MATERIALS SELECTION FOR SPACECRAFT

AND LAUNCH VEHICLE APPLICATIONS

September, 2002

Table of Contents
List of Figures ..................................................................................................................... viii
List of Tables ......................................................................................................................... ix
PART I: SPACE ENVIRONMENT, DESIGN AND MATERIAL
CONSIDERATIONS............................................................................................................. 1
1.0

EXECUTIVE SUMMARY ........................................................................................ 3

2.0

INTRODUCTION....................................................................................................... 7

3.0

SPACE ENVIRONMENTS ..................................................................................... 11

4.0

LAUNCH VEHICLE ENVIRONMENTS ............................................................ 15

5.0

DESIGN CRITERIA FOR SPACECRAFT SUBSYSTEMS............................. 17

5.1
5.2
5.3
5.4
5.5
5.6
5.7

Introduction........................................................................................................................................17
Structure Subsystems .......................................................................................................................19
Mechanism Subsystems....................................................................................................................20
Electronic Subsystems ......................................................................................................................21
Power Subsystems .............................................................................................................................21
Thermal Control Subsystem............................................................................................................22
Propulsion Subsystems.....................................................................................................................23

6.0 DESIGN CRITERIA FOR EXPENDABLE & REUSABLE LAUNCH

VEHICLE SUBSYSTEMS................................................................................................. 25
7.0

MONOLITHIC METALS ....................................................................................... 29

7.1
Introduction........................................................................................................................................29
7.2
Aluminum and Aluminum Alloys...................................................................................................30
7.2.1
Specific Aluminum Alloys.........................................................................................................31
7.3
Copper and Copper Alloys ..............................................................................................................38
7.4
Beryllium and Beryllium Alloys......................................................................................................38
7.5
Nickels and Superalloys....................................................................................................................41
7.6
Shape Memory Alloys (SMA)..........................................................................................................44
7.7
Intermetallics .....................................................................................................................................44
7.8
Steels....................................................................................................................................................45
7.9
Refractory Metals and Alloys..........................................................................................................46
7.10 Conclusion..........................................................................................................................................48

8.0
8.1
8.2

MONOLITHIC CERAMICS .................................................................................. 51

Introduction........................................................................................................................................51
Properties of Ceramics.....................................................................................................................51

PART III: SELECTION OF COMPOSITE MATERIALS........................................ 55

AMPTIAC

9.0
9.1
9.2
9.3
9.4
9.5

OVERVIEW OF COMPOSITE MATERIALS................................................... 57

Introduction........................................................................................................................................57
Classes and Characteristics of Composite Materials...................................................................58
Comparative Properties of Composite Materials.........................................................................60
Mechanical and Physical Property Considerations .....................................................................65
Manufacturing Considerations .......................................................................................................67

10.0 COMPOSITE REINFORCEMENT MATERIALS............................................ 69

10.1 Introduction........................................................................................................................................69
10.2 Fibers...................................................................................................................................................69
10.2.1 Glass Fibers.................................................................................................................................70
10.2.2 Carbon (Graphite) Fibers............................................................................................................71
10.2.3 Boron Fibers................................................................................................................................72
10.2.4 Fibers Based on Silicon Carbide................................................................................................72
10.2.5 Fibers Based on Alumina (Aluminum Oxide) ..........................................................................72
10.2.6 Aramid Fibers..............................................................................................................................72
10.2.7 High Density Polyethylene Fibers .............................................................................................73
10.3 Whiskers .............................................................................................................................................73
10.4 Particles...............................................................................................................................................73

11.0 METAL MATRIX COMPOSITES........................................................................ 75

11.1 Introduction........................................................................................................................................75
11.2 Mechanical Properties of Metal Matrix Composites...................................................................75
11.2.1 Mechanical Properties of Continuous Fiber-Reinforced MMCs.............................................76
11.2.2 Mechanical Properties of Discontinuous Fiber-Reinforced MMCs ........................................77
11.2.3 Mechanical Properties of Particle-Reinforced MMCs .............................................................77
11.3 Physical Properties of Metal Matrix Composites.........................................................................78
11.3.1 Physical Properties of Continuous Fiber-Reinforced Metal Matrix Composites ...................78
11.3.2 Physical Properties of Silicon Carbide Particle-Reinforced Metal Matrix Composites ........79
11.4 Manufacturing Processes for Metal Matrix Composites............................................................80
11.5 Applications of Metal Matrix Composites ....................................................................................81

12.0 POLYMER MATRIX COMPOSITES.................................................................. 83

12.1 Introduction........................................................................................................................................83
12.2 Polymer Matrix Materials ...............................................................................................................83
12.2.1 Thermosetting Resins .................................................................................................................84
12.2.2 Thermoplastic Resins..................................................................................................................85
12.2.3 New High Temperature Resins..................................................................................................85
12.3 Mechanical Properties of Polymer Matrix Composites..............................................................86
12.4 Physical Properties of Polymer Matrix Composites....................................................................89
12.5 Manufacturing Processes for Polymer Matrix Composites .......................................................91
12.6 Polymer Matrix Composite Applications ......................................................................................92
12.6.1 Launch Vehicles..........................................................................................................................92
12.6.2 Spacecraft ....................................................................................................................................94

13.0 CARBON MATRIX COMPOSITES..................................................................... 97

13.1
13.2
13.3
13.4
13.5
13.6

Introduction........................................................................................................................................97
Oxidation Protection.........................................................................................................................98
Mechanical Properties of Carbon Matrix Composites ...............................................................98
Physical Properties of Carbon Matrix Composites.....................................................................98
Manufacturing Processes for Carbon Matrix Composites.......................................................100
Applications of Carbon Matrix Composites...............................................................................100

14.0 CERAMIC MATRIX COMPOSITES.................................................................103

vi

MATERIALS SELECTION FOR SPACECRAFT

AND LAUNCH VEHICLE APPLICATIONS
September, 2002
14.1
14.2
14.3
14.4
14.5

Introduction......................................................................................................................................103
Mechanical Properties of Ceramic Matrix Composites............................................................106
Physical Properties of Ceramic Matrix Composites..................................................................107
Manufacturing Processes for Ceramic Matrix Composites.....................................................108
Applications of Ceramic Matrix Composites..............................................................................108

15.0 SUMMARY AND CONCLUSIONS ....................................................................111

BIBLIOGRAPHY..............................................................................................................113
CITED REFERENCES ....................................................................................................125

vii

AMPTIAC

List of Figures
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15

Typical Materials of Construction for the Space Shuttle Orbiter2...............................................33

Confined System for Explosive Forming9 .....................................................................................35
Unconfined System for Explosive Dome Forming9 .....................................................................36
Diagram of Shear Forming Processes15 .........................................................................................38
Nickel-Base Alloy Chart Showing Alloys Containing Varying Amounts of Nickel and Iron.
Chromium Contents (for most alloys) are Constant at Approximately 18 to 20% 27 ..................42
Test Temperature Versus Ultimate Tensile Strength for Pure Refractory Metals41 ...................46
Technology Demonstrator Engine Fabricated from Rhenium.....................................................48
Reinforcement Forms .....................................................................................................................59
Specific Tensile Strength as a Function of Specific Modulus (Composite Materials, Monolithic
Metals, Ceramics)............................................................................................................................61
Number of Cycles to Failure as a Function of Maximum Stress .................................................62
Variation of Coefficient of Thermal Expansion with Particle Volume Fraction for Silicon
Carbide Particle-Reinforced Aluminum........................................................................................63
Thermal Conductivity as a Function of Electrical Resistivity of Metals and Carbon Fibers.....64
Temperature Capability of Materials as a Function of Density...................................................65
Cycles to Failure as a Function of Maximum Stress ....................................................................89
Stress-Strain Curve for Ceramic Matrix Composites Reinforced with Continuous Fibers .....105

viii

MATERIALS SELECTION FOR SPACECRAFT

AND LAUNCH VEHICLE APPLICATIONS
September, 2002

List of Tables
Table 1
Table 2
Table 3
Table 4
Table 5
Table 6
Table 7
Table 8
Table 9
Table 10
Table 11
Table 12
Table 13
Table 14
Table 15
Table 16
Table 17
Table 18
Table 19
Table 20
Table 21
Table 22
Table 23
Table 24
Table 25
Table 26
Table 27
Table 28
Table 29
Table 30
Table 31
Table 32
Table 33
Table 34
Table 35
Table 36

Typical Historical Dry Mass Breakdown ......................................................................................18

Improvement in Communication Satellite Structure Efficiency..................................................18
Typical Mechanical Properties of Alloys 2219-T87 and 2519-T87.3.........................................31
Al-Li Aerospace Alloys Manufactured by Alcoa, Reynolds & INCO3.......................................34
Al-Li Alloy Compositions (Wt. %)3 ..............................................................................................34
2195 Alloy Compositions (Weight %)..........................................................................................38
Selected Physical Properties of Beryllium18 .................................................................................39
Properties of Selected Beryllium and Aluminum Aerospace Alloys...........................................40
Mechanical Properties of AlBeMet AM162 at 20 oC (70oF) .......................................................41
Room-Temperature Mechanical Properties of Selected Nickel-Based Alloys (for Annealed
Sheet)27.............................................................................................................................................43
Properties of Selected Spacecraft and Launch Vehicle Metal Alloys .........................................49
Properties of Cordierite taken from Four Sources........................................................................52
Fracture Toughness and Critical Flaw Size for Monolithic Ceramics, Steel and Aluminum....52
Properties of Alumina, Silicon Carbide and Silicon Nitride........................................................53
Types of Composite Materials .......................................................................................................58
Properties of Selected Matrix Materials ........................................................................................59
Effect of Fiber Form and Volume Fraction on Properties of E-Glass Reinforced Polyester
Composites ......................................................................................................................................66
Properties of Key Reinforcing Fibers ............................................................................................70
Mechanical Properties of Selected Continuous Fiber-Reinforced Metal Matrix Composites...76
Mechanical Properties of Silicon Carbide Particle-Reinforced Aluminum Compared to those of
Aluminum, Titanium, and Steel Alloys.........................................................................................78
Physical Properties of Selected Unidirectional Metal Matrix Composites .................................79
Physical Properties of Silicon Carbide Particle-Reinforced Aluminum. ....................................79
Characteristics of High Temperature Resins.................................................................................85
Mechanical Properties of Selected Unidirectional Polymer Matrix Composites .......................86
Mechanical Properties of Selected Quasi-Isotropic Polymer Matrix Composites......................88
Physical Properties of Selected Unidirectional Polymer Matrix Composites.............................90
Physical Properties of Selected Quasi-Isotropic Polymer Matrix Composites...........................91
Mechanical Properties of Carbon Matrix Composites..................................................................99
Mechanical Properties of Carbon/Carbon Composites Reinforced with Unbalanced Fabrics
having a Warp-to-Fill Ratio of 4:1.................................................................................................99
Physical Properties of Unidirectional P-100 Fiber-Reinforced Carbon/Carbon Composites..100
Physical Properties of Carbon/Carbon Composites Reinforced with Unbalanced Fabrics having
a Warp-to-Fill Ratio of 4:1...........................................................................................................100
Fracture Toughness of Structural Alloys, Monolithic Ceramics and Ceramic Matrix
Composites ....................................................................................................................................104
Mechanical Properties of Enhanced Silicon Carbide Fiber-Reinforced Silicon Carbide.........106
Mechanical Properties of Heat-Treated Carbon Fiber-Reinforced Silicon Carbide.................107
Physical Properties of Enhanced Silicon Carbide Fiber-Reinforced Silicon Carbide..............107
Physical Properties of Heat-Treated Carbon Fiber-Reinforced Silicon Carbide......................108

ix