Advanced Architecture, Super Lightweight Structural Composites for Space Applications

Future communication satellites require advances in materials and structures to increase vehicle payload ratio. Traditional metal- and composite-based approaches have matured to the point that meaningful improvements in structural efficiency are difficult to achieve. KaZaK proposes to develop and demonstrate a unique composite reinforcement architecture based on novel carbon fiber preforms in combination with matrices optimized specifically for spacecraft applications. Carbon/epoxy composites manufactured by techniques proposed here have already demonstrated surprising improvements in mechanical properties over conventional composites, including a 30% increase in tensile strength, an order of magnitude improvement in fatigue life, increased stiffness and reduction in delamination damage. KaZaK will show that expanding this revolutionary reinforcement architecture from epoxy to include novel high performance matrices tailored for space environments will provide higher temperature capability and lower outgassing. In addition, the proposed technology will enable production of thinner-walled composite parts with mechanical properties equivalent to conventional thickness structures, leading to super lightweight components. In addition to demonstrating improved material properties in Phase I, KaZaK will work with a commercial satellite company to develop a new satellite structure that takes maximum advantage of our improved composite technology, then compare this composite alternative to a current technology aluminum satellite baseline.