New Possibilities of Creating the Efficient Dimensionally Stable Composite Honeycomb Structures for Space Applications

Today there is a great need in the optimal designing and manufacturing of dimensionally stable precision structures for satellite communication systems and sensing systems, in order to implement the international space programs successfully. It is well known that sandwich panels with load-bearing skins made of polymeric composites based on carbon, organic or glass fibers and honeycomb filler of aluminum foil or other materials providing combined action of skins, feature high dimensional stability. Optimization of design parameters was performed on a specimen of operating section of the composite solar panel with honeycomb filler. Results of the analysis of various reinforcement patterns for the load-bearing skins and rational distribution of material for several loading cases of the solar panel are presented. Technological warpage of these panels was analyzed and assessed. Causes of defects generated during the manufacturing process in the form of continuous and discrete strips of thin load-bearing skins of CFRP (carbon fiber reinforced plastic) were also investigated. With the use of the analytical methods supported by finite element method, the integrated study of the adhesive joint’s bearing capacity of solar panel composite skins with the honeycomb filler at transverse avulsion for the main technological methods of applying the adhesive (as a continuous layer and targeted dosing to the ends of the honeycomb) was carried out. The results obtained allow predicting the fracture behavior of the load-bearing skins’ bonding with the honeycomb filler depending on parameters and properties of the honeycomb cell material and the adhesive layer.