The space environment is a volatile and challenging place for satellites to survive in. For Low Earth Orbiting (LEO) satellites, atomic oxygen (AO) is a constant corrosive effect that degrades the outer surface of satellites over long durations. Atomic oxygen exists in the atmosphere between 180 and 675 km and has a relatively high energy at 4.5 eV, which allows AO to break molecular bonds in materials on the surfaces of spacecraft. As the number and complexity of CubeSat missions increase, there is an increased risk that AO degradation on commercial off the shelf parts (COTS), such as antenna, could degrade the satellite’s ability to communicate with ground systems. This thesis looks at how AO erosion affects the performance of patch antennas for CubeSat applications. Patch antennas are small, cheap, low-profile antennas that can be used on CubeSats to communicate with the ground or other satellites. Patch antennas are semi-directional, providing higher gain and higher available frequencies than omnidirectional antennas. An AO chamber in the California Polytechnic State University San Luis Obispo’s (Cal Poly) Spacecraft Environments Testing Lab was used to expose the patch antennas for 24-hour and 48-hour tests. The 24-hour exposure saw an average AO fluence of 8.757 ± 0.807•1020 atoms/cm2 which corresponds to roughly 3.5 months of on-orbit AO exposure on the Ram side when in a 28.5° inclined orbit with an altitude of 400 km. The 48-hour exposure saw an average AO fluence of 1.595 ± 0.076•1021 atoms/cm2 which corresponds to approximately 6.4 months of on-orbit AO exposure on the Ram side when in a 28.5° inclined orbit with an altitude of 400 km. To test the performance of the patch antenna before and after AO exposure, an anechoic chamber in the Microwave Lab at Cal Poly was used to measure boresight gain and radiation pattern in the E-plane and H-plane. From the testing in the anechoic chamber it was determined that there was no apparent difference in the patch antenna’s gain and radiation pattern before and after AO exposure. By using a Fourier Transform Infrared Spectrometer (FTIR) it was discovered that the outer surface of the patch antennas were forming a silicon dioxide layer, which did not affect the performance of the patch antenna. Since silicon dioxide is resistant to AO erosion, it may be beneficial for CubeSats to include silica additives to their exposed antenna surfaces to prevent erosion.

Out-of-Autoclave (OoA) processes for manufacturing aerospace-grade parts needs to be better understood to further the development and success of industries that are manufacturing reusable launch vehicles, military and commercial aircraft, and spacecraft. Overcoming the performance limitations associated with OoA, also known as low-pressure prepreg curing, methods (void count, energy absorption, etc.) will help decrease the costs associated with aerospace composite manufacturing and the negative environmental effects correlated with high-pressure composite curing methods. Experimental, theoretical, and numerical approaches are used to explore both low and high-pressure curing cycles and how the two different processes affect final cured parts. Quasi-static uniaxial compression tests on 33mm diameter tubular specimens concluded that the high-pressure curing methods (up to 90 psi) increased the likelihood of a final part with increased stiffness compared to the lower atmospheric-pressure methods (14.7 psi) on an order of 22%. After further extension and deformation past the linear elastic region, tests concluded that although the autoclaved specimens may have been higher-quality parts, the low-pressure-cured specimens performed more efficiently with respect to energy absorption. Considering the specific energy absorption (SEA) and crush force efficiency (CFE) are both on average around 6% higher for the low-pressure specimens, it is concluded that they can perform similarly to the high-pressure specimens and possibly even more efficiently depending on the loading conditions and desired purpose of the structure.

The space environment possesses numerous unique and unusual attributes, creating challenges that must be considered in order to accomplish a successful space mission. Two of the detrimental aspects of the space environment include Atomic Oxygen, AO, and Ultraviolet, UV, radiation. UV radiation becomes more severe in space as there is no atmosphere to attenuate incoming photons, thereby exposing spacecraft to radiation that never reaches the surface of the Earth. Overall, space vehicles are exposed to a total of 107.4 Watts/m2 of light shorter than 400 nm. AO is created by the photo disassociation of molecular oxygen by UV radiation with wavelengths less than ~242.1 nm. AO is a major portion of the neutral atmosphere, and is the dominant species for altitudes between 180 and 675 km. Each of these environments can cause significant damage to spacecraft materials as they have sufficient energy to break molecular bonds: a generalization of AO energy is 4.5 +/- 1 eV while Vacuum Ultraviolet, VUV, radiation can break bonds as strong as 12.4 eV. Synergistic affects are observed when these two environments interact with materials simultaneously, resulting in an accelerated erosion rate. An apparatus has been developed in California Polytechnic State University’s, Cal Poly’s, space environments laboratory that can simulate the AO and VUV environments individually and simultaneously. This apparatus utilizes a radio frequency, RF, generator to produce a capacitively coupled plasma to create AO in conjunction with a deuterium lamp capable of emitting UV radiation as short as 115 nm. The system has been shown to produce an AO flux of 1.70 +/- 0.07•1016 atoms/cm2 while providing an equivalent sun power 4.5 times greater the solar output in the 120-200 nm region of UV light; all of this has been performed at a base pressure near 175 mTorr. Long duration tests of 24 hours, which would be analogous to durations used in a material interaction study, have shown an effective fluence of 1.47 +/- 0.06•1021 atoms/cm2, which would equate to an orbital exposure on the order of weeks to months. For the same duration a sample can be exposed to 108 equivalent sun hours of 120-200 nm radiation. Results from the simultaneous exposure also manifested an accelerated erosion rate, the expected synergetic reactions between the two environments.

Composites are now being incorporated into aircraft designs because of their high strength to weight ratio compared to traditional metal materials. Due to the complexity of the material, composite parts are presently being over designed to satisfy static and fatigue requirements. A greater understanding of composite fatigue behavior will allow for even greater weight savings leading to increased fuel economy. A critical part of an aircraft that is subjected to fatigue bending loads are its wings. The forces acting on the wings include its lift distribution, powerplant, and fuel which can be carried in the wing body. When in flight these forces repeatedly cause cyclic displacements which could ultimately lead to failure. It is important to design the wing spars which carry the bending loads, to be fatigue resistant so that damage or expensive inspections could be avoided. Wing models were be made from composite materials with a NACA 0016 airfoil shape, chord length of 9.25”, and a span of 15.25”. The C – channel spars were located at 22% and 72% of the chord. Strain gages on the wing model were used to measure strain at different locations. Static test were conducted on the specimens in order to validate a finite element analysis(FEA) model to be used for simulations. Overall, the strain measurements on the leading edge from two of the wings matched the model within 9% of the simulation results. Additional spar designs were then analyzed to determine the optimal one for static and fatigue bending loads. The wings were fatigue tested under displacement control at a test frequency. A model 8801 servo-hydraulic Instron machine and Wave Matrix software was used to fatigue the wings. After 100,000 cycles the test would be deemed a success and concluded.

Materials exposed to the space plasma environment acquire electric charge, which can have harmful effects if it leads to arcing or electrostatic breakdown of important spacecraft components. In fact, spacecraft charging is the leading environmentally induced cause of spacecraft anomalies. This study focuses on measuring electron yield, a property of materials that describes how many electrons are ejected from a material under energetic electron bombardment, which can vary depending on the energy of incident electrons. Intrinsic electron yield is defined as the average number of electrons emitted per incident electron from an electrically neutral material. The specific aim of this work is to improve yield measurements for insulator materials, which can be difficult to test using conventional methods due to charge accumulation in insulators.Most studies of electron yield use a steady current electron beam in a vacuum chamber to irradiate materials to be tested. By comparing the amount of current deposited in the material to the total incident current, the emitted current can be calculated. This works well for conductors; however, insulators charge up quickly, which either repel incident electrons or reattract emitted electrons producing erroneous yield measurements. This study improves on methods that use a pulsed electron beam to measure yield with small amounts of charge per pulse, as well as neutralization methods to dissipate stored charge between pulse measurements.The improvements to instrumentation and data analysis techniques are quantified to demonstrate their validity. These improvements will allow for continued studies on extreme insulator materials. Future studies will provide new understanding of interactions between electron radiation and materials, which will allow for better modeling of spacecraft charging and the development of materials that meet desired electron emission specifications.

Design of thermoelastic structures can be highly counterintuitive due to design-dependent loading and impact of geometric nonlinearity on the structural response. Thermal loading generates in-plane stresses in a restrained panel, but the presence of geometric nonlinearity creates an extension-bending coupling that results in considerable transverse displacement and variation in stiffness characteristics, and these affects are enhanced in post-bucking regimes. Herein a methodology for structural sizing of thermally stressed post-buckled stiffened panels is proposed and applied for optimization of the blade and hat stiffeners using a gradient-based optimizer. The stiffened panels are subjected to uniform thermal loading and optimized for minimum mass while satisfying stress and stability constraints. The stress constraints are used to avoid yielding of the structure, whereas the stability constraints are used to ensure static stability. Corrugation of the hat stiffeners is also studied through variation of its magnitude and position. A continuation solver has been validated to tackle the highly nonlinear nature of the thermoelastic problem, and formulations for the stability constraints have been derived and imposed to satisfy the static stability of the structure. The study confirms that geometric nonlinearity is an important aspect of sizing optimization and is needed for an accurate modeling of the structural behavior. The results also show that modeling of geometric nonlinearity adds extra complexity to the thermoelastic problem and requires a path-tracking solver. Finally, this work supports that corrugation enhances the stability features of the panel but requires a blending function to reduce stresses at the panel boundaries.

This research aims to investigate the influence of 3D through-thickness stitching on the gas permeability and transverse microcracking of cryogenically cycled carbon/epoxy composites. 3D through-thickness stitching can be used to improve the interlaminar properties of polymer matrix composites (PMCs) and produce lightweight, unitized structures for cryogenic storage tanks. To fully utilize stitched composite structures for these applications, their inherent gas permeability challenges must be understood. Therefore, in this study, the stitched composites' damage evolution and gas permeability was experimentally characterized under a) pure thermal stress, b) thermal and uniaxial mechanical stress, and c) thermal and biaxial mechanical stress. Helium gas permeability was measured for each specimen at room or cryogenic temperatures under a mechanically strained state following the thermo-mechanical cycles. Optical microscopy was used to measure microcrack densities and monitor their evolution through the thickness of the composite specimens. Thin plies, graphene nanoplatelets (GNP) modified resin, and a hybrid barrier layer comprising of both were incorporated in the stitched specimens as barrier layers to reduce their gas permeability. The dependence of gas permeability of stitched composites on the mechanical strain, test temperature, and load history was evaluated and correlated to microcrack density. A significant reduction in permeability and damage evolution (transverse microcracks and delaminations) was obtained for all thermo-mechanical cases using the hybrid barrier layer laminate. Additionally, the permeability was several orders of magnitude lower than the allowable. Overall, the hybrid barrier layer shows tremendous promise as a viable barrier layer for stitched/unstitched composites undergoing thermo-mechanical fatigue involving a cryogenic environment.

CubeSats, specially the 6U standard, is nowadays the tendency where many developers point towards. The upscaling size of the standard and payloads entail the increase of the satellite overall mass. Composite materials have demonstrated the ability to fulfill expectations like reducing structural masses, having been applied to different types of spacecraft, including small satellites. This Thesis is focused on designing, manufacturing, and dynamic testing of a 6U CubeSat made of carbon fiber, fiberglass, and aluminum. The main objective of this study was obtaining a mass reduction of a 6U CubeSat structure, maintaining the stiffness and strength. Considering the thermal effects of the used materials an outgassing test of the used materials was performed and the experimental results are presented. The CubeSat structure was entirely manufactured and tested at Cal Poly Aerospace Engineering Department facilities. A mechanical shock test and random vibration test were performed using a shock table and a shake table respectively. Results of both tests are presented. A correlation between the Experimental data and the Finite Element Model of the satellite was carried out. Finally, a comparison between 6U structure studied and aluminum 6U structures available in the market is presented.

A vibration model was developed for CubeSats inside the Poly-Picosatellite Orbital Deployer (P-POD). CubeSats are fixed in the Z axis of deployers, and therefore resonate with deployer peaks. CubeSats generally start fixed in the X and Y axes, and then settle into an isolated position. CubeSats do not resonate with deployers after settling into an isolated position. Experimental data shows that the P-POD amplifies vibration loads when CubeSats are fixed in the deployer, and vibration loads are reduced when the CubeSats settle into an isolated position. A concept for a future deployer was proposed that isolates CubeSats from the deployer at the rail interface using viscoelastic foam sandwiched in the deployer rails. By creating an isolator frequency far below the deployer resonant frequency, CubeSats loads are not amplified at the deployer’s resonant peak. Feasibility tests show that CubeSat vibration loads can be reduced to 50% of the vibration input in certain cases. Testing also shows that it is much easier to define vibration loads for isolated CubeSats than CubeSats in the current P-POD.

Global awareness and preservation have spurred increasing interest in utilizing environmentally friendly materials for high-performance structural applications. Biocomposites pose an appealing solution to this issue and are characterized by their sustainable lifecycles, biodegradable qualities, light weight, remarkable strength, and exceptional stiffness. Many of these structural qualities are found in applications that exhibit flexural loading conditions, and this study focuses on improving the bending performance of engineered biocomposite structures. The current application of biocomposites is increasing rapidly, so this expanding research explores other natural constituent materials for biocomposite structures under flexural loading. The renewable material investigated in this study was experimentally and numerically validated by optimizing the mechanical characteristics of bamboo fibers in biocomposite structures under flexural loading conditions through various thermal and organic chemical treatment methods. Therefore, bending performance of a biocomposite truss and I-beam are analyzed to demonstrate the benefits of utilizing optimally treated bamboos in their design. To accomplish this goal, the first task consisted of treating bamboos by thermal and chemical means to determine the resulting effects on the compressive and tensile mechanical properties through experimental testing. Results indicated a significant improvement in strength, stiffness, and weight reduction. An extensive analysis determined the optimal treatment method that was utilized for flexural loading conditions. The second task entailed studying the flexural behavior of the optimally treated bamboo in two geometric configurations, a hollow cylinder and veneer strip, to determine the resultant properties for the truss and I-beam structure. The effect of node location on flexural performance was also studied to establish design guidelines for the applied structures. Bending tests indicated that node location affects the strength and stiffness of the hollow cylindrical configuration but has minimal effects on the veneer strip. Observations discovered by this study were employed into the designs of the applied structures that yielded excellent mechanical performance through flexural testing. The final task required conducting a finite element analysis in Abaqus/CAE on the performance of each structural application to validate experimental results. A conclusive analysis revealed good agreement between the numerical method and experimental result.