Mass Savings Research Articles

Unveiling the Multifunctional Carbon Fiber Structural Battery.

Structural batteries refer to the multifunctional device capable of both storing electrical energy and bearing mechanical loads concurrently. In this context, carbon fibers emerge as a compelling choice of material and serve dual purpose by storing energy and providing stiffness and strength to the battery. Previous investigation has demonstrated proof-of-concept of functional positive electrodes against metallic lithium in structural battery electrolyte. Here, an all-carbon fiber-based structural battery is demonstrated utilizing the pristine carbon fiber as negative electrode, lithium iron phosphate (LFP)-coated carbon fiber as positive electrode, and a thin cellulose separator. All components are embedded in structural battery electrolyte and cured to provide rigidity to the battery. The energy density of structural battery is enhanced by use of the thin separator. The structural battery composite demonstrates an energy density of 30Whkg-1 and cyclic stability up to 1000 cycles with ≈100% of Coulombic efficiency. Remarkably, the elastic modulus of the all-fiber structural battery exceeds 76GPa when tested in parallel to the fiber direction - by far highest till date reported in the literature. Structural batteries have immediate implication in replacing structural parts of electric vehicles while reducing the number of conventional batteries. Thus, offering mass savings to future electric vehicles.

Fast-Charging Carbon Fiber Structural Battery Electrodes Using an Organic Polymer Active Material

Structural batteries require electrodes with integrated energy storage and load-bearing properties. Adoption of structural batteries can lead to mass and volume savings in electrified transportation and aerospace applications by storing energy within the object’s structural elements. However, to date, active materials investigated in structural batteries exhibit poor rate capabilities at higher C-rates and even worse performance at lower temperatures due to diffusion limitations. Organic radical polymers are promising alternatives because they possess fast-charging properties and good cycling stability. In this work, we integrate an organic radical polymer with carbon fiber (CF) fabric, in which the polymer acts as the active cathode material and the CF fabric possesses excellent tensile strength, modulus and electronic conductivity. At 20 °C, the structural cathodes exhibited a reversible capacity of 67 mAh g−1 at 1C-rate and an 88% capacity retention at 25C-rate. Further, these structural electrodes retained more than 50% of their performance at −10 °C (vs 20 °C). These electrodes were further examined in a full cell containing a graphite-based anode, demonstrating a pathway for utilizing redox-active polymer-based active materials in structural and fast-charging organic batteries.

Design and control of high-speed railway bridges equipped with an under-deck adaptive tensioning system

This work investigates the application of an external adaptive tensioning (EAT) system for high-speed railway (HSR) bridges. The design of HSR bridges involves strict displacement and acceleration limits, which typically results in oversizing. The EAT system comprises under-deck cables deviated by compressive struts that are equipped with linear actuators. Since the cable is eccentric to the bridge neutral axis, tensioning the under-deck cables by adjusting the length of the linear actuators generates a bending moment that counteracts the effect of the external loads. The response under variable loading is reduced by computing the actuator commands with a linear quadratic regulator (LQR). Numerical results show that active control through the EAT system allows satisfying displacement and acceleration limits, which otherwise cannot be met without increasing the stiffness and mass of the bridge. A significant reduction of the response is achieved when resonance conditions occur. In addition, peak stresses are significantly reduced, showing the potential for fatigue-life extension. Parametric analyses comparing different bridge depths and spans, EAT system dimensions, controller parameters and actuator placement are carried out to investigate system efficacy. Results show that the adaptive bridge solution can achieve up to 32% mass savings compared to an equivalent passive bridge.

Determination of the features of integrated design of civil long-range aircraft with transonic truss-braced wing at the preliminary design stage

The object of research is a civil mainline aircraft with a transonic truss-braced wing. The problem of designing an aircraft of this scheme at the preliminary design stage is being solved in the work. The results of the work include the concept of designing aircraft with a transonic truss-braced wing, the main advantages of such a scheme, the process of determining the geometric parameters of the truss-braced, features of the preliminary design of an aircraft with an extremely high aspect ratio truss-braced wing, possible approaches to the arrangement of units and their mutual arrangement. The results are explained by the difference in the design model (the cantilever beam is replaced by a beam on two supports) in mass analysis and the increased wing aspect ratio in aerodynamic calculation. The final data are based on a statistical study to determine the basic geometric parameters of assemblies of modern mainline passenger aircraft, synthesis of parameters of analog aircraft. For example, an aircraft capable of carrying 250 passengers over a distance of 13.000 km is considered. In the design process, values of aspect ratio, taper ratio, wing area, vertical tail and horizontal tail area ratio, and fuselage dimensions are accepted. Drawings of the general appearance of the aircraft have been developed and, based on it, a master geometry of the theoretical contour has been constructed. Graphs of first-order polar and maximum lift-to-drag ratio have been plotted, the reduction of aerodynamic drag in percentage terms has been determined, and the increase in aerodynamic lift-to-drag ratio in percentage terms for an aircraft with an extremely high aspect ratio truss-braced wing compared to similar characteristics of an aircraft with a conventional non-braced wing has been calculated. The approximate mass savings when using a truss-braced wing on the aircraft are determined in percentage terms. The expediency of using wings of greater aspect ratio, than modern aircraft currently have, has been justified. The expediency of using a brace for the aircraft with an extremely high aspect ratio wing has been justified. The obtained results can be used in practice in the process of developing the preliminary design of an aircraft with a truss-braced wing or in the modifications of existing aircraft to increase their fuel efficiency or increase the durability of wing elements due to reduced loads acting on them.

Origami-Wrapped Structures with Corrugated Unfolded Forms

Stowage schemes based on origami wrapping patterns are useful for the design of various deployable spacecraft structures. These origami patterns allow for the compact stowage of flat sheets of small thickness. Typically, some other structure is needed to stiffen this thin sheet when it is fully deployed and flat. This paper describes a class of thin-shell structures that can be compactly stowed using origami wrapping methods but have a corrugated form when deployed. These structures cannot reach a flat state by design. The persistent corrugations provide stiffness without the need for an external structure, thus leading to overall savings in mass and complexity. The geometrical design of the corrugations is highly tunable. This paper describes a method for generating the form of these folding structures; the method guarantees that the structure can be unstrained both when compactly wrapped and when fully deployed. Test articles are fabricated to demonstrate the concept, and stowage experiments and stiffness experiments are conducted. A structural finite element modeling procedure is described to predict the deployed stiffness of these structures, and the stiffness predictions match the experimental results.

CFRP Conical Grid Space Structure with Embedded Fiber Optics: Design, Manufacturing and Test

This article discloses the activity developed in the framework of the research project “GRID” aiming at the feasibility demonstration of a fiber optic sensing system (FOS), based on fiber Bragg gratings (FGB), embedded in the ribs of a conical grid structure demonstrator in composite material (CFRP), manufactured by means of dry robotic winding, liquid resin infusion and oven curing. This structure represents an optimized and highly efficient conical adapter for satellite applications that was designed under the same requirements of a conventional CFRP benchmark solution in order to evaluate possible mass savings. Specific interfaces were conceived in order to facilitate the insertion of the fiber optics in the center of helical ribs—pausing the automated deposition phase of the dry preform—and secure them to the structure. Representative grid articles were produced and tested to select the materials and evaluate the preliminary feasibility of the integrated system in conjunction with the infusion process. The proper functioning and use of the sensing system were finally proven during the various phases of the mechanical testing campaign of the demonstrator. Such a campaign included stiffness and strength evaluations and culminated with the catastrophic failure of the structure. The significant amount of data collected from several sensors embedded in the ribs and from conventional sensors glued outside the ribs helped us to better understand the structural behavior and to validate the design and analysis models. The main steps of the design, manufacturing and tests of this project are here addressed.

Design of ultra-lightweight and energy-efficient civil structures through shape morphing

This paper gives a new formulation to synthesize load-responsive structures through shape morphing. The design method is based on the minimization of the whole-life energy, which comprises an embodied share in the material and an operational share for adaptation. Target shapes that counteract the effect of the design loads are obtained through geometry and sizing optimization. Adaptation through shape morphing enables effective stress redistribution so that the design is not dominated by peak loads with long return periods. Material utilization is maximized, and therefore embodied energy is significantly reduced. The geometry is controlled through length changes of optimally-placed linear actuators. The actuator commands are computed through minimization of the operational energy to satisfy safety and serviceability criteria. Minimum energy solutions are obtained through a univariate optimization process in which embodied and operational energy minimization are nested. Numerical benchmarks between adaptive and mass-optimized passive solutions are provided on a truss bridge and multi-story frame configurations. Parametric studies show that mass and energy savings are significant for slender structures and when the live load is dominant over the permanent load. Generally, larger shape bounds result in a greater reduction of mass and embodied energy at the cost of a larger operational energy.

International planetary sunshade concept with a function-integrated and scalable support structure based on coreless filament winding

Despite all current efforts, climate change is the greatest challenge of the 21st century. Since existing measures will fail to prevent critical tipping points from being reached, in addition to terrestrial geoengineering methods, efforts are underway to explore new ways to implement space-based geoengineering methods into the short-term construction of a buffer solution - the International Planetary Sunshade (IPSS). The IPSS system reduces solar irradiation mitigating the global mean temperature rise while offering a sustainable energy supply. The developement of the system poses multifaceted challenges only to be mastered by a collaboration of space agencies and private companies, while supported by society. Therefore, tackling the IPSS within international roadmaps is essential to exploit synergies, shorten development time, and promote international cooperation. An evolutionary concept achieves stepwise Earth independence by utilizing lunar resources. The feasibility of the IPSS also depends on the foil’s supporting structure. Therefore, a lightweight manufacturing technology that meets several criteria, such as scalability, adaptivity, material compatibility, full automation, on-orbit manufacturing, in-situ resource utilization, and digital design including function integration, must be adopted. Hence, coreless filament winding (CFW) may be a suitable technology for realizing the demanded mass savings. The prerequisite for the superiority of CFW structures is an application- and material-compliant component and fiber net design. Previous experience with CFW cannot be directly transferred to the IPSS system due to the changed requirements for space application. This paper will present a systematic design concept for the IPSS, initially exploring a CFW support structure by discussing segmentation and modularity, proposing a new connection system, and implementing function integration.

Path planning for graded concrete element fabrication

AbstractThe technology of functionally graded concrete (FGC) is a new methodology in the field of concrete construction, striving for mass savings by adjusting the elements interior design. A promising approach herein is meso-gradation, where concrete hollow spheres are placed inside the formwork before casting the element; this allows up to 50% mass savings without a loss in load-bearing capacity, whilst also ensuring recyclability compared to e.g. bubble decks. In order to prevent damage/displacement of the spheres during automated fabrication, the extruded concrete flow must avoid the spheres, whilst neatly covering the elements area in order to prevent cavities. Both requirements formulate a complex path planning problem that must be solved in order to achieve automated fabrication. In this paper, we propose a method for solving this problem, which is based on theoretical findings on Hamiltonian triangulations. Our approach is based on the idea that the elements area is triangulated, such that all sphere centers are corners of triangles. For each triangle, a smooth path can be planned straightforwardly on a consideration of the geometry, such that the global path is made of a sequence of local ones. This necessitates finding a triangulation that is hamiltonian, i.e. a sequence where all triangles are visited exactly once. To this end, we first present a new class of triangulations and proof their hamiltonicity, followed by an algorithm that generates such triangulations on certain FGC element geometries. This is followed by the local path planning problem, whose special structure with start/end tangential and curvature constraints facilitates the use of a polar coordinate approach.

How 3D-Printing Is Changing RF Front-End Design for Space Applications

3D-printing is leading to a major transformation in many industrial and application sectors, ranging from medical to aerospace. In the space sector, 3D-printing has firstly been adopted for the development of structural and thermal parts, such as brackets and heat pipes. In more recent years, thanks to improvements in precision and surface roughness, 3D-printing technologies have steadily been investigated also for the development of radio frequency components and advanced payloads. Indeed, the unique features of 3D-printing, including the free-form capability and the ease for customization, make these manufacturing technologies very appealing in the development of complex radio-frequency front-ends for space applications, including New Space constellations and next generation software-defined communication satellites. They also enable a drastic simplification of mechanical designs by reducing the number of interfaces and assembling screws of large radio-frequency front-ends, thus leading to significant mass savings and higher integration. This paper briefly reports on recent advances in 3D-printing that have been carried out according to the current trends in radio-frequency front-ends for satellite communications.

Using 3D Density-Gradient Vectors in Evolutionary Topology Optimization to Find the Build Direction for Additive Manufacturing

Given its layer-based nature, additive manufacturing is known as a family of highly capable processes for fabricating complex 3D geometries designed by means of evolutionary topology optimization. However, the required support structures for the overhanging features of these complex geometries can be concerningly wasteful. This article presents an approach for studying the manufacturability of the topology-optimized complex 3D parts required for additive manufacturing and finding the optimum corresponding build direction for the fabrication process. The developed methodology uses the density gradient of the design matrix created during the evolutionary topology optimization of the 3D domains to determine the optimal build orientation for additive manufacturing with the objective of minimizing the need for support structures. Highly satisfactory results are obtained by implementing the developed methodology in analytical and experimental studies, which demonstrate potential additive manufacturing mass savings of 170% of the structure’s weight. The developed methodology can be readily used in a variety of evolutionary topology optimization algorithms to design complex 3D geometries for additive manufacturing technologies with a minimized level of waste due to reducing the need for support structures.

Radiation effects in ultra-thin GaAs solar cells

Ultra-thin solar cells are of significant interest for use in space due to their intrinsic radiation tolerance, which may allow them to be used in particularly harsh radiation environments, where thicker cells would degrade rapidly and enable reduction in cover glass thickness to reduce launch mass. In this study, devices with an 80 nm GaAs absorber layer were irradiated with 3 MeV protons. It is shown that integrated light management in these ultra-thin devices offers enhanced efficiency, in addition to extended lifetime through radiation resilience. Time-resolved cathodoluminescence is employed to map the introduction of radiation-induced defects with increasing proton fluence and characterize a decrease in carrier lifetime from 198 ± 5 ps pre-radiation to 6.2±0.6 ps, after irradiation to 2×1014 cm−2 fluence. Despite the substantial reduction in carrier lifetime, short-circuit current does not degrade up to a proton fluence of 1 × 1015 cm−2, beyond which a collapse in short-circuit current is observed. This exposure correlates with the point at which the carrier lifetime, extrapolated from cathodoluminescence, becomes comparable to the transit time for carriers to cross the ultra-thin device. Variation in current–voltage behavior with carrier lifetime and fluence shows that the recombination statistics are similar to those of a Shockley–Read–Hall single deep-level trap model, but that bimolecular recombination does not fully describe the observed behavior. An implication of these highly radiation tolerant cells for space power systems is shown to offer significant savings in cover glass mass, compared with a thicker cell.

Novel propellant settling strategies for liquid rocket engine restart in microgravity

The active deorbiting and passivation of launch vehicles has become key for the implementation of modern space debris mitigation guidelines. Appropriate engine restart conditions must be provided as part of this process. Ullage motors have been traditionally employed to induce active settling and ensure a gas-free propellant supply to the engines. Although robust and reliable, ullage motors are also heavy, which motivates the study of alternative approaches to the problem. Classic propellant management devices could potentially be employed in this context, but they are hardly applicable to high flow rate cryogenic liquid systems. This paper explores several novel propellant settling strategies that are particularly well suited for cryogenic propellants. In particular, three distinct Magnetic Positive Positioning concepts, a hydrogen-peroxide-based Propellant Gasification System, and a hybrid device that combines both approaches are introduced. The preliminary technical analysis indicates that the successful development of these technologies could lead to mass savings of hundreds of kilograms and economic gains of several hundred thousand dollars per launch.

Autonomous Wheel Off-Loading Strategies for Deep-Space CubeSats

Deep-space CubeSats missions require careful trade-offs on design drivers such as mass, volume, and cost, while ensuring autonomous operations. This work elaborates the possibility of off-loading the reaction wheels without the need of carrying a bulky and expensive reaction control system or the field-dependent magnetotorquers. The momentum accumulated along two body axes can be removed by either offsetting the main thruster with a gimbal mechanism or by tilting differentially the solar wings. The dumping on the third axis can be still accomplished by imposing a specific attitude trajectory with the motion of either the gimbal or the arrays drive mechanism. The M-Argo CubeSat is selected as case study to test the techniques along its deep-space trajectory. The strategies decision-making is autonomously carried out by a state machine. The off-loading during the cruising arcs employs the gimballed thruster and takes typically 3 h, granting a mass savings of more than 99% with respect to the usage of a reaction control system. The trajectory is shown to have negligible differences with respect to the nominal one, since the thrust is corrected accordingly. During the coasting arcs, the solar arrays are tilted and several hours are required, depending on the Sun direction and intensity, but the propellant is completely saved. Sensitivity analyses are also carried out on the initial angular momentum components and the center of mass displacement to check the robustness of the algorithms.

Phase Change Material Behavior in Finite Thickness Slabs Under a Step Response Heat

Abstract Phase change materials (PCMs) can provide thermal buffering to systems that experience transient heat loads, including electronics and optoelectronics packaging. Placing the PCM in the primary path of heat rejection decreases the thermal resistance between the heat source and the PCM volume, but increases the total thermal resistance between the heat source and heat sink. In systems that operate in both steady-state and transient regimes, this introduces tradeoffs between cooling performance in these distinct regimes. Employing a conductive finite volume model, Parapower, we investigate those tradeoffs considering the impact of adding a layer of gallium (Ga), a low melting point metal, and a layer of copper (Cu) between a planar heat source and a convective boundary condition heatsink. We demonstrate: (1) side-by-side comparisons of latent (Ga) and sensible (Cu) heat storage layers must consider different layer thicknesses to account for the different thermal storage mechanisms, (2) for short periods of time, conditions exist in which a PCM outperforms a traditional heat sink for transient thermal buffering at an equivalent steady-state temperature rise, and (3) under these conditions, the Ga layer is approximately an order of magnitude thinner than the equivalent Cu, leading to significant mass and volume savings.

System-Level Optimization of Passive Energy Balancing

A common issue with morphing structures is that the actuators must work against significant structural and aerodynamic stiffness. The concept of passive energy balancing (PEB) aims to ameliorate this, and thereby reduces system mass, by connecting negative stiffness elements to the actuated degrees of freedom. However, these devices can be complex to design and will also add their own mass to the system. It is therefore difficult to determine the potential for system-level mass saving without significant detailed design effort. This work treats a PEB device as essentially a local energy storage mechanism. This framework leads to an approach to optimization that will deliver a lightweight PEB mechanism in addition to reducing actuator requirements. It also allows a high-level method to obtain an approximate evaluation of system-level benefits with only basic information about the application being considered, by comparing general properties of the actuators used to the energy storage properties of the underlying materials used in the PEB device. The work concludes with a case study that shows how the PEB can potentially reduce system mass both through reduced energy consumption requirements and actuator mass savings, and can work particularly well for actuators with nonideal stroke/force profiles.

Parametric Design Studies of Mass-Related Global Warming Potential and Construction Costs of FRP-Reinforced Concrete Infrastructure.

Fibre-reinforced polymers (FRPs) are a promising corrosion-resistant alternative to steel reinforcement. FRPs are, however, generally costly and have a high energy demand during production. The question arises whether the high performance of FRPs and possible savings in concrete mass can counterbalance initial costs and environmental impact. In this paper, a parametric design study that considers a broad range of concrete infrastructure, namely a rail platform barrier, a retaining wall and a bridge, is conducted to assess the mass-related global warming potential and material costs. Design equations are parametrised to derive optimum reinforced concrete cross-sectional designs that fulfil the stated requirements for the serviceability limit state and ultimate limit state. Conventional steel reinforcement, glass and carbon FRP reinforcement options are evaluated. It is observed that the cross-sectional design has a significant influence on the environmental impact and cost, with local extrema for both categories determinable when the respective values become a minimum. When comparing the cradle-to-gate impact of the different materials, the fibre-reinforced polymer-reinforced structures are found to provide roughly equivalent or, in some cases, slightly more sustainable solutions than steel-reinforced structures in terms of the global warming potential, but the material costs are higher. In general, the size of the structure determines the cost competitiveness and sustainability of the FRP-reinforced concrete options with the rail platform barrier application showing the greatest potential.

Optimization of post-tensioned concrete slabs for minimum cost

We present a methodology and computational procedure for optimization of arbitrary post-tensioned slabs. The method is not restricted to any predefined cable layout and therefore non-trivial, curved cables patterns emerge, achieving nearly 50% savings in cost and cable mass. The cost function that is minimized accounts for the material and labor costs with a penalty on complex cable layouts, leading to a more realistic cost estimate. Stress and deflection constraints are imposed so that the optimized layouts satisfy the requirements for limit states of serviceability. Together with curvature constraints and an explicit representation of the cables’ geometry, a computational design process is obtained that yields optimized designs that do not require additional post-processing. Furthermore, a Pareto optimum front is generated from a large set of optimized designs, demonstrating the critical trade-off between cable mass and construction complexity. Subsequently, the Pareto front can be utilized for decision making: finding the most suitable balance between material and construction costs, according to the added cost of constructing complex cable patterns.

Vibration of a Satellite Structure with Composite Lattice Truss Core Sandwich Panels

Composite materials are widely employed in spacecraft, aiming at increasing mass savings and load bearing capacities. Due to the excellent static and dynamic performance, lattice truss core sandwich structures have become one alternative of satellite structure materials. In addition, the dramatic potentials of multifunctional integration accelerate development of new spacecraft technology. In this investigation, a novel satellite structure concept with composite lattice truss core sandwich panels is proposed. A series of vibration tests and a finite element analysis campaign are conducted to determine the dynamic responses of the satellite structure. The developed finite element models provide a feasible numerical analytical scheme to address the vibration performance and structural integrity inspection. And the current satellite structure prototype demonstrates outstanding prospects of significant mass reduction and rapid assembly process.

Design of Fiber-Composite/Metal–Hybrid Structures Made by Multi-Stage Coreless Filament Winding

Additive manufacturing processes, such as coreless filament winding with fiber composites or laser powder bed fusion with metals, can produce lightweight structures while exhibiting process-specific characteristics. Those features must be accounted for to successfully combine multiple processes and materials. This hybrid approach can merge the different benefits to realize mass savings in load-bearing structures with high mass-specific stiffnesses, strict geometrical tolerances, and machinability. In this study, a digital tool for coreless filament winding was developed to support all project phases by natively capturing the process-specific characteristics. As a demonstration, an aluminum base plate was stiffened by a coreless wound fiber-composite structure, which was attached by additively manufactured metallic winding pins. The geometrical deviations and surface roughness of the pins were investigated to describe the interface. The concept of multi-stage winding was introduced to reduce fiber–fiber interaction. The demonstration example exhibited an increase in mass-specific component stiffness by a factor of 2.5 with only 1/5 of the mass of a state-of-the-art reference. The hybrid design approach holds great potential to increase performance if process-specific features, interfaces, material interaction, and processes interdependencies are aligned during the digitized design phase.