Currently, the consortium was able to produce European-based IMCF and the mechanical testing confirmed that they are in the range of the defined requirements for launchers.
Although additional optimization work still needs to be performed, the fibre properties already achieved for IM CF (in the figure, shown in pink, references E2021, E2022 and E2045) can be related with the ones from the fibres commercialized by non-European companies (mostly Hexcel and Toray), as demonstrated in the picture below (Figure 4), showing a good progress regarding the state of the art of materials availability at Europe. This is representative of a significant progress of the European capacity to manufacture these specialty materials, potentially boosting the economy, besides opening more opportunities for emerging markets to benefit by the use of these fibres and prepregs.
Tensile properties are lower than launcher’s requirements, in the three types of tested CF (50, 24 and 12k), in the case of elongation, except for 50k CF, which reaches the requirement for some of the performed trials, the obtained results were lower than requirements.
First uni-directional laminate plates, manufactured at INEGI with SGL IMCF using 50k and 24k filament fibres, were successfully tested with respect to its tensile properties parallel and normal to the fibre direction. Both values were above the required values for AVIO´s launcher application.
Furthermore, a number of suitable resin systems for prepreg production selected by INEGI were subjected to outgassing test (at AAC facilities) in order to validate its applicability to Space applications. All four resin systems demonstrated their suitability to be used in composite parts for Space components.
The fibres manufactured by SGL during 2020 for the launcher demonstrators (cable duct and pressure vessel) show tensile strength values lower than the requirements (4900-5150 MPa), very similar to the previously manufactured fibres E2045 and E2022. After an involvement of AVIO`s design department, it was decided that a reduction of about 10% in the tensile strength values could be accepted, however, the payload mass to be launched would need to be reduced accordingly. For the cable duct demonstrator, AVIO accepts lower TS fibres, since this parameter is not so critical. Cable ducts require materials that withstand to aerodynamic environment and forces acting on the external surfaces of the launcher and the acceleration of the launcher during the ascent phase, therefore not so high mechanical properties are needed.
Current efforts are being made in order to produce high modulus precursor and fibre, taking into consideration the very large amount required for testing purposes and demonstrator manufacturing, and the tight mechanical property range.
The consortium gathered in a roundtable for the exploitation of the SpaceCarbon results. For that, NUTA was responsible for gathering the data previously ad after the meeting, based on the partners input, namely industrial ones (AVIO, AIRBUS and SGL). A document containing important information concerning the project materials was gathered for the effect, with data such as product cost, market coverage, production capacity, among others. On the meeting, the partners were encouraged to share their opinions regarding the future market, potential buyers and applications. The impact of this exploitation results is that the industrial members may see their materials/processes shortly becoming commercially available and competitive, compared with existing materials, For instance, SGL can become a supplier of carbon fibres for demanding sectors such as the space one, and AVIO can use these fibres to produce semiproducts (prepregs) for other applications that are not currently included in their portfolio.
