Progress in Lightweight Design Methods for Large-Size Panel Structures in Manned Pressurized Capsules
Abstract
:1. Introduction
2. Overview of Pressurized Capsule Structure
2.1. Pressurized Capsule
2.2. Typical Flight Environment
2.3. Pressurized Capsule Structure
2.4. The Development Course of Pressurized Capsule Structure
3. Structural Requirements of Manned Deep Space Exploration Pressurized Capsule
- (1)
- Lower structural weight [16]
- (2)
- Longer structural life requirements
- (3)
- Reusable function
- (4)
- More complex load conditions [7]
- (5)
- Higher spatial environmental adaptability
4. Technical Analysis of MDSEM
4.1. Problems Existing in WPPCS
4.2. The Emergence of IPPCS
5. Research Progress on Key Technologies of IPPCS
- (1)
- The strength criterion of the pressurized capsule structure based on shakedown: the shakedown limit of the structure is taken as the ultimate bearing capacity of the internal pressure load of the pressurized capsule structure, which improves the bearing capacity of the structure (the post-yield performance of the material is applied) and the safety of the bearing capacity of the structure whose local material is in the plastic stage.
- (2)
- The design method of the IPPCS: a design process and optimization method for the IPPCS is proposed, which can guide the design of both local and overall structures.
- (3)
- Upgrading of pressurized capsule structure material: through the application research, the promotion of material upgrades for the pressurized capsule structure to materials such as 5B70 aluminum alloy.
- (4)
- The overall manufacturing process of pressurized capsule structure: master the spinning process of large-size parts and lay the foundation for the overall manufacturing of the pressurized capsule.
5.1. The Strength Criterion of the Pressurized Capsule Structure Based on Shakedown
5.1.1. Problems of Conventional Strength Criterion
5.1.2. Application of Shakedown Theory on Pressurized Capsule Structure
- (1)
- (2)
- Experimental verification of shakedown limit analysis of pressurized capsule structure
5.2. Research on the Design Method of IPPCS
- (1)
- (2)
- (3)
- Design of transition zone stiffener configuration [18]
- (4)
5.3. Material Upgrading of the Pressurized Capsule Structure
5.3.1. Application Analysis of Al-Mg-Sc Alloy in Pressurized Capsule Structure
5.3.2. Analysis of Application Potential of Al-Mg-Sc Alloy in Deep Space Exploration Pressurized Capsule Structure
- (1)
- Fatigue limit
- (2)
- Fracture toughness
- (3)
- Large size and ultra-large thickness plate supply
5.4. Research Progress on Manufacturing Technology of Pressurized Capsule Structure
5.4.1. Analysis of the Spinning Process
5.4.2. Research on Spinning Process of 5B70
6. Concluding Remarks
- (1)
- As an essential section of the manned spacecraft, the pressurized capsule structure is the key to realize the functions of bearing and sealing. With the stiffer requirements of the life and reliability of the pressurized capsule structure, the panel pressurized capsule structure represented by the WPPCS instead of the semi-monocoque shell type is the current mainstream pressurized capsule structure.
- (2)
- The MDSEM requires the pressurized capsule structure to have extremely low structural weight, long space service life of more than 15 years, reusability and adaptability to the harsh deep space environment. The conventional WPPCS has inherent shortcomings such as low bearing efficiency, large structural weight and conservative strength criterion, which makes it unable to be widely used in MDSEMs. As a method to meet the new requirements, the new structure of the IPPCS replaces the frame by the local panel structure, eliminates the segmentation of the weld zone, realizes the global stiffener continuity of the capsule, overcomes the shortcomings of the WPPCS and significantly improves the lightweight level of the pressurized capsule structure.
- (3)
- The key technology research progress of the IPPCS is rapid and has the engineering application conditions. The technical progress is organized as follows: Firstly, through the internal pressure cyclic loading experiment, the validity of the numerical analysis technology of the internal pressure shakedown limit of the pressurized capsule structure is verified. The bearing safety of the pressurized capsule structure with local plastic deformation can be evaluated by the shakedown analysis. A strength criterion of the pressurized capsule structure is added, that is, the allowable stress level of the local area of the pressurized capsule structure in the shakedown state should be higher than the yield strength of the material. Secondly, the IPPCS design method is proposed including four steps of shell cross-section, basic stiffener configuration, transition zone stiffener configuration and local structure, which guides the full realization of the optimization-based structural design in engineering applications and provides a tool guarantee for the structural design of the IPPCS. Thirdly, the 5B70 has excellent comprehensive performance, with the advantages of medium strength, weldability and corrosion resistance. It also meets the material selection requirements of the pressurized capsule structure, and can be widely used in the pressurized capsule structure instead of 5A06. Fourthly, the spinning process of large-size ultra-thick plates can realize the structural integrity manufacturing of the pressurized capsule structure, which provides a process guarantee for the development of the IPPCS.
- (1)
- The quantitative prediction method of internal pressure shakedown limit load of the pressurized capsule structure will be studied: The calculation time of numerical methods for the shakedown limit load is long, and sometimes it does not meet the need of rapid evaluation of bearing capacity. The establishment of approximate prediction formulas can quickly calculate the shakedown limit prediction load.
- (2)
- The structural technology of lightweight pressurized capsule structures with large temperature gaps will be studied: Extreme high and low temperature alternation is one of the challenges of MDSEMs. Providing suitable temperature conditions for the pressurized capsule structure through an independent thermal control subsystem is not conducive to reducing the weight of the spaceflight. The structural technology of the pressurized capsule adapted to the boundary of large temperature differences is the key to optimize the system scheme and cancel the thermal control subsystem.
- (3)
- The reuse design and verification technology of the IPPCS will be studied: Reuse can reduce the service cost of the high pressurized capsule structure. How to carry out the reuse design and verification of the pressurized capsule structure is the key technology that needs to be overcome in the future.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Serial Number | Type | Spacecraft | Nation/Institution | Module Name | First Launch Date | Structure Form |
---|---|---|---|---|---|---|
1 | manned spacecraft | Vostok | Russia | pressurized capsule | April 196 | s-MPCS |
2 | manned spacecraft | Mercury | USA | pressurized capsule | February 1962 | s-MPCS |
3 | manned spacecraft | Voskhod | Russia | pressurized capsule | October 1964 | s-MPCS |
4 | manned spacecraft | Gemini | USA | pressurized capsule | March 1965 | s-MPCS |
5 | manned spacecraft | Soyuz | Russia | reentry capsule orbital capsule | April 1967 | s-MPCS |
6 | manned spacecraft | Shenzhou | China | reentry capsule orbital capsule | November 1999 | s-MPCS |
7 | manned spacecraft | Apollo | USA | command capsule | July 1969 | s-MPCS |
8 | cargo spacecraft | Progress | Russia | cargo pressurized module | January 1978 | WPPCS |
9 | cargo spacecraft | Automatic transfer of aircraft | European Space Agency | cargo pressurized module | March 2008 | WPPCS |
10 | cargo spacecraft | Tianzhou | China | cargo pressurized module | April 2017 | WPPCS |
11 | space laboratory | Salyut | Russia | docking module orbital module | April 1971 | WPPCS |
12 | space laboratory | Skylab | USA | orbital module | May 1973 | WPPCS |
13 | space laboratory | Tiangong-1 space laboratory | China | experiment module | September 2011 | WPPCS |
14 | space station | Mir | Russia | core module | February 1986 | WPPCS |
15 | space station | Russia | Quantum-I/1 module | April 1987 | WPPCS | |
16 | space station | Russia | Crystal module | May 1990 | WPPCS | |
17 | space station | Russia | Spectrum module | May 1995 | WPPCS | |
18 | space station | Russia | Priroda module | April 1996 | WPPCS | |
19 | space station | International Space Station | Russia | Zarya cargo module | November 1998 | WPPCS |
20 | space station | USA | Unity node module | December 1998 | WPPCS | |
21 | space station | Russia | Zvezda service module | July 2000 | WPPCS | |
22 | space station | USA | Destiny experiment module | February 2001 | WPPCS | |
23 | space station | USA | Quest airlock module | July 2001 | WPPCS | |
24 | space station | Russia | Mooring compartment module | September 2001 | WPPCS | |
25 | space station | USA | Harmony node module | October 2007 | WPPCS | |
26 | space station | European Space Agency | Columbus experiment module | February 2008 | WPPCS | |
27 | space station | Japanese | Japanese experiment module | March 2008 | WPPCS | |
28 | space station | China Space Station | China | Tianhe core module | April 2021 | WPPCS |
29 | China | Wentian lab module | July 2022 | WPPCS | ||
30 | China | Mengtian lab module | October 2022 | WPPCS |
Preset Crack Orientation | 5A06 KR(MPa·m1/2) | 5B70KR(MPa·m1/2) |
---|---|---|
Direction L | 105.6 | 115.018 |
Direction T | 110.2 | 120.237 |
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Zhou, Z.; Yu, C.; Han, X.; Zheng, K.; Jiang, C.; Tian, K. Progress in Lightweight Design Methods for Large-Size Panel Structures in Manned Pressurized Capsules. Appl. Sci. 2023, 13, 8635. https://doi.org/10.3390/app13158635
Zhou Z, Yu C, Han X, Zheng K, Jiang C, Tian K. Progress in Lightweight Design Methods for Large-Size Panel Structures in Manned Pressurized Capsules. Applied Sciences. 2023; 13(15):8635. https://doi.org/10.3390/app13158635
Chicago/Turabian StyleZhou, Zhiyong, Chenfan Yu, Xiuzhu Han, Kaiwei Zheng, Chao Jiang, and Kuo Tian. 2023. "Progress in Lightweight Design Methods for Large-Size Panel Structures in Manned Pressurized Capsules" Applied Sciences 13, no. 15: 8635. https://doi.org/10.3390/app13158635
APA StyleZhou, Z., Yu, C., Han, X., Zheng, K., Jiang, C., & Tian, K. (2023). Progress in Lightweight Design Methods for Large-Size Panel Structures in Manned Pressurized Capsules. Applied Sciences, 13(15), 8635. https://doi.org/10.3390/app13158635