrawal
Maker, Space enthusiast, Researcher,
Designer and a talker
1RV16AS003
Gunjan Javaria
Thinker, Observer, Hard worker, Good
at heart
1RV16AS015
Vaibhav Mahawar
Humble mathematician, Believer
1RV16AS061
Team
page 31

32. THANK
YOU!
Project Works and Co.
+91 9721170745
adarshagrawal.ae16@rvce.edu.in
rvce.edu.in