Le elevate prestazioni per materiali composite in ambito Spazio guidano fin dalla fase di progetto la scelta di fibre e sistemi di resina per soddisfare i requisiti di missione. In particolare, per la scelta del sistema di resina, i differenti scenari di missione prevedono applicazioni in temperatura e bassi assorbimenti di umidità durante le fasi realizzative e di assemblaggio dei manufatti in composito a terra per garantire alta stabilità in orbita. Essendo Thales Alenia Space – Italia una realtà operante nel settore Spazio, l’applicazione dei compositi si concentra su strutture satellitari e strutture secondarie per moduli abitativi per cui le caratteristiche di alta resistenza e rigidezza specifica danno notevoli vantaggi in termini di massa strutturale al lancio a favore del carico trasportato.

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Level 5 – Century Gothic 7 – RGB 0.171.199 Compositi 4.0 - La nuova
generazione
Torino 3 Maggio 2017
Materiali compositi per applicazioni Spazio

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TAS Space Applications
2
THALES ALENIA SPACE applies composite materials to its range of Space Products:

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Ref.:
Aerospace Composites
Aerospace Main Design Drivers for Composites
A rough distinction can be made as follows:
Aeronautics: design primarily driven by strength &
fatigue
Space: design primarily driven by stiffness to avoid
coupled resonant responses (e.g. between a satellite
and its launcher) and long term on-orbit environment
Common: mass optimization to maximize the
embarked payload (aerospace), reduce fuel
consumption (aircrafts)
The different design needs address the choice of
different composite materials (fibers & resin systems)
for aircrafts and space structures
Satellites: design driven by
stiffness performance
Composite in AeroSpace
(images credit: Arianespace)

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Subtitle – Century Gothic 10 – RGB 0.171.199
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Level 1 – Century Gothic 11 – RGB 36.54.70
Level 2 - Century Gothic 10 – RGB 0.171.199
Level 3 - Century Gothic 9 – RGB 36.54.70
Level 4 – Century Gothic 8 – RGB 127.127.127
Level 5 – Century Gothic 7 – RGB 0.171.199
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Ref.:
Drawbacks for Space Applications
Material cost (recurring & nonrecurring,
storage and expiring)
Low thermal & electrical conductivity
(improvable with conductive fibers)
Properties of structural laminates tend to
deteriorate due to environmental
conditions (transportation, prelaunch,
launch)
Strong concurrent design to
manufacturing & tooling required
NDI: more complex wrt metals, wide
variety of defectology
Repair: complex to recover structural
integrity, impact damage visibility
Advantages for Space Applications
Specific Strength/Stiffness: Light Weight
Low Coefficient of Thermal Expansion
Tailorable Thermo-Mechanical properties in
terms of:
Fibers (type, diameter, UD, fabrics)
Resin Systems Polymeric Matrix
Mix Resin/Fiber
Lay-up sequence & number of plies
Reduced machining (mostly limited to cutting
& holing)
Composite in Space - Main Issues

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Level 4 – Century Gothic 8 – RGB 127.127.127
Level 5 – Century Gothic 7 – RGB 0.171.199
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Composite in Space – Main Issues for Application in Manned Modules
5
Use of Composite & Polymeric Materials in a Manned
Environment (Space Modules) main concerns:
Off-gassing ruled and limited by ECSS-Q-ST-70-
29C (from European Space Agency): gaseous
products emission from on-board materials
possibly resulting in toxic concentrations, odors,
etc.
Flammability ruled by ECSS-Q-ST-70-21C: flame
propagation, melting & dripping, release of
toxic fumes
Bacterial & fungus growth ruled by
ECSS‐Q‐ST‐70‐55C: proliferation and growth
must not be favored by the material (on board
health hazard)
(images credit: NASA & ESA)

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Level 5 – Century Gothic 7 – RGB 0.171.199
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Composite in Space – Main Issues for Application to Unmanned Structures
6Use of Composite & Polymeric Materials in Unmanned Space
Vehicles (e.g. Satellites) main concerns:
Outgassing ruled by ESA ECSS-Q-70-02: molecular
contaminants release in thermal-vacuum environment
leading to payload contamination (e.g. optical
instrumentation)
Moisture desorption: contamination by condensation
(e.g. of optical instrumentation) is a type of outgassing
Thermal distortion: resulting from anisotropy in CTE of
composite materials (controllable with lay-up of
laminates)
Low thermal & electrical conductivity: replacement
with metal (Al alloy) where necessary, use of
conductive fibers
(images credit: TAS)

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Ref.:
Aerospace Main- F Fiber Typologies for
CompositesThe composite materials fiber typologies for Space Applications:
Fiber Typology Density Tensile Strength Tensile modulus
[kg/m3] [MPa] [GPa]
Carbon HT & SHT 1800 3100 - 4500 <100 – 200
Carbon IM 1800 4000 - 5600 200 – 350
Carbon HM 1800 2500 - 3500 350 – 450
Carbon UHM 2000 1700 - 2000 > 450
Aramid LM 1450 3600 60
Aramid HM 1450 3100 120
Aramid UHM 1470 3400 180
E-Glass 2500 2400 70
S-Glass 2500 3450 90
Glass – quartz 2500 3700 70
Aircrafts: Primary
Structures
Satellites: Primary
Structures
Space Modules: MDPS (Micro-
Meteroids & Debris Protection
Systems, Deployable Arms
Space Modules: Thermal
Decoupling Elements
Composite in Space – Fibers Typologies

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Ref.:
Aerospace Main Resin Typologies for
CompositesThe composite resin systems typologies:
Epoxy for normal use where high stability and release of
chemicals does not affect the performance, max
working temperature of 150 °C - 180 °C curing systems
Cyanate Esters working temperature of 150 °C - 180 °C
superior thermal stability, low out-gassing, low moisture
absorption, radiation resistance
Bismaleimidic up to about 250 °C find application in re-
entry and exploration vehicles (low –medium heat
applications)
Polyimide up to about 330 °C find application in re-entry
and exploration vehicles (low –medium heat
applications)
Satellites
Satellites
Space Re-Entry Vehicles
& Exploration Missions
Composite in Space – Resin Matrix Typologies
Space Re-Entry Vehicles
& Exploration Missions

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Ref.:
Composite Application in Space
Space Manned Applications - Internal
Equipment Racks in Manned Structures (Epoxy CFRP)
Composite in Space – Application Examples
(images credit: NASA & ESA)

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Level 1 – Century Gothic 11 – RGB 36.54.70
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Level 4 – Century Gothic 8 – RGB 127.127.127
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Ref.:
Composite Application in Space
Space Manned Applications - External
Thermal Decoupling Washers (GFRP) for MDPS (Micro Meteoroids & Debris Protection
System) panels attachment points
GFRP Washer in MDPS
panels attachment points
Composite in Space – Application Examples
(images credit: NASA & TAS-I)

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Ref.:
Composite Application in Space
Experiments
CPD – Coarse Pointing Device(Epoxy CFRP &
Metal): solar emission measurement
Composite in Space – Application Examples
(images credit: NASA & ESA )
CFRP

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Level 1 – Century Gothic 11 – RGB 36.54.70
Level 2 - Century Gothic 10 – RGB 0.171.199
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Level 4 – Century Gothic 8 – RGB 127.127.127
Level 5 – Century Gothic 7 – RGB 0.171.199
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Ref.:
Aerospace Composite Configurations
Satellite Structure Typical Structural Configuration
Typical configurations given by:
Sandwich (mostly for high stiffness applications e.g. satellite primary structures)
Inserting & potting for equipment fixation
Brackets & machined parts under skin embedding
Connection of panels via angular shapes cleats
Perspective of high multi-functional panels
Partial Insert
Composite in Space – Typical Structural Configuration
Inserts in Composite Sandwich
Full Insert

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Level 1 – Century Gothic 11 – RGB 36.54.70
Level 2 - Century Gothic 10 – RGB 0.171.199
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Level 4 – Century Gothic 8 – RGB 127.127.127
Level 5 – Century Gothic 7 – RGB 0.171.199
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Ref.:
Satellite Structure Typical Configuration
The satellite structural is typically based on a sandwich
panels’ assembly: Al honeycomb with CFRP skins :
Satellite Primary Structure
Satellite with Subsystems
Satellite in Flight
Composite Application in SpaceComposite in Space – Typical Structural Configuration
(images credit: TAS)

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Level 1 – Century Gothic 11 – RGB 36.54.70
Level 2 - Century Gothic 10 – RGB 0.171.199
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Level 4 – Century Gothic 8 – RGB 127.127.127
Level 5 – Century Gothic 7 – RGB 0.171.199
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Ref.:
Composite Application in Space
Composite in Space Unmanned Applications
Solar Arrays (sandwich structure)
Antenna Reflectors (sandwich structure)
Truss Structures (tubular structure)
Solar Arrays
Antenna Reflectors
Truss Structures
Composite in Space – Typical Structural Configuration
(images credit: TAS)

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Subtitle – Century Gothic 10 – RGB 0.171.199
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Level 1 – Century Gothic 11 – RGB 36.54.70
Level 2 - Century Gothic 10 – RGB 0.171.199
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Level 4 – Century Gothic 8 – RGB 127.127.127
Level 5 – Century Gothic 7 – RGB 0.171.199
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Ref.:
TAS-I Composite Capabilities, FacCailities &
EquipmentTAS-I Composite Capabilities
Manufacturing of composite structures by hand lay-up
or filament winding plus autoclave cure:
Bonding of Aluminum/CFRP sandwich panels,
insert potting, edge taping
TAS-I Facilities & Equipment:
Autoclave (dimensions diam. 4 m x 12 m length).
Numerically-controlled 4-axis filament winding
machine (FWA1 Bolenz & Schaefer) for the
automatic manufacture of axis-symmetrical
composite parts up to 1.8 m in diameter and 3 m in
length
Clean rooms (100000 class, according to FED-STD-
209) covering an area of 800 m2
Filament Winding Plant
Autoclave
Composite in Space – TAS-I Manufacturing Capabilities
(images credit: TAS)