Introduction
This project successfully tested a carbon-corbon composite in a spacecraft. The
composite
formed the face sheets of an aluminum honeycomb panel, which served as a combined
radiator
and structural panel on the Earth Orbiter-1 (EO-1) spacecraft of the New Millenium
Program,
which flew successfully on November 21, 2000.
A carbon-carbon composite is similar to other composites, such as fiberglass-epoxy,
in that
it consists
of fibers in a matrix. In a carbon-carbon composite, both the fibers and the matrix
consist
of carbon.
The advantages of carbon-carbon composite are:
- it has high strength
- it has low weight (density less than aluminum)
- it has high thermal conductivity
- it can be used at high temperatures (has been used in the Space Shuttle
wing leading edge and is currently used in aircraft brakes).
The disadvantages are:
- high cost
- long production lead time
- low shear strength between layers
- large difference between thermal expansion of carbon-carbon and of aluminum.
The long-term goals of the project are:
- reduce spacecraft weight
- reduce the cost of spacecraft thermal control
- extend spacecraft lifetime
This test showed that carbon-carbon panels can help simplify the design and
construction of
spacecraft. The single carbon-carbon honeycomb panel replaced two separate
components:
an exterior structural panel and a radiator. When used on the interior of a future
spacecraft, a similar panel
might replace both a structural member and a heat pipe, thermal bus, or other heat
transport
device.
Program Organization
The program was carried out by the Carbon-Carbon Spacecraft Radiator Partnership
(CSRP) with
members from:
- government
- NASA Langley
- NASA Goddard
- Air Force
- Naval Surface Warfare Center
- industry
- TRW
- Lockeed Martin
- Amoco Polymers
- B. F. Goodrich
- Materials Research & Design
- Swales Aerospace.
Panel Construction
- Inner layer: honeycomb of aluminum 5056
- Face sheets: fabric of P30X carbon fiber, in a carbon matrix produced by
chemical vapor
infiltration
- Panel dimensions: 28.62 inches x 28.25 inches x 1 inch
- Panel weight: 5.5 pounds
Both carbon-carbon composite panels were coated with epoxy encapsulant. The surface
on the
exterior of the spacecraft was covered with silver Teflon tape.
Mounting Fixtures
Inserts were used both for mounting the panel to the spacecraft and for mounting
electronics
boxes to the panel. Potting compound holds the inserts in place, transferring the
loads to
the
honeycomb core and to the carbon-carbon face sheets. The potting compound absorbs
the
strains caused by
the difference between the thermal
expansion coefficients of the carbon-carbon sheets and the aluminum spacecraft
structure.
Flight
The panel survived launch and operations in orbit. Thermal performance on orbit was
close
to performance during tests and to thermal models. The program successfully
demonstrated the
usefulness of carbon-carbon composite panels as spacecraft radiators and structural
members.
References
These references are available through the
NASA Technical Reports Server
(NTRS)
- Butler, Dan; Carbon-Carbon Radiator, Document ID: 20020010573
- Kuhn, Jonathan; Benner, Steve; Butler, Dan; Silk, Eric; Thermal and Mechanical
Performance of a Carbon/Carbon Composite Spacecraft Radiator; Document ID:
19990041155
- Minning, Charles P.; Luers, Philip; The New Millennium Program: Validating
Advanced
Technologies for Future Space Missions; Document ID: 20000057365