Spacecraft Manufacturing Research Articles

Analytical Analysis of Buckling Of Layered Composite Columns

Abstract: Lightweight composite construction is of great interest in the design and manufacture of spacecraft and marine vehicles because of high specific stiffness and strength. In addition, sandwich construction offers enhanced corrosion resistance, noise suppression and reduction in life-cycle costs. There are several issues and questions related to the use of composite construction that require attention and answers. One of the important issues is the prediction of buckling loads, under either static or sudden load application. For the static case, closed form solutions are derived for a symmetric composite column under axial compression and for various boundary conditions. In this study, improved analytical models are developed to characterize interface behavior of layered composite column-type structures. The mechanics models of the bonded interface with and without adhesive layer are established, from which the interface fracture, delamination buckling, free vibration and stress analysis across the adhesive layer of corresponding interface are studied.

Analysis and diagnosis of abnormal SLR validation results for BeiDou-3 SECM-B MEO C225 and C226 satellite orbits

Satellite laser ranging (SLR) is the only stand-alone and external tool for verifying the accuracy of microwave-based GNSS orbits. On February 2, 2023, the International Laser Ranging Service initiated the SLR global tracking campaign for the complete BeiDou-3 medium Earth orbit (MEO) constellation. This initiative provides an opportunity to unveil the potential issue for BeiDou-3 MEO orbit modeling. An examination of the SLR validation results of precise BeiDou-3 MEO orbits across different IGS/Multi-GNSS Experiment (MGEX) analysis centres (ACs) reveals that the SLR residual standard deviation for BeiDou-3 SECM-B MEOs C225 and C226 orbits reaches 18 cm. This figure is approximately four to nine times those for other BeiDou-3 MEOs. This contradicts the fact that the orbit quality of C225 and C226 is comparable to other satellites. By analyzing the correlation between SLR residuals and de-trend clock residuals, detector-specific bias performance, and the distribution characteristics of SLR residuals relative to satellite azimuth and nadir angles, we diagnose that abnormal SLR validation results for C225 and C226 originate from a large deviation in the official horizontal offsets for the laser retroreflector arrays (LRAs) in the satellite reference frame. LRA horizontal offsets for C225 and C226 are estimated based on SLR residuals. With our adjusted LRA offset estimates, the SLR residual metrics for C225 and C226 orbits (across various IGS/MGEX ACs) are comparable to the results obtained for other BeiDou-3 MEOs. Additionally, our adjustments enable the identification of their orbit modeling errors across different IGS/MGEX ACs according to the pattern of SLR residual variation. From the study, spacecraft manufacturers should be encouraged to conduct a comprehensive review of ground calibrations for BeiDou LRA offsets. This is crucial for optimizing BeiDou orbit model and enhancing its applications in high-precision geosciences.

Phase transitions in chrome

In astronautics, stainless steel is widely used for the manufacture of spacecraft. Rocket fuel tanks are now made of stainless steel. In order for steel to be stainless, for example, grades 08X13 and 12X13, it must contain up to 13% chromium. In pure chromium and its alloys, phase transitions occur under temperature fluctuations and mechanical loads, during which the plastic, strength, and magnetic characteristics of steel alloys change. The article describes distinguishes between phase transformations of the 1st and 2nd kind in chromium and the inconsistency in the definition of the type of transition by different authors. The change in the form of the crystal lattice during the transition from an antiferromagnet to a paramagnet at the Neel point TN = 38 85 °C, is described. An analysis of the relationship between the type of phase transition and the type of symmetry is given. An explanation is given for the difficulties in studying phase transitions in chromium due to the imperfection of the model of the electronic configuration in the 3d layer of the chromium atom.

Initial study for the response of Ti–6Al–4V plate used in tank material

We have been conducting hypervelocity impact tests and numerical simulations to develop a Japanese spacecraft design guideline for the protection of satellites from a certain degree of M/OD impacts. A working group is formed by members of JAXA, spacecraft manufacturers, experts, and researchers in the field of hypervelocity impacts to investigate the effects of M/OD impacts on satellite critical parts and bumpers by hypervelocity impact (HVI) tests and analysis. The knowledge acquired is now being reflected in the spacecraft design guidelines.We investigated the effect of hypervelocity impacts of micrometeoroids and small-scale space debris on space structures by comparing numerical simulation results obtained using the AUTODYN-2D hydrocode with the results of experiments using a two-stage light gas gun since 2005. We will consider the case of a satellite hydrazine fuel tank and the consequences of a hypervelocity impact from space debris. The final purpose of this study is to better understand the mechanisms of detonation of hydrazine vapor during a hypervelocity impact on a low-pressure reservoir.As part of this effort and an initial study, the response of a Ti–6Al–4V plate which is used tank material to 6 km/s high-velocity impacts is shown and discussed. It was found that the ballistic limit of the titanium tank material for both curved and flat plates was generally predictable using the existing ballistic limit equation. The effect of curvature on the impact scar size of flat (t = 1.2 mm) and curved plates was examined, and no significant difference was found.

Correlation between Mechanical Properties—Structural Characteristics and Cavitation Resistance of Rolled Aluminum Alloy Type 5083

The 5000 series aluminum alloy 5083 is distinguished by excellent processability, excellent welding characteristics, and a strong resilience to corrosion, particularly in maritime environments. It is employed in the manufacture of ships, automobiles, spacecraft, and industrial buildings. The goal of the current study is to determine whether there is any relationship between the mechanical properties, structural characteristics, and cavitation erosion properties of aluminum alloy 5083 in the H111 state (rolled from 454 °C to 399 °C and annealed at 343 °C by holding in cooled air), followed by artificial ageing at (180 °C) with three maintenance periods of 1 h, 12 h, and 24 h, and at (140 °C) with three maintenance periods of 1 h, 12 h, and 24 h. The cavitation resistance experiments of the experimental samples were performed in accordance with ASTM G32-2016. The resistance to cavitation erosion was determined by making mean erosion penetration rate (MDER) or mean depth of erosion (MDE) analytical diagrams according to the duration of the cavitation attack and by measuring the maximum depth of cavitation erosion in the samples analyzed by stereomicroscopy and scanning electron microscopy. Finally, a structural correlation between the condition of the artificially aged laminate alloy and its resistance to cavitation erosion could be achieved: ageing at 180 °C, maintained for 24 h, could lead to a maximum depth of cavitation erosion MDEmax of about 5 µm.

Performance adjustable event-triggered policy to spacecraft attitude tracking

Plug-and-play modular design is the future of spacecraft manufacturing. The employment of wireless communication between different modules instead of wire connections can reduce weight and simplify assembly. This paper focuses on the design of spacecraft attitude tracking control policies under wireless communications. A new event-based control policy with performance adjustable functions is proposed to achieve intermittent sampling to save system resources. Under the designed policy, the sampling frequency and convergence rate of the considered system can be traded off by designing different performance adjustable functions. Based on the Lyapunov function method, it proves that the spacecraft attitude tracking errors are uniformly ultimately bounded. In comparison with the previous results, the proposed policy provides a more general triggering condition and has the property of freely adjustable performance, which is suitable for scenarios with different performance requirements. Numerical simulations support the conclusion of its effectiveness and superiority.

Intelligent Bayesian regularization‐based solution predictive procedure for hybrid nanoparticles of AA7072‐AA7075 oxide movement across a porous medium

AbstractThe research community has shown great interest for investigation in the nanofluids models involving Aluminum Alloys AA7072 and AA7072 +AA7075 due to their advantageous impact on heat transfer, physical and mechanical characteristic exploiting in broad engineering applications such as manufacturing of spacecraft, aircraft parts and building testing. The hybrid nanomaterial AA7072‐AA7075 based fluidic system is investigated in this paper using an artificial neural network with Bayesian regularization scheme (ANNs‐BRS). The derived partial differential equations (PDEs) are transformed into ordinary differential equations system ODEs and obtained the reference datasets for the estimated solution dynamics of hybrid nanofluidic system. For prominent parameters, the influence of flow on the temperature distribution and velocity plot are investigated. The performance on 80% training samples, 5% testing and 15% validation dataset for ANNs‐BRS is well‐established in terms of error histogram plots, regression analysis, and MSE based statistics. The results for entropy generation, Eckert number Ec, magnetic interaction parameter M, suction parameter S, and heat generation parameter Q are also discussed. The results show that the Eckert number Ec has the effect of slowing down the rate of heat transfer while increasing the temperature and increases in suction parameter causes decrease in temperature while increase in temperature profile due to enhancement of suction parameter.

Advanced fault detection and diagnosis in spacecraft attitude control systems: Current state and challenges

A review of advanced fault detection and diagnosis (FDD) techniques in attitude control systems (ACSs) of spacecraft is presented. In the first part of the paper, several types of ACS failure scenarios with their practical solutions are presented. Next, the existing approaches to FDD are considered and classified based on different criteria, including applications and design techniques. The literature of this part showed that to enhance ACS operational safety, predictability of failure of an ACS and/or of its components as well as reducing the possibility of failure occurrence is imperative. In addition, fast FDD of various kinds of failures is necessary to guarantee the required reliability of an ACS. The second part of this study highlights challenges involved with different FDD approaches, emphasizing their practical applicability. Current research gaps in FDD techniques such as insensitive residual signal, process monitoring methods, accurate plant model design, easy-to-use software development, FDD tuning process, dealing with noisy sensor measurements, time taken for fault management, the sensitivity of FDD system to faults, and FDD robustness are further elaborated on. Subsequently, the state-of-the-art FDD and its future needs are reflected on. The results of this study could direct spacecraft manufacturers and ACS providers to focus on future needs and improve ground testing for enhanced operational reliability and redundancy.

Served space: new achievements and perspectives

The number of works aimed at developing technologies for services in space has increased significantly over the past five years. In addition to such industrial giants as Orbital-ATK, Northrop Grumman, MDA, Maxar Technologies, startups are also entering the service market that develop and demonstrate practically operating technologies. Given this trend, it is expected that maintenance in space will become a hot topic over the next few years. The article discusses the designed and operating service spacecraft of foreign countries, the state and directions of their development. Brief characteristics and capabilities of service spacecraft are given. The directions of solving the main tasks for the design and manufacture of promising service spacecraft are outlined. Satellites MEV-1 and MEV-2, manufactured by Northrop Grumman, ELSA-d, manufactured by Astroscale and SSTL, and See also OSAM-1 by Maxar Technologies, which allows robotic refueling in space and demonstrates the possibility of constructing large structures in space without direct human involvement. The results of a study carried out using available Internet sources are summarized and presented in this material. The purpose of the article is to analyze the need, ways and methods of development of services, to assess the prospects of the technologies used.

Multiobjective Fusion Decision Model for Key Technologies of Aircraft Intelligent Lightweight.

As a tool for aviation exploration, aircraft plays a pivotal role in the aerospace field. The aircraft's lightweight can ensure that the aircraft can carry more loads, so it is of great significance to the research on the key technologies of aircraft lightweight. This paper organizes the intelligent technology system from the multiobjective fusion technology relationships and considers the complex changes between technology units. A technology group model for the intelligent technology system of spacecraft welding is formed to provide a decision-making basis for the realization of batch, stable, and efficient intelligent and lightweight manufacturing of spacecraft. We expand the technology development research from single technology research to technology system research. We research and build a three-dimensional perspective intelligent technology system based on technology unit, technology system, and technology group. It reveals the internal relationship description of technological development and expands and perfects the current research theory of technological development.

Investigations on effect of bending radius on springback behaviour of three-ply clad sheet

Bending operation is widely used in manufacturing of automobiles, aircraft, spacecraft, structures, and home appliances etc. During bending operations, springback is a very common and critical defect. For dimensional accuracy springback must be minimized sufficiently. In the present investigation, the effect of bending radius/punch profile radius on the springback behaviour of SS304/Al1050/SS304 clad sheet has been studied. It has been observed that bending radii /punch profile radii have great impact on the prediction of springback of clad sheet. Springback can be reduced by reducing the bending radius/punch profile radius. The present study confirms that the springback can fairly be controlled by taking optimal value of bending radius/punch profile radius. Sheet placing arrangement of 3-ply clad sheet also affect the springback behaviour minutely. A good agreement has been observed between analytical, numerical, and experimental results of the springback of a 3-ply clad sheet. To evaluate the mechanical properties of three-ply clad sheet, tensile and micro hardness testing have been conducted. The average hardness of 3-ply clad sheet is evaluated as 113.18 HV which may be attributed to the individual hardness of layers of SS304, Al1050 and SS304.

ПЕРСПЕКТИВИ РОЗВИТКУ УКРАЇНСЬКО-КИТАЙСЬКОГО СПІВРОБІТНИЦТВА В КОСМІЧНІЙ ГАЛУЗІ

Introduction. China has long been a member of the prestigious Space Club and is now the most powerful space power in some respects, having managed not only to develop a strategic plan for the conquest of space but also to strictly follow it step by step. According to official documents adopted by the State Council of China, the space program is an extremely important area of national development. This is especially true of China's ambitious goal of becoming a leader in the world's science-intensive industry. The more specific goals of the space program are defined by the country's five-year development plans, as well as the national development strategy. Many scientific publications are devoted to the problems of economic cooperation between Ukraine and China. However, most issues concern the intensification of Ukrainian-Chinese cooperation in trade, economic, scientific, technical, investment and industrial spheres. At the same time, researchers are ignoring issues related to cooperation in such a science-intensive field as space, which objectively actualizes this area of research and requires additional study. Accordingly, the purpose of the study is to analyze and evaluate the Ukrainian-Chinese cooperation in space in order to determine the prospects for their further development. Particular attention will be paid to the capabilities of Ukraine's space industry and China's interests. Materials and methods. Theoretical and methodological base of research consists of scientific works, methodological research of leading Ukrainian and foreign scientists. Research on scientific issues related to the intensification of Ukrainian-Chinese cooperation in space was conducted using critical and scientific analysis, methods of scientific generalization and systematization, induction and deduction in determining the causal relationship between internal and external factors affecting bilateral cooperation in the space industry. The results of the research, conclusions and recommendations are substantiated on the basis of an integrated approach. Results and discussion. Ukraine is one of the few countries in the world that has a closed technological cycle of rocketry, starting with rocket fuel and ending with launch vehicles and spacecraft, there are problems in the industry that need to be solved. This is, first of all, a significant disproportion between the level of space potential and its impact on the solution of urgent national and social problems. The main reasons for the problems are related to the long-term lack of effective state support in the field of space activities, as well as the need to reform it. One of the directions of deepening international cooperation in the field of space activities was the Agreement between the Government of Ukraine and the Government of the People's Republic of China on cooperation in the study and use of outer space for peaceful purposes, signed in 1995. Among the main areas of such cooperation are: research, manufacture, production and testing of spacecraft; research, manufacture, production and testing of media (delivery); ground-based control and measuring devices, control and measuring complexes and objects of the experimental base for modelling and testing of space technology in ground conditions; environmental research, space materials science, remote sensing of the Earth and other areas of mutual interest. It is proved that the deepening of international cooperation in the field of space activities with China is promising for both Ukraine and China. This is due to the fact that today Ukraine has all the components in the space sphere – scientific, technological, production and human resources – for the implementation of full-scale space projects. Conclusions. In order to deepen Ukrainian-Chinese cooperation in space, it is proposed to be actively involved in supporting Chinese companies by increasing the number of commercial orders for space activities; creating preferential taxation for space companies and those who invest in the development of science; creating conditions for reducing the payback period of investment projects in the space industry by introducing project financing; to increase the efficiency of using the space potential of Ukraine to solve urgent problems of socio-economic, environmental, cultural, informational and scientific-educational development of society; to introduce a transparent system of information openness of space activities, on the distribution of investment funds, to inform investors about the prospects and expected results of activities, to publicly set the financial performance of science-intensive enterprises.

Optimization of 1U nanosatellite on the basis of strength and weight using different Materials: A numerical approach

As the intricacy of problems encountered increases, humans need to explore space, hence demanding more experiments to be performed at different physical conditions. Nanosatellites are not only cheap and flexible but they are also validated in space which can be used as extensions for the larger satellites for more wider applications. The materials chosen for space applications are based on their properties, costs and complexity. Some of the materials that are used include, metal and its alloys, fiber composites. Out of these, aluminum and its alloys such as, Al 7075 – T6, are widely used for spacecraft manufacturing. Due to certain disadvantages of aluminum, there is an increase in the research and development of composite materials such as, HTM143/M55J and T300/5208, are used for space applications because they offer high structural strength in comparison to metallic alloys, but at a lighter weight which improves fuel efficiency and performance. The main objective of the research is to provide a comprehensive description and comparative study of the materials that can be used in improving the structural design and weight of the nanosatellite. Static structural analysis was carried out to analyze the feasibility of using composites as an alternative to metallic alloys on the basis of stress and deformation value. The material HTM143/M55J shown major improvement in the weight and strength ratio as compared to other two materials.

Методичний підхід до розрахунку вартості дослідно-конструкторських ро-біт зі створення космічних апаратів

The aim of this work is to develop a methodological approach to the development of a unified, common for all developers, computer-aided branch procedure for spacecraft development cost estimation based on a spacecraft cost model and practical recommendations on computer-aided branch procedure development. The cost parameters of the development, manufacturing, and operation of new spacecraft and their technical level (perfection) are the determining factors in competitiveness assessment. To decide on the advisability of starting or resuming the development of a new spacecraft, one has to correctly estimate the development cost. Using the standardized calculation method in estimating the development cost for new space hardware is unacceptable for lack of bug-free design and production documentation, which is the end product of any development activity. Parametric methods (the basic methods used to estimate the spacecraft development cost in the USA and Europe) cannot be used in the development of a high-quality procedure for spacecraft development cost estimation for lack of a branch statistical database on spacecraft development labor intensiveness and materials consumption at the State Space Agency of Ukraine. This calls for a nonstandard cost model of spacecraft development. The authors’ cost model is based on a method of componentwise analogy for simple spacecraft components, moving (up and down) along the edges of a weighted oriented tree graph that models the spacecraft technical structure, and fuzzy analysis methods. The tree graph Gi(V(С),D) models the spacecraft technical structure (V, C, and D are the sets of graph vertices and edges and spacecraft components, respectively; to each graph vertex there corresponds a spacecraft component). The paper presents a nonstandard cost model of spacecraft development, which in its essence is close to a nonlinear parametric cost model, and a scientific methodology for the development of an advanced branch procedure for spacecraft development cost calculation with component and stage detailing.

Thermal transport investigation in AA7072 and AA7075 aluminum alloys nanomaterials based radiative nanofluids by considering the multiple physical flow conditions

Now a day’s variety of nanomaterials is available, among these Aluminum Alloys AA7072 and AA705 are significant due to their thermal, physical and mechanical characteristics. These extensively used in manufacturing of spacecraft, aircraft parts and building testing. Keeping in view the significance of nanoliquids, the analysis of methanol suspended by AA7072 and AA7075 alloys under the multiple physical flow conditions is reported. The model is successfully treated by coupling of RK and shooting algorithm and examined the results for the flow regimes by altering the ingrained physical parameters. Then physical interpretation of the results discussed comprehensively. To validate the analysis, a comparison between the presented and existing is reported under certain assumptions on the flow parameters. It is found that the results are reliable inline with existing once.

ASSESSMENT OF THE IN HOMOGENEITY OF THE PHYSICO-MECHANICAL PROPERTIES OF PARTS OF AEROSPACE ENGINEERING OBTAINED BY SELECTIVE LASER MELTING

The article considers the problem of assessing the damage and heterogeneity of a material obtained by selective laser melting. To study these characteristics, it is planned to adapt a new method of ultra-jet diagnostics, developed at the Bauman Moscow State Technical University. Its feature is the ability to assess the damage to the material and its technological memory, i.e. conditions, modes and factors that influenced the formation of the structure and operational characteristics in the process of manufacturing parts by selective laser melting. The article compares traditional control methods and the method of ultra-jet diagnostic, which, as studies have shown, will expand the arsenal of applied monitoring and diagnostics, which is extremely important for critical parts of aerospace technology. The experiments were conducted on special samples and witness samples obtained from materials widely used in the manufacture of spacecraft. The most important result of the research was the conclusion about the relationship between the variability of the parameters of the surface micro relief due to the process of hydroerosion under the action of a high-speed jet of water and structurally inhomogeneous, physically anisotropic material obtained by the selective laser melting technology.

Application of integrated manufacturing system of flexible production line in spacecraft manufacturing line

The realization of automatic control and information management is an important basis for the automation, information and intelligence of manufacturing industry. We have applied computer and network technology, programmable control technology, field-bus technology, information management and other technologies to the control, monitoring and management of the production line. We have developed a flexible production line integrated manufacturing system, which realizes the local monitoring and remote monitoring management of the operation status of multiple equipment on the production line of manned spacecraft manufacturing equipment, and creates a new intelligent manufacturing system Pattern.

ВЛИЯНИЕ КРИСТАЛЛИЧЕСКОЙ СТРУКТУРЫ SiO2 НА ТЕРМИЧЕСКОЕ ЦИКЛИРОВАНИЕ ПОЛИМЕРНЫХ КОМПОЗИТОВ

polymer composites are widely used in the space industry for the manufacture of spacecraft, satellite panels, antennas, thermostatically controlled coatings, etc. In space, they are subjected to harsh environmental conditions, such as ultraviolet, deep vacuum, atomic oxygen, charged particles, anthropogenic debris, micrometeoids, electromagnetic radiation and thermal cycles that cause severe degradation of the material. One of the most important environmental effects of materials based on polymers is the thermal cycle, in which the composite undergoes a large temperature difference from -170˚C to + 200˚C. The paper presents an assessment of the use of composites based on a polyalkane-rich matrix and a filler in the form of an SiO2 amorphous and crystalline structure under thermal cycling conditions. The data on the change in tensile strength, modulus of elasticity in tension and relative elongation in tension of materials after several cycles of a sharp differential temperature (from -190 to +200°C) are presented. The thermal cycle was repeated 5, 10 and 20 times. It is shown that the sample polyalkanimide has a large value of tensile strength and elastic modulus compared with highly filled composites.However, during thermal cycling there is a significant decrease in these parameters.For a highly filled composite sample with 65% crystalline SiO2 content, the decrease in tensile strength and elastic modulus after thermal cycling is insignificant and is within the measurement error. A composite with amorphous SiO2 is more susceptible to a change in mechanical properties after thermal cycling in comparison with a composite containing crystalline SiO2.

Cabin posture adjustment method based on redundant constrained parallel mechanism

PurposePosture adjustment plays an important role in spacecraft manufacturing. The traditional posture adjustment method, which has a large workload and is difficult to guarantee the quality of posture adjustment, cannot meet the requirements of modern spacecraft manufacturing. This paper aims to optimize the trajectory of posture adjustment, reduce the internal force of the posture adjustment mechanism and improve the accuracy of the system.Design/methodology/approachFirst, the measuring point is measured by a laser tracker and the position and posture of the cabin is solved. Then, Newton–Euler method is used to construct the dynamic model of the posture adjustment system (PAS) without internal force. Finally, the adjustment time is optimized based on Fibonacci search method and the trajectory of the cabin is fitted by the fifth order polynomial.FindingsThe simulation results show that, compared with the other trajectory planning methods, this method can effectively avoid the internal force of posture adjustment caused by redundant driving, and the trajectory of velocity and acceleration obtained are continuous, meeting the engineering constraints.Originality/valueIn this paper, a dynamic model of PAS without internal force is constructed. The trajectory planning of posture adjustment based on this model can improve the quality of cabin assembly.

Research on the Improvement of Spacecraft Manufacturing Enterprise Quality Management System Audit Based on Process Method

This article combines the spacecraft manufacturing enterprises that simultaneously build and operate ISO9001 and AS9100 quality management system. According to the process strengthening requirements of quality management system standards, research and improve the audit work with process method as the core. This article introduces the "turtle chart" process method audit management tool, summarizes the specific model and implementation points of the process method in the quality management system audit. This article analyzes the important role of this method in the internal audit of quality management system, in order to provide reference for spacecraft manufacturing enterprises to improve the audit of quality management system.