MetPreg Fiber Reinforced Aluminum for Hard Upper Torso Spacesuit Components

Currently, NASA is seeking new technologies to be incorporated into their Hard Upper Torso (HUT) design for spacesuits that will be used in off-planet applications. This next generation of spacesuits will require technologies that are stronger and more durable than the current state-of-the-art materials that were used for previous space exploration. Touchstone proposes to replace the existing HUT materials with a lightweight high-strength metal matrix composite (MMC), known commercially as MetPreg. MetPreg is a fiber reinforced aluminum (FRA) composite composed of continuous alumina fibers within a pure aluminum matrix. Metal matrix composites such as MetPreg offer unmatched durability, and composite-adjacent strength to weight ratios, both of which are critical in remote and off-planet applications. Additionally, these materials permit repair, recycling, and remanufacturing opportunities that are seldom considered with traditional epoxy (thermoset) aerospace composites. Therefore, a metallic structure will provide many benefits in off-planet situations, especially regarding durability, maintenance, repair and off-gassing. Phase I of this study intends to prove the ability of MetPreg to be thermally formed into shaped coupons and maintain strength properties. As part of this study, Touchstone plans to manufacture 10 tensile samples and 5 hemispherical shaped coupons. 5 of the tensile samples will be tested to the appropriate ASTM standard and the 5 remaining samples are planned to be delivered to NASA for future vendor testing. 5 Hemispherical coupons will be manufactured to prove the ability to form coupons of MetPreg and manufactured for use within NASA HUTs and for use in future testing. All testing and learnings from this study will be supplied to NASA at its completion.