Composite materials in aircraft. The concept of composite materials and application in rocket science

The department was organized in 2002-2008. led Bulanov Igor Mikhailovich(1941–2008), Vice-Rector of the Moscow State Technical University named after N. E. Bauman, Doctor of Technical Sciences, Professor, Laureate of the Prize of the Government of the Russian Federation, Honorary Worker of Higher Professional Education of the Russian Federation, full member of the Russian Academy of Natural Sciences and the Russian Academy of Cosmonautics. K. E. Tsiolkovsky. From 2008 to the present, the department is headed by Reznik Sergey Vasilievich, Doctor of Technical Sciences, Professor, Honorary Worker of Higher Professional Education of the Russian Federation.

The department was organized in 2002 to train specialists in the field of design, production and testing of rockets and spacecraft, with the wide use of composite materials (CM) capable of operating in the most difficult conditions (extremely high / low temperatures, vacuum, high pressures, chemically active environments). , flows of erosive particles, etc.).

Formation and development of the scientific school of MSTU. N. E. Bauman in the field of spacecraft is inextricably linked with the history of the development of rocket and space technology. The bright pages of this history are the result of close cooperation between workers in industry, academic science and higher education, many of whom graduated from our university. A feature of the scientific school is a combination of advanced research in the field of mechanics, thermal physics, materials science and the latest technologies.

At the end of the 1940s, the designers of the first domestic long-range guided ballistic missiles (URBRDD), headed by S.P. Korolev, faced the problem of thermal protection of missile warheads from aerodynamic heating during atmospheric entry. Graduates of MVTU them. N. E. Bauman - employees of NII-88 V. N. Iordansky, G. G. Konradi, together with fellow materials scientists from OKB-1 (A. A. Severov and others) and VIAM (A. T. Tumanov and others .) for the first time in the world solved this problem by applying an ablative coating of polymer KM (asboplastic) on the head of the R-5 (8K51) rocket. This approach to overcoming the "thermal barrier" was later successfully implemented in the designs of the descent vehicles of the manned spacecraft "Vostok", "Voskhod", "Soyuz", automatic spacecraft (SC) of the type "Zenith", "Zond", "Venus" and Mars, has become the backbone solution for similar applications in solid propellant rocket engines and power plants. A deep study of the issues of thermal protection with the use of CM was reflected in the works of professors of our university I. S. Epifanovskiy, V. V. Gorsky, D. S. Mikhatulin, Corr. RAS Yu. V. Polezhaeva, acad. RAS S. T. Surzhikova.

In the 1960s–1980s, the USSR solved the problems of unprecedented complexity in the creation of mobile and silo missile systems with solid-propellant UBRDD. There was a need to develop composite mixed solid propellants and technologies for winding large-sized cylindrical shells of a rocket engine housing made of fiberglass, and later shells of the “cocoon” type made of organoplastic. Among the pioneers in this direction are the chief designer of OKB-1, academician S.P. Korolev, who initiated the design of 8K95 and 8K98 missiles, and Yu. A. Pobedonostsev, a well-known scientist in the field of solid fuel rockets. Under the guidance of a graduate of Moscow State Technical University. N. E. Bauman, chief designer of TsKB-7 (KB Arsenal) P. A. Tyurin, in the early 1960s, the first mobile missile system RT-15 with an 8K96 medium-range missile was designed, an intercontinental ballistic missile 8K98P was developed, which was on combat duty in the Strategic Missile Forces in 1971–1994 (Fig. 1).

Rice. 1. The first domestic intercontinental ballistic missile on solid fuel 8K98P consists of 90% composites (engines, warhead, mixed fuels). The rocket was created under the guidance of MVTU graduates. N. E. Bauman - S. P. Korolev and P. A. Tyurin. Museum of OAO Motovilikhinskiye Zavody, Perm

An outstanding contribution to the creation of modern missile systems RT-2PM "Topol" and RT-2PM2 "Topol-M" was made by the general designers of MIT B. N. Lagutin and Yu. S. Solomonov. In recent years, the latest intercontinental ballistic missiles of the Yars and R-30 Bulava complexes have been created at MIT.

An integral part of the mobile missile systems "Temp-2S", "Pioneer", "Topol" and others became transport and launch containers made of CM (Fig. 2). In the research and implementation of technologies for winding composite shells of rocket engine cases and transport and launch containers, the role of a student of the Moscow State Technical University named after V.I. N. E. Bauman chief designer and director of TsNIISM, corresponding member. RAS V. D. Protasov, his colleagues and followers V. I. Smyslov, V. A. Barynin, A. A. Kulkov, A. B. Mitkevich and others.

Rice. 2. Mobile ground missile system "Topol-M" with a rocket 15Zh55: the rocket and the transport and launch container are made of composites

Thanks to the breadth of views of a number of prominent scientists and educators, such as V.I. Feodosyev and E.A. N. E. Bauman at the departments M-1 (now SM-1) and M-8 (now SM-12) training courses were delivered, reflecting the specifics of the design, production and testing of composite structures. In 1986, the Collegium of the Ministry of General Mechanical Engineering of the USSR decided on the expediency of opening a new specialty "Design and production of products from composite materials" at Moscow Higher Technical School. The recruitment of not one, but three groups of students at once was organized. Considerable attention was paid to the creation of a modern testing base in the Educational and Experimental Center in the village of Orevo, Dmitrovsky District, Moscow Region (now the Dmitrovsky branch of the N.E. Bauman Moscow State Technical University).

A. K. Dobrovolsky, S. S. Lenkov, I. M. Bulanov, M. A. Komkov, V. M. Kuznetsov, G. E. Nekhoroshikh, V. A. Shishatsky became enthusiasts of a new direction in the field of technology. Students mastered the methods of calculating the strength of composite structures under the guidance of N. A. Alfutov, P. A. Zinoviev, B. G. Popov, V. I. Usyukin. Features of thermal and heat-strength calculations of composite structures were covered in lectures by V. S. Zarubin, V. N. Eliseev, S. V. Reznik. Under the leadership of G. B. Sinyarev, the theory of thermal testing of composite structures was developed, many of the provisions of which were based on the results of experiments carried out on new test benches in the village of Orevo.

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Composite materials in aircraft

Introduction

Modern rocket and space technology is unthinkable without polymer composite materials. When developing space exploration tools, new materials are required that must withstand the loads of space flights (high temperatures and pressures, vibration loads at the launch stage, low temperatures of outer space, deep vacuum, radiation exposure, exposure to microparticles, etc.), having this is a fairly low weight. Composite materials meet all these requirements. Composite materials are widely used in aircraft and space engineering because of their good weight and mechanical characteristics, which make it possible to create light and strong structures that operate even at elevated temperatures.

1. The concept of composite materials and application in rocket science

Today, composites are the most popular and commonly used materials in aircraft and rocketry. Many of these materials are lighter and stronger than metal (aluminum and titanium) alloys that are most suitable in terms of their physical properties. In most composites (with the exception of layered ones), the components can be divided into a matrix (or binder) and reinforcing elements (or fillers) included in it. In structural composites, reinforcing elements usually provide the necessary mechanical characteristics of the material (strength, stiffness, etc.), and the matrix ensures the joint operation of the reinforcing elements and protects them from mechanical damage and aggressive chemical environments. When reinforcing elements and a matrix are combined, a composition is formed that has a set of properties that reflect not only the initial characteristics of its components, but also new properties that individual components do not possess

The use of composite materials makes it possible to reduce the weight of a product (rocket, spacecraft) by 10...50%, depending on the type of structure, and, accordingly, reduce fuel consumption, while increasing reliability. Composite materials have also been created in which the plastic (polymer) base is reinforced with glass, Kevlar or carbon threads. Composite materials are widely used in aircraft and space engineering because of their good weight and mechanical characteristics, which make it possible to create light and strong structures that operate even at elevated temperatures.

Weight reduction is a top priority in spacecraft design. Many advances in the field of thin-walled shells owe their origin to this requirement. Typical examples of this design are the Atlas liquid propellant launch vehicle and the solid propellant rocket design. A special supercharged monocoque shell was created for the Atlas. A rocket with a solid propellant engine is obtained by winding a glass thread around a mandrel in the form of a solid propellant charge and impregnating the wound layer with a special resin, which is cured after vulcanization. With this technology, both the carrier shell of the aircraft and the rocket engine with a nozzle are obtained at once. Using modern composite materials, returnable spacecraft were designed with a conical shell covered with a layer of heat-shielding material, which, evaporating at high temperatures, cools the structure.

Another striking example of the use of composite materials is the Shuttle orbital spacecraft capable of flying in the Earth's atmosphere at hypersonic speeds (more than 5 Mach or 6000 km/h). The wings of the apparatus have a multi-spar frame; reinforced monocoque cockpit, like wings, made of aluminum alloy. The doors of the cargo compartment are made of graphite-epoxy composite material. The thermal protection of the apparatus is provided by several thousand light ceramic tiles, which cover parts of the surface exposed to large heat fluxes.

For the Alpha space station, created in accordance with the Russian-American program, many structural elements were made of composite materials: high-strength truss rods, solar panels, pressure vessels, "dry" compartments, reflectors, etc.

Light vessels and containers made of polymer composite materials and operating under pressure are successfully used in rocket and space technology. Fuel tanks, balloons, rocket motor housings, pressure accumulators, breathing cylinders for pilots and astronauts have been created and are being used. The use of organic and glass fibers will make it possible to create durable pressure cylinders with a high coefficient of weight perfection.

At present, carbon fiber reinforced plastics, i.e., are widely used in aviation and rocketry. polymers reinforced with carbon fibers.

Carbon fibers and their composites have deep blacks? color and conduct electricity well, which provides special electrophysical properties (for example, for radar antennas), as well as requirements for heat resistance and thermal conductivity.

CFRP is used to make rocket nose fairings, high-speed aircraft components subjected to maximum aerodynamic loads, rocket engine nozzles, and so on. In addition, given that graphite is a solid lubricant, carbon fiber is used to make brake pads and discs for high-speed aircraft, space shuttles and racing cars. Mirrors of antenna structures made of carbon fiber will find wide application for solving problems of communication via satellites. It is important to take into account that their use with a mass of up to 15 kg will provide a breaking load of 900 kgf with a service life of at least 20 years. Composite materials (three-layer) made of carbon fiber in load-bearing structural elements in comparison with single-layer (monolithic) under given operating conditions and increased loads for a given element mass will provide: a reduction in the mass of a structural element by 40 ... 50% and an increase in its rigidity by 60...80%; increase in reliability by 20...25% and increase in the warranty period by 60...70%.

2. Application of nanotechnology in the development of composite materials

NASA and the Johnson Space Center have drawn up an agreement on the joint development and application of high technologies and, in particular, nanotechnology for space exploration. NASA plans to simplify the withdrawal of space vehicles ??? into orbit using a space elevator based on nanotubes.

Nanotubes are characterized by high rigidity, and therefore, materials based on them can replace most modern aerostructural materials. Composites based on nanotubes will reduce the weight of modern space vehicles??? almost double.

NASA researchers and LiftPort Inc. offer to simplify the output of large objects ??? into orbit using what they call the "space elevator". A space elevator is a ribbon, one end of which is attached to the surface of the Earth, and the other is in orbit of the Earth in space (at an altitude of 100,000 km). The gravitational attraction of the lower end of the tape is compensated by the force caused by the centripetal acceleration of the upper end and the tape is constantly in a taut state.

By varying the length of the ribbon, different orbits can be achieved. Space capsule containing useful? the load will move along the belt. At the final station, if necessary, the capsule is disconnected from the elevator and goes into outer space.

The speed of the capsule in this case will be 11 km/s. This speed will be enough to start a journey to Mars and other planets. Based on the above, we come to the conclusion that the cost of launching the capsule will be only at the beginning of its journey into orbit. The descent will be made in the reverse order - at the end of the descent, the capsule will be accelerated by the Earth's gravitational field.

Single-walled carbon nanotubes, invented in 1991, are strong enough to form the basis of an elevator belt.

They are 100 times stronger than steel and theoretically 3-5 times stronger than what is needed to build an elevator.

A tape consisting of nanotubes 1 m long and 5 cm wide has high strength. The strength/weight ratio of the belt material is higher than that of high hardened steel.

Nanotubes will also be very useful in the development of nanoelectronic devices, super-powerful computers and memory devices.

3.Self-healing composite materials

composite rocket science structural material

Experimental? structural? material for spacecraft will double the life of their hulls. Cracks and small dents will be immediately filled with a special fast curing compound without causing a reduction in structural strength.

Spacecraft bodies??? constantly exposed to extreme temperatures. The sun's rays can heat the surface up to 100°C or more. Once in the earth's shadow, the apparatus begins to cool rapidly. Even simple rotation leads to constant temperature fluctuations on the surface of the device.

Constant temperature fluctuations generate stresses in the case material and lead to the appearance of microcracks.

Another mechanism of cosmic erosion is impacts of micrometeor???. We are not talking about objects capable of causing serious damage - such are extremely rare. But at the same time, space dust particles and particles of space debris smaller than a millimeter are quite numerous and, at speeds of tens of kilometers per second, cause gradual degradation of structures.

New material developed? in the European Space Agency, has increased resistance to space erosion factors due to the ability to self-repair when damaged. When creating it, the developers were inspired by the ability of living tissues to heal small wounds on their own due to the effect of blood clotting.

True, blood clotting occurs under the influence of air, so a slightly different approach had to be used for space technology. Many very thin glass vessels with an outer diameter of 60 microns and an inner diameter of 30 microns were introduced into the composite material. The vessels were filled with two liquids, which, like the components of an epoxy resin, quickly harden when mixed. When a crack occurs, the glass vessels break and the liquids they contain fill the crack. The speed of the process is such that liquids do not have time to evaporate in the vacuum of space. Thus, the further propagation of the crack is immediately stopped - a process that causes much more damage than the crack itself.

Samples of the new material have successfully passed the first tests in a vacuum chamber. Numerous tests are still ahead, primarily for strength and thermal stability. So the practical application of self-healing materials in spacecraft can be expected no earlier than ten years from now. Nevertheless, ESA already believes that the new material will allow a doubling of the operating time of those spacecraft???, for which erosion is a limiting factor.

Conclusion

As practice shows, composite materials, despite their high cost and complexity in production, can become the most used and convenient materials if used correctly. Composite materials provide structures with high strength and wear resistance, as well as low weight of the structure, which is vital in the design of aircraft and spacecraft. In addition, composite materials are no less successfully used in other areas, from mechanical engineering to medicine. Broad prospects are opening up in the creation of new composite materials with unique properties, which will open up new horizons in many areas of human activity.

Bibliography

1. Reference book on composite materials: in 2 books. Book 2 Ed. J. Lubina. - M.: Engineering, 1988

2. Zuev N.I., Golikovskaya K.F. - Journal "Proceedings of the Samara Scientific Center of the Russian Academy of Sciences" Issue No. 4-2 / Volume 14 / 2012

3. Journal "Actual problems of aviation and astronautics" Issue No. 6 / volume 1 / 2010

4. Composite Materials in Rocket and Space Apparatus Engineering Ed. Gardymova G.P. - St. Petersburg: SpetsLit, 1999

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Rice. 2. Mobile ground missile system "Topol-M" with a rocket 15Zh55: the rocket and the transport and launch container are made of composites

From 2008 to the present, the department is headed by Reznik Sergey Vasilievich, Doctor of Technical Sciences, Professor, Honorary Worker of Higher Professional Education of the Russian Federation.

One of the features of CM is that they cannot be considered separately from the design and production technology. At the present stage of development of rocket and space technology, there are several areas in which the use of spacecraft will play a key role: deployable space structures (antennas, power plants, large-volume structures), rocket head fairings, reusable spacecraft, hypersonic aircraft with direct-flow air jet engines.

Mesh shells made of CM have become a new word in the creation of load-bearing space structures (Fig. 3-6). The theory and technology for the production of such structures are being developed at TsNIISM under the guidance of Corr. RAS V. V. Vasiliev, his colleagues A. F. Razin, V. A. Bunakov and others.

Rice. 3 Composite mesh compartment of the Proton-M launch vehicle

Rice. 4 Composite Mesh Payload Adapter

Rice. 5 Composite mesh load-bearing structure of the body of the spacecraft of the Express series

Rice. 6 Composite mesh spokes of a deployable space antenna

The objects of scientific research of professors A. M. Dumansky, G. V. Malysheva, P. V. Prosuntsov, S. V. Reznik, M. Yu. Rusin, B. I. Semenov, O. V. Tatarnikova, V. P. Timoshenko are units, assemblies and compartments of artificial Earth satellites, planetary and orbital stations, space antennas, tourist-class reusable spacecraft, various rockets, engines. A characteristic feature of these studies is the combination of computational and physical experiment (Fig. 7-9).

Rice. 7 Ultralight reflectors of on-board mirror space antennas made of carbon fiber

Rice. 8 Results of mathematical modeling of the temperature state of the reflector of the onboard reflector space antenna

Rice. 9 Student project of the reusable spacecraft "Sivka" (the project was initiated by the first scientist-cosmonaut, Professor K. P. Feoktistov and was developed by students of the departments SM-1 and SM-13)

Within the framework of R&D with PJSC RSC Energia im. S.P. Korolev” with the help of finite element analysis programs of the “CAR” package, temperature fields, stresses and deformations in thin-walled elements of the composite structure of the antenna reflector with a diameter of 14 m of a promising geostationary communication satellite were studied. The results obtained are in good agreement with the results of independent calculations carried out by Italian specialists from Alenia Spazio using the European Space Agency ESATAN and EASARAD computer programs, as well as with data obtained during thermal tests at the European Center for Space Research and Technology in Noordwijk, the Netherlands.

Among the successfully completed projects is participation in the design and debugging of test benches and installations at JSC ONPP Tekhnologiya im. A. G. Romashina. According to the terms of reference of OJSC “Composite”, a number of research and development works were carried out to master production technologies and comprehensive study of the characteristics of carbon-ceramic materials. Since 2011, several large projects have been implemented in the community of the REC "New Materials, Composites and Nanotechnologies" with a total volume of about 300 million rubles.

For 15 years, under the scientific guidance of the professors of the department, 25 candidate and 3 doctoral dissertations have been defended. Teachers, graduate students and students of the department were participants in research under 5 RFBR grants.

Every year, students of the department present 12-15 reports at the conference of the SNTO named after. N. E. Zhukovsky.

Graduates of the department receive the knowledge, skills and abilities necessary for a modern engineer to conduct scientific research and produce new technology. The theoretical foundation of the educational process is the disciplines of the mathematical and natural science cycle - higher mathematics, chemistry, physics, theoretical mechanics, thermodynamics and heat transfer. Among the special disciplines are "Fundamentals of the physical chemistry of composites", "Building mechanics of composite structures", "Mechanics of composite media", "Optimization of composite structures and technologies", "Fundamentals of rocket and space technology". The curriculum provides for the study of methods of computer design, production and testing of composite structures with various combinations of fillers and matrices. In recent years, new disciplines have been included in the curriculum: "Spacecraft Nanoengineering", "Methods for Forming an Innovative Environment", "Technical Training of Space Expeditions", "Technology of Reusable Spacecraft", which are not available in any university in Russia.

The showroom contains unique samples of materials and full-scale structures (the element of the edge of the wing of the Buran spacecraft, the nose fairing of the spacecraft Bor, mesh adapters of the Proton launch vehicle, pipelines for supplying propellant components, compressed gas cylinders, rocket nose fairings S-300, X-35, nozzle blocks, repair adhesive kits, etc.). The Department has established a Center for Information Technology Design, equipped with modern computers.

Students from Belarus, Bulgaria, Vietnam, India, Italy, Kazakhstan, China, Korea, Myanmar, Slovakia, France, graduate students from Belarus, Vietnam, Kazakhstan, China, Myanmar study at the department. Relations have been established with a number of foreign universities: the University of Ljubljana (Slovenia), the University of Glyndora (Wrexham, Great Britain), the Ecole Polytechnic (Leon, France), the Beijing Institute of Technology (University), the Harbin Polytechnic University (China), the National Aerospace University named after . N. E. Zhukovsky (KhAI), Kharkiv, Ukraine, etc. Fruitful partnerships are maintained with the Institute of Heat and Mass Transfer. A. V. Lykova National Academy of Sciences of Belarus, Minsk.

Employees of the department are organizers of international scientific conferences and symposiums: "Materials and coatings in extreme conditions" (together with I. N. Frantsevich IPM of the National Academy of Sciences of Ukraine, Katsiveli village, Crimea, 6 conferences in 2002–2012), Advanced Composite Materials and Aerospace Technologies (Wrexham, Wales, UK, annually in 2011–2015), Advanced Technical Systems and Technologies (Sevastopol, annually since 2005), Rocket -space technology: fundamental and applied problems” (Moscow, 5 conferences in 1998–2018).

Within the framework of the international project INTAS 00-0652 in 2000–2005. carried out joint research with specialists from Belarus, Germany, Spain and France in the field of heat-shielding materials for promising reusable spacecraft, the results of which are world-class.

Introduction

The concept of composite materials and application in rocket science

At present, carbon fiber reinforced plastics, i.e., are widely used in aviation and rocketry. polymers reinforced with carbon fibers.

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