| Customer: ESA/ESTEC and DLR (2006 – 2008) | |
 | By the use of Titanium Metal Sheets in between the CFRP layers bolted joints can be loaded higher than without reinforcement. The study includes application reviews, sample test programs and a breadboard phase. |
The objectives of the study are to
- investigate advanced concepts for highly loaded bolted composite structural joints,
- perform a detailed evaluation for different concepts and
- manufacture breadboard joint structures to demonstrate performance compared to conventional design
The project is foreseen in three parts:
- Technology Review (Work Package 1)
- Joint Design and Evaluation (Work Package 2)
- Breadboard Design and Manufacturing (Work Package 3)
In Work Package 1 typical highly loaded joints in space structures and launchers shall be identified and the specific environmental requirements shall be determined. A survey of possible solutions and applications of new and advanced bolted joint concepts shall be conducted. Joints for monolithic and sandwich laminates with various thickness shall be assessed. Focus shall be on hybrid CFRP/metal laminates. Local softened joints and other options shall be considered as well.
For hybrid laminates the focus shall be on local usage in the joint area. It is not intended to study the use of hybrid laminates in the complete structure.
In Work Package 2 a design approach for the selected advanced joint concepts shall be developed. Performance of the joints shall be evaluated by numerical analysis and sample testing. Critical parameters shall be identified and sensitivity studies performed. Compatibility of the concepts with state-of-the-art manufacturing technologies employed for space and launcher structures and compatibility with space environment shall be addressed. The performance of the advanced joint concepts shall be compared to that of conventional joining technologies.
Finally in Work Package 3 at least one dedicated breadboard shall be designed, manufactured and test characterized under the expected environmental loads.
This study is lead by the DLR Institute of Fibre Composite and Adaptronics in Braunschweig. HPS, as subcontractor, has the responsibility to manage the study in conformance to ESA management rules and to elaborate application examples and a trade-off for reference cases. Further main subcontractors are EADS-CASA in Spain and INEGI in Portugal. Further subcontractors are MT Aerospace, Kayser-Threde, Contraves and SABCA.
Publications:
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Statement of Work:
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