Thermal design and analysis of a flexible solar array system based on shape memory polymer composites

Smart structures based on shape memory polymer composites (SMPCs) have attracted extensive attention because of their unique self-deployment behavior. This study investigated the thermal design and analysis of the SMPC flexible solar array system (SMPC-FSAS). The thermal design ensured the reliability of the deployment functionality and desirable structural temperatures. The fundamental properties of the shape-memory materials were obtained by mechanical analysis (DMA) and shape fixity ratio tests. Thermal experiments, including the thermal balance test (TBT), thermal vacuum test (TVT) and thermal cycle test (TCT) were conducted to verify the safety and reliability of the SMPC-FSAS. Additionally, the temperature distribution of the SMPC-FSAS was simulated using numerical analysis. Notably, a geostationary satellite carrying the SMPC-FSAS was successfully launched into a geosynchronous orbit and controlled deployment was accomplished for the first time. The prediction of the numerical model was consistent with the TBT and on-orbit data, thus validating the accuracy of the numerical method. The research in this work has important reference significance for ultra-large SMPC-FSAS in the future.

Laser welding of austenitic ferrofluid container for the KRAKsat satellite

The production of a ferrofluid container, intended for use in the KRAKsat (CubeSat type) satellite in space conditions, is presented. Mechanized laser beam welding for AISI 316L stainless steel test joint and container prototype was developed and tested. The welded test joints were examined by non-destructive visual, penetration and radiographic testing and destructive testing by macro- and microscopic examination, static tensile test, static bending test, and hardness measurements. The welded container prototype was examined by leak test, temperature-vacuum test and vibration test. Test joints’ evaluation showed a proper selection of welding parameters and expected quality of joints. Austenitic microstructure with small δ-ferrite content in base materials, heat-affected zones, and welds guarantees sufficient mechanical properties for this part geometry. The tensile strength range of test joints was 687–729 MPa, hardness range was 140–200 HV3, and the bending angle was 180°. Welding of the prototype container and testing of tightness, resistance to temperature changes, and vibration were successful. Compliance with flywheel design and manufacturing requirements will enable the launch of a research satellite into orbit with such a wheel.

Effectiveness and Value of Space Vehicle Thermal Vacuum Testing

Environmental testing of spacecraft flight hardware is performed to detect design and workmanship defects and verify mission requirements prior to launch. At the space vehicle level of assembly, the thermal vacuum test simulates an environment particularly well-suited for verifying mission performance requirements. In this paper, the test objectives of the space vehicle thermal vacuum test are reviewed and an assessment is made of the effectiveness and value of the test. Recent thermal vacuum test data is used to determine how the uniqueness of the thermal vacuum test environment achieves test purposes and how the test ensures mission assurance for space vehicles.