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15 pages, 14754 KiB

Open AccessArticle

Compressive Behavior, Mechanical Properties and Energy Absorption of Al Honeycomb and Al Closed-Cell Foam: A Comparison

by Alessandra Ceci, Girolamo Costanza and Maria Elisa Tata

Aerospace 2025, 12(1), 32; https://doi.org/10.3390/aerospace12010032 - 8 Jan 2025

Cited by 1 | Viewed by 762

Abstract

In this work, we focused on the characterization of closed-cell Al foams and aluminum honeycomb panels, in particular their energy absorption capacity under conditions of static compressive stress. Through experimental tests, the specific energy absorbed by different samples was evaluated: in the honeycomb [...] Read more.

In this work, we focused on the characterization of closed-cell Al foams and aluminum honeycomb panels, in particular their energy absorption capacity under conditions of static compressive stress. Through experimental tests, the specific energy absorbed by different samples was evaluated: in the honeycomb panels the mechanical behavior was analyzed both for large assemblies and for structures with a reduced number of cells, and the effect of the number of cells was studied too. Furthermore, for larger structures, the specific energy absorbed was calculated from stress–strain compressive graphs. For the closed-cell Al foams, manufactured in the laboratory using the powder compaction method with different percentages of SiC and TiH₂ and characterized by different relative densities, the specific energy absorbed was evaluated too. The experimental results showed that the specific energy absorbed by the Al honeycomb was always higher than that of the different types of closed-cell foams. However, when selecting the material for each specific application, it is necessary to take into account numerous parameters such as the relative density, absorbed energy, peak stress, plateau stress, plateau extension, densification strain and so on. Consequently, the overall performance must be evaluated from time to time based on the type of application in which the best compromise between strength, stiffness and lightness can be achieved. Full article

(This article belongs to the Special Issue Advanced Design for Lightweight Space Materials and Structural Systems)

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23 pages, 8708 KiB

Open AccessArticle

Development of a Passive Vibration Damping Structure for Large Solar Arrays Using a Superelastic Shape Memory Alloy with Multi-Layered Viscous Lamination

by Gi-Seong Woo, Jae-Hyeon Park, Sung-Woo Park and Hyun-Ung Oh

Aerospace 2025, 12(1), 29; https://doi.org/10.3390/aerospace12010029 - 2 Jan 2025

Cited by 1 | Viewed by 673

Abstract

In the space environment, the elastic vibrations of satellite solar panels are caused by various factors that disturb satellite missions. Therefore, we propose a multi-layered high-damping yoke structure based on a passive control method. To optimize the proposed yoke structure, we performed a [...] Read more.

In the space environment, the elastic vibrations of satellite solar panels are caused by various factors that disturb satellite missions. Therefore, we propose a multi-layered high-damping yoke structure based on a passive control method. To optimize the proposed yoke structure, we performed a free vibration test on various multi-layered blade specimens and designed a yoke structure with the maximum damping performance based on the test results. This high-damping yoke structure was mounted on a dummy solar panel with flexible mode (0.79 Hz) and basic characteristic tests were performed to validate the effectiveness of the solar panel vibration suppression. The test results demonstrated that the proposed multi-layered high-damping yoke is effective in suppressing the vibrations of the first and second modes. In addition, a thermal vacuum test was performed to investigate the delamination between multi-layered structures, and the test results proved the applicability of the proposed yoke structure in an actual space environment. Full article

(This article belongs to the Special Issue Advanced Design for Lightweight Space Materials and Structural Systems)

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17 pages, 5930 KiB

Open AccessArticle

Recycling Space Beverage Packaging into LDPE-Based Composite Materials

by Federica De Rosa, Flavia Palmeri and Susanna Laurenzi

Aerospace 2024, 11(12), 957; https://doi.org/10.3390/aerospace11120957 - 21 Nov 2024

Viewed by 765

Abstract

Long-term space missions require careful resource management and recycling strategies to overcome the limitations of resupply missions. In this study, we investigated the potential to recycle space beverage packaging, which is typically made of low-density polyethylene (LDPE) and PET-aluminum-LDPE (PAL) trilaminate, by developing [...] Read more.

Long-term space missions require careful resource management and recycling strategies to overcome the limitations of resupply missions. In this study, we investigated the potential to recycle space beverage packaging, which is typically made of low-density polyethylene (LDPE) and PET-aluminum-LDPE (PAL) trilaminate, by developing a LDPE-based composite material with PAL inclusions. Due to the limited availability of space beverage packaging, we replaced it with LDPE powder and commercial coffee packaging for the experiments. Fourier transform infrared spectroscopy (FTIR) was employed to thoroughly analyze the composition of the commercial coffee packaging. The simulant packaging was reduced to a filler, and its thermal properties were characterized by differential scanning calorimetry (DSC), while the particle size was analyzed via scanning electron microscopy (SEM) and the bootstrap resampling technique. Composite specimens were then fabricated by incorporating the filler into the LDPE matrix at loadings of 5 wt% and 10 wt%, and their mechanical and thermal properties were assessed through dynamic mechanical analysis (DMA) and thermal conductivity measurements. The 10 wt% corresponds approximately to the radio between PAL and PE in space beverage packaging and is, therefore, the maximum usable percentage when considering a single package. The results indicate that, as the filler loading increased, the mechanical performance of the composite material decreased, while the thermal conductivity was significantly improved. Finally, 10 wt% LDPE/PAL filaments, with a diameter of 1.7 mm and suitable for the fused filament technique, were produced. Full article

(This article belongs to the Special Issue Advanced Design for Lightweight Space Materials and Structural Systems)

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16 pages, 4859 KiB

Open AccessArticle

Study on the Dynamic Crushing Behaviors of Hourglass Honeycomb Sandwich Panels

by Xinhai Chen, Kai Wang, Lu Cao, Pengyu Guo, Jiangyi Qin and Hexiang Wu

Aerospace 2024, 11(11), 881; https://doi.org/10.3390/aerospace11110881 - 25 Oct 2024

Cited by 1 | Viewed by 943

Abstract

In response to the problem of enclosed internal spaces in existing honeycomb sandwich panels, the concept of an hourglass honeycomb sandwich panel model is proposed for the first time, which provides a breakthrough approach for achieving the multifunctional integration of honeycomb sandwich panels. [...] Read more.

In response to the problem of enclosed internal spaces in existing honeycomb sandwich panels, the concept of an hourglass honeycomb sandwich panel model is proposed for the first time, which provides a breakthrough approach for achieving the multifunctional integration of honeycomb sandwich panels. Numerical simulation methods are employed to investigate the dynamic performance of the hourglass honeycomb sandwich panels. The focus is on discussing the influences of the geometric parameters on the deformation mode, dynamic response, load uniformity, and energy absorption capacity of the hourglass honeycomb sandwich panel under different impact velocity conditions. The research results indicate that under low-velocity-impact conditions, the influence of the geometric parameters is predominant. In contrast, under high-velocity-impact conditions, the influence of the impact velocity conditions is predominant. Hourglass honeycomb sandwich panels with low density, a large inclination angle of the honeycomb wall, and small contact distances between the hourglass honeycomb cell and the panel have excellent load uniformity, and the distances between the contact points of the hourglass honeycomb cell and the panel have a great influence on the energy absorption capacity of the sandwich panels. This study provides a theoretical basis for the application of honeycombs in aerospace and other engineering areas. Full article

(This article belongs to the Special Issue Advanced Design for Lightweight Space Materials and Structural Systems)

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18 pages, 7191 KiB

Open AccessArticle

Experimental Evaluation of the Effectiveness of the Printed Circuit Board Strain-Based Methodology in Space-Borne Electronics with Vertically Mounted Printed Circuit Boards

by Kwang-Woo Kim, Jae-Hyeon Park, Tae-Yong Park and Hyun-Ung Oh

Aerospace 2024, 11(7), 562; https://doi.org/10.3390/aerospace11070562 - 9 Jul 2024

Cited by 1 | Viewed by 4060

Abstract

The Oh-Park methodology was proposed to overcome the limitations of Steinberg’s theory for evaluating the structural safety of space-borne electronics and has been experimentally verified at the printed circuit board (PCB) specimen level for various types of electronic packages, such as ball grid [...] Read more.

The Oh-Park methodology was proposed to overcome the limitations of Steinberg’s theory for evaluating the structural safety of space-borne electronics and has been experimentally verified at the printed circuit board (PCB) specimen level for various types of electronic packages, such as ball grid arrays (BGAs), column grid arrays (CGAs), and small-outline packages (SOPs). However, it is necessary to validate the design methodology because the PCB mounted on the housing is affected by the elastic mode of the mechanical housing. In addition, although the validity of the existing theory based on critical strain has been verified for horizontally mounted structures, there are cases where PCBs are mounted vertically. Therefore, it is essential to consider the dynamic influence of the boundary conditions of mounted electronics. In this study, electronics specimens with corresponding boundary conditions were fabricated, and a fatigue-life test was performed. In addition, a structural analysis using Steinberg’s theory and the Oh-Park methodology was performed, and the results were compared with those of the fatigue-life test. The results showed that the analysis using the Oh-Park methodology accurately represented the test results, and the validity of the Oh-Park methodology for vertical electronics was verified experimentally. Full article

(This article belongs to the Special Issue Advanced Design for Lightweight Space Materials and Structural Systems)

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12 pages, 3823 KiB

Open AccessArticle

Optimization Design of Core Ultra-Stable Structure for Space Gravitational Wave Detection Satellite Based on Response Surface Methodology

by Changru Liu, Zhenbang Xu, Kang Han, Chengshan Han and Tao He

Aerospace 2024, 11(7), 518; https://doi.org/10.3390/aerospace11070518 - 26 Jun 2024

Cited by 1 | Viewed by 1715

Abstract

In order to meet the urgent demand for novel zero-expansion materials and ultra-stable structures in space gravitational wave detection, it is necessary to develop an ultra-stable structural spacecraft system. This paper focuses on the research of the optimization of the core ultra-stable structure [...] Read more.

In order to meet the urgent demand for novel zero-expansion materials and ultra-stable structures in space gravitational wave detection, it is necessary to develop an ultra-stable structural spacecraft system. This paper focuses on the research of the optimization of the core ultra-stable structure design of spacecraft, proposing a cross-scale parameterized model of structural deformation response and a multi-objective optimization method. By satisfying the prerequisites of mass and fundamental frequency, this paper breaks through the limitations of current linear analysis methods, and the overall thermal deformation of nonlinear material composite structures is optimized by modifying structural parameters. Full article

(This article belongs to the Special Issue Advanced Design for Lightweight Space Materials and Structural Systems)

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14 pages, 4466 KiB

Open AccessArticle

Design and Rate Control of Large Titanium Alloy Springs for Aerospace Applications

by Lei Li, Qiufa Xu, Haiying Yang, Yang Ying, Zuhan Cao, Dizi Guo and Vincent Ji

Aerospace 2024, 11(7), 514; https://doi.org/10.3390/aerospace11070514 - 25 Jun 2024

Cited by 1 | Viewed by 1428

Abstract

During the separation between satellite and launch vehicles, large steel springs are often used as compression separation spring sets in a catapult separation system. Replacing the steel springs with titanium alloy springs could reduce weight by about 50%. Although titanium alloy springs have [...] Read more.

During the separation between satellite and launch vehicles, large steel springs are often used as compression separation spring sets in a catapult separation system. Replacing the steel springs with titanium alloy springs could reduce weight by about 50%. Although titanium alloy springs have been widely used in the aerospace field due to their excellent performance, there are few reports on the design of high-precision titanium alloy springs. The current spring design standards mainly focus on steel springs with helix angles between 5° and 9°, which are not applicable to titanium springs. Moreover, the change in spring rate with ambient temperature should also be considered. In this paper, β-C titanium alloy was used to design and prepare large compression separation springs, replacing steel springs in the catapult separation system. The design of titanium alloy springs took into account the big helix angle. The relationship between helix angle and the number of active coils was calculated. The parameters of titanium alloy springs were determined by the shear stress of the spring at working length. The effects of aging temperature and aging duration on the mechanical properties and modulus of β-C alloy were studied. By adjusting the aging process, the β-C alloy spring rate was controlled to meet the design requirements. The effect of ambient temperature on the mechanical properties and modulus of β-C titanium alloy were also investigated. It was found that as the ambient temperature increased, the rate of the β-C alloy spring gradually decreased. Full article

(This article belongs to the Special Issue Advanced Design for Lightweight Space Materials and Structural Systems)

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Review

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18 pages, 7338 KiB

Open AccessReview

Wood and Wood-Based Materials in Space Applications—A Literature Review of Use Cases, Challenges and Potential

by Raphaela Guenther, Martin Tajmar and Christian Bach

Aerospace 2024, 11(11), 910; https://doi.org/10.3390/aerospace11110910 - 5 Nov 2024

Viewed by 1364

Abstract

Current political and sociological efforts to respond to the need for more environmentally friendly technologies have inspired a revival of wood and wood-based material utilization in space systems. The popularity of these materials has faded since their widespread use in the early days [...] Read more.

Current political and sociological efforts to respond to the need for more environmentally friendly technologies have inspired a revival of wood and wood-based material utilization in space systems. The popularity of these materials has faded since their widespread use in the early days of aerospace engineering. This work reviews the literature to provide an overview of use cases, the motivation for using wood and wood-based materials and the challenges involved. A small number of applications were identified in which wood and wood-based materials were preferred over non-renewable raw materials. They are mainly applied for less-stressed disposable components or as a thermal protection material. It can be shown that the applied wooden materials have advantages such as low production costs, easy availability, easy and environment-friendly decomposition and low weight. However, only a limited number of applications have achieved a high level of technological readiness so far. Properties such as anisotropy and a lack of uniformity, defects in wood, the quantity available material and a lack of standards for the certification of wooden materials represent challenges. These are addressed in the current research, which additionally focuses on sustainable growth, enhanced environmental friendliness and advanced lightweight design. Full article

(This article belongs to the Special Issue Advanced Design for Lightweight Space Materials and Structural Systems)

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