Researching and Selecting Composite Materials for Extreme Aerospace Applications

The selection of composite materials for aerospace applications in extreme environments requires an interdisciplinary approach integrating materials science, structural mechanics and aerodynamics. This study evaluates the suitability of carbon fiber reinforced polymers (CFRPs), glass fiber reinforced polymers and ceramic composites for high temperature, high pressure and radiation exposure conditions [1]. Special emphasis is placed on CFRP composites, in particular KMU-3, which are used in the truss structures of high-altitude pseudo-satellites (HAPS) operating at altitudes of up to 30 km. Mechanical, thermal and aerodynamic properties of CFRP-based structures have been analyzed using finite element methods (FEM), computational fluid dynamics (CFD) and experimental prototyping. The results show that a 0.1 mm thick CFRP shell reduces the mass of the HAPS to 400 kg while maintaining structural integrity against dynamic loads caused by high-altitude turbulence. The study highlights the critical influence of fiber orientation, joint types and additive manufacturing techniques in the development of lightweight and durable aerospace composites [2].