Aluminium Foam Sandwich Structures for Space Applications

Paper number

IAC-06-C2.4.10

Author

Dr. Dirk Schwingel, alm GmbH, Germany

Coauthor

Dr. Hans-Wolfgang Seeliger, alm GmbH, Germany

Coauthor

Mr. Claude Vecchionacci, Centre National d'Etudes Spatiales (CNES), France

Coauthor

Mr. Detlef Alwes, Deutsches Zentrum fur Luft und Raumfahrt e.V. (DLR), Germany

Coauthor

Mr. Jürgen Dittrich, Deutsches Zentrum fur Luft und Raumfahrt e.V. (DLR), Germany

Year

2006

Abstract

Sandwich materials in general are typical lightweight materials and thus frequently used in various space applications.
State of the art sandwich structures are composed of a number of individual layers bond to each other by means of adhesives. This fact yields an incompatibility to processes or applications involving heat.  Consequently they are unsuitable for joining techniques such as welding or soldering – components made of these materials have to be integrated into structures by means of screwing, riveting, and adhesives or similar.
Due to their particular structure the final shape of components made of classical sandwich material has to be given during the manufacture of the sandwich material itself. Reshaping of the material or of components made thereof is usually not possible. Thus, structures made of classical sandwich materials are either flat or have to be individually manufactured while accepting high production costs. 
Within the scope of the present paper a new class of sandwich material, so called aluminium foam sandwiches (AFS) will be presented that do not show above disadvantages. These sandwiches consist of 2 external aluminium sheets and an internal layer of aluminium foam. Since the layers are bound to each other metallically, the sandwich is free of any adhesive and suitable for welding.
While AFS have the advantages of classical sandwiches such as high stiffness and low weight, they can be reshaped by technologies well known from metal sheet material. Processes such as deep drawing or pressing may be applied.
Within the frame of a French-German research project, the suitability of AFS for space applications was examined. For this purpose an Ariane cone was designed of AFS taking into account its specific material properties. Subsequently complexly shaped cone segments were produced and assembled by welding. Then the cone structure was mechanically tested and the results obtained compared to calculations done in advance.
The present paper will present the research project and its outcome as well as perspectives for future space applications of this new class of sandwich materials. 

Abstract document

IAC-06-C2.4.10.pdf

Manuscript document

IAC-06-C2.4.10.pdf (🔒 authorized access only).

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