Structural and Material Optimization of a Sensor-Integrated Autonomous Aerial Vehicle Using KMU-3 CFRP

This study addresses the selection and application of composite materials for aerospace systems operating in extreme environmental conditions, with a particular focus on high-altitude pseudo-satellites (HAPS). This research is centered on the development of a 400 kg autonomous aerial vehicle (AAV) c...

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Vydané v:	Polymers Ročník 17; číslo 16; s. 2175
Hlavní autori:	Nurgizat, Yerkebulan, Uzbekbayev, Arman, Fedorov, Igor, Bebenin, Andrey, Karypov, Andrey
Médium:	Journal Article
Jazyk:	English
Vydavateľské údaje:	Switzerland MDPI AG 08.08.2025 MDPI
Predmet:	Aerodynamics Aerospace systems Altitude Aluminum Analysis Carbon fiber reinforced plastics Carbon fiber reinforcement Composite materials Computational fluid dynamics Corrosion resistance Design Drone aircraft Dynamic loads Epoxy resins Fatigue Fatigue life Fatigue testing machines Fiber orientation Finite element method High altitude Interfacial bonding Load Longerons Material properties Materials Optimization Polymers Prototyping Radiation Radiation tolerance Sensors Shear strength Simulation methods Structural integrity Tensile strength Thermal stability Trussed structures Unmanned aerial vehicles Wall thickness carbon fibers truss structures finite element analysis computational aerodynamics aerospace engineering composite materials
ISSN:	2073-4360, 2073-4360
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Abstract	This study addresses the selection and application of composite materials for aerospace systems operating in extreme environmental conditions, with a particular focus on high-altitude pseudo-satellites (HAPS). This research is centered on the development of a 400 kg autonomous aerial vehicle (AAV) capable of sustained operations at altitudes of up to 30 km. KMU-3’s microstructure, comprising high-modulus carbon fibers (5–7 µm diameter) in a 5-211B epoxy matrix, provides a high specific strength (1000–2500 MPa), low density (1.6–1.8 g/cm3), and thermal stability (−60 °C to +600 °C), ensuring structural integrity in stratospheric conditions. The mechanical, thermal, and aerodynamic properties of KMU-3-based truss structures were evaluated using finite element method (FEM) simulations, computational fluid dynamics (CFD) analysis, and experimental prototyping. The results indicate that ultra-thin KMU-3 with a wall thickness of 0.1 mm maintains structural integrity under dynamic loads while minimizing overall mass. A novel thermal bonding technique employing 5-211B epoxy resin was developed, resulting in joints with a shear strength of 40 MPa and fatigue life exceeding 106 cycles at 50% load. The material properties remained stable across the operational temperature range of −60 °C to +80 °C. An optimized fiber orientation (0°/90° for longerons and ±45° for diagonals) enhanced the resistance to axial, shear, and torsional stresses, while the epoxy matrix ensures radiation resistance. Finite element method (FEM) and computational fluid dynamics (CFD) analyses, validated by prototyping, confirm the performance of ultra-thin (0.1 mm) truss structures, achieving a lightweight (45 kg) design. These findings provide a validated, lightweight framework for next-generation HAPS, supporting extended mission durations under harsh stratospheric conditions.
AbstractList	This study addresses the selection and application of composite materials for aerospace systems operating in extreme environmental conditions, with a particular focus on high-altitude pseudo-satellites (HAPS). This research is centered on the development of a 400 kg autonomous aerial vehicle (AAV) capable of sustained operations at altitudes of up to 30 km. KMU-3’s microstructure, comprising high-modulus carbon fibers (5–7 µm diameter) in a 5-211B epoxy matrix, provides a high specific strength (1000–2500 MPa), low density (1.6–1.8 g/cm3), and thermal stability (−60 °C to +600 °C), ensuring structural integrity in stratospheric conditions. The mechanical, thermal, and aerodynamic properties of KMU-3-based truss structures were evaluated using finite element method (FEM) simulations, computational fluid dynamics (CFD) analysis, and experimental prototyping. The results indicate that ultra-thin KMU-3 with a wall thickness of 0.1 mm maintains structural integrity under dynamic loads while minimizing overall mass. A novel thermal bonding technique employing 5-211B epoxy resin was developed, resulting in joints with a shear strength of 40 MPa and fatigue life exceeding 106 cycles at 50% load. The material properties remained stable across the operational temperature range of −60 °C to +80 °C. An optimized fiber orientation (0°/90° for longerons and ±45° for diagonals) enhanced the resistance to axial, shear, and torsional stresses, while the epoxy matrix ensures radiation resistance. Finite element method (FEM) and computational fluid dynamics (CFD) analyses, validated by prototyping, confirm the performance of ultra-thin (0.1 mm) truss structures, achieving a lightweight (45 kg) design. These findings provide a validated, lightweight framework for next-generation HAPS, supporting extended mission durations under harsh stratospheric conditions. This study addresses the selection and application of composite materials for aerospace systems operating in extreme environmental conditions, with a particular focus on high-altitude pseudo-satellites (HAPS). This research is centered on the development of a 400 kg autonomous aerial vehicle (AAV) capable of sustained operations at altitudes of up to 30 km. KMU-3’s microstructure, comprising high-modulus carbon fibers (5–7 µm diameter) in a 5-211B epoxy matrix, provides a high specific strength (1000–2500 MPa), low density (1.6–1.8 g/cm[sup.3]), and thermal stability (−60 °C to +600 °C), ensuring structural integrity in stratospheric conditions. The mechanical, thermal, and aerodynamic properties of KMU-3-based truss structures were evaluated using finite element method (FEM) simulations, computational fluid dynamics (CFD) analysis, and experimental prototyping. The results indicate that ultra-thin KMU-3 with a wall thickness of 0.1 mm maintains structural integrity under dynamic loads while minimizing overall mass. A novel thermal bonding technique employing 5-211B epoxy resin was developed, resulting in joints with a shear strength of 40 MPa and fatigue life exceeding 10[sup.6] cycles at 50% load. The material properties remained stable across the operational temperature range of −60 °C to +80 °C. An optimized fiber orientation (0°/90° for longerons and ±45° for diagonals) enhanced the resistance to axial, shear, and torsional stresses, while the epoxy matrix ensures radiation resistance. Finite element method (FEM) and computational fluid dynamics (CFD) analyses, validated by prototyping, confirm the performance of ultra-thin (0.1 mm) truss structures, achieving a lightweight (45 kg) design. These findings provide a validated, lightweight framework for next-generation HAPS, supporting extended mission durations under harsh stratospheric conditions. This study addresses the selection and application of composite materials for aerospace systems operating in extreme environmental conditions, with a particular focus on high-altitude pseudo-satellites (HAPS). This research is centered on the development of a 400 kg autonomous aerial vehicle (AAV) capable of sustained operations at altitudes of up to 30 km. KMU-3's microstructure, comprising high-modulus carbon fibers (5-7 µm diameter) in a 5-211B epoxy matrix, provides a high specific strength (1000-2500 MPa), low density (1.6-1.8 g/cm3), and thermal stability (-60 °C to +600 °C), ensuring structural integrity in stratospheric conditions. The mechanical, thermal, and aerodynamic properties of KMU-3-based truss structures were evaluated using finite element method (FEM) simulations, computational fluid dynamics (CFD) analysis, and experimental prototyping. The results indicate that ultra-thin KMU-3 with a wall thickness of 0.1 mm maintains structural integrity under dynamic loads while minimizing overall mass. A novel thermal bonding technique employing 5-211B epoxy resin was developed, resulting in joints with a shear strength of 40 MPa and fatigue life exceeding 106 cycles at 50% load. The material properties remained stable across the operational temperature range of -60 °C to +80 °C. An optimized fiber orientation (0°/90° for longerons and ±45° for diagonals) enhanced the resistance to axial, shear, and torsional stresses, while the epoxy matrix ensures radiation resistance. Finite element method (FEM) and computational fluid dynamics (CFD) analyses, validated by prototyping, confirm the performance of ultra-thin (0.1 mm) truss structures, achieving a lightweight (45 kg) design. These findings provide a validated, lightweight framework for next-generation HAPS, supporting extended mission durations under harsh stratospheric conditions.This study addresses the selection and application of composite materials for aerospace systems operating in extreme environmental conditions, with a particular focus on high-altitude pseudo-satellites (HAPS). This research is centered on the development of a 400 kg autonomous aerial vehicle (AAV) capable of sustained operations at altitudes of up to 30 km. KMU-3's microstructure, comprising high-modulus carbon fibers (5-7 µm diameter) in a 5-211B epoxy matrix, provides a high specific strength (1000-2500 MPa), low density (1.6-1.8 g/cm3), and thermal stability (-60 °C to +600 °C), ensuring structural integrity in stratospheric conditions. The mechanical, thermal, and aerodynamic properties of KMU-3-based truss structures were evaluated using finite element method (FEM) simulations, computational fluid dynamics (CFD) analysis, and experimental prototyping. The results indicate that ultra-thin KMU-3 with a wall thickness of 0.1 mm maintains structural integrity under dynamic loads while minimizing overall mass. A novel thermal bonding technique employing 5-211B epoxy resin was developed, resulting in joints with a shear strength of 40 MPa and fatigue life exceeding 106 cycles at 50% load. The material properties remained stable across the operational temperature range of -60 °C to +80 °C. An optimized fiber orientation (0°/90° for longerons and ±45° for diagonals) enhanced the resistance to axial, shear, and torsional stresses, while the epoxy matrix ensures radiation resistance. Finite element method (FEM) and computational fluid dynamics (CFD) analyses, validated by prototyping, confirm the performance of ultra-thin (0.1 mm) truss structures, achieving a lightweight (45 kg) design. These findings provide a validated, lightweight framework for next-generation HAPS, supporting extended mission durations under harsh stratospheric conditions. This study addresses the selection and application of composite materials for aerospace systems operating in extreme environmental conditions, with a particular focus on high-altitude pseudo-satellites (HAPS). This research is centered on the development of a 400 kg autonomous aerial vehicle (AAV) capable of sustained operations at altitudes of up to 30 km. KMU-3's microstructure, comprising high-modulus carbon fibers (5-7 µm diameter) in a 5-211B epoxy matrix, provides a high specific strength (1000-2500 MPa), low density (1.6-1.8 g/cm ), and thermal stability (-60 °C to +600 °C), ensuring structural integrity in stratospheric conditions. The mechanical, thermal, and aerodynamic properties of KMU-3-based truss structures were evaluated using finite element method (FEM) simulations, computational fluid dynamics (CFD) analysis, and experimental prototyping. The results indicate that ultra-thin KMU-3 with a wall thickness of 0.1 mm maintains structural integrity under dynamic loads while minimizing overall mass. A novel thermal bonding technique employing 5-211B epoxy resin was developed, resulting in joints with a shear strength of 40 MPa and fatigue life exceeding 10 cycles at 50% load. The material properties remained stable across the operational temperature range of -60 °C to +80 °C. An optimized fiber orientation (0°/90° for longerons and ±45° for diagonals) enhanced the resistance to axial, shear, and torsional stresses, while the epoxy matrix ensures radiation resistance. Finite element method (FEM) and computational fluid dynamics (CFD) analyses, validated by prototyping, confirm the performance of ultra-thin (0.1 mm) truss structures, achieving a lightweight (45 kg) design. These findings provide a validated, lightweight framework for next-generation HAPS, supporting extended mission durations under harsh stratospheric conditions.
Audience	Academic
Author	Fedorov, Igor Uzbekbayev, Arman Karypov, Andrey Nurgizat, Yerkebulan Bebenin, Andrey
AuthorAffiliation	1 Research & Development Center “Kazakhstan Engineering” LLP, Astana 010000, Kazakhstan figor.ole@gmail.com (I.F.); abebenin_77@mail.ru (A.B.) 2 Institute of Telecommunications and Space Engineering, Almaty University of Power Engineering and Telecommunications Named Gumarbek Daukeev, Almaty 050062, Kazakhstan
AuthorAffiliation_xml	– name: 2 Institute of Telecommunications and Space Engineering, Almaty University of Power Engineering and Telecommunications Named Gumarbek Daukeev, Almaty 050062, Kazakhstan – name: 1 Research & Development Center “Kazakhstan Engineering” LLP, Astana 010000, Kazakhstan figor.ole@gmail.com (I.F.); abebenin_77@mail.ru (A.B.)
Author_xml	– sequence: 1 givenname: Yerkebulan orcidid: 0000-0002-9712-5592 surname: Nurgizat fullname: Nurgizat, Yerkebulan – sequence: 2 givenname: Arman orcidid: 0009-0003-6728-0748 surname: Uzbekbayev fullname: Uzbekbayev, Arman – sequence: 3 givenname: Igor orcidid: 0000-0002-8158-5092 surname: Fedorov fullname: Fedorov, Igor – sequence: 4 givenname: Andrey orcidid: 0000-0002-3603-6860 surname: Bebenin fullname: Bebenin, Andrey – sequence: 5 givenname: Andrey surname: Karypov fullname: Karypov, Andrey
BackLink	https://www.ncbi.nlm.nih.gov/pubmed/40871122$$D View this record in MEDLINE/PubMed
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Cites_doi	10.3390/ma2042369 10.2478/adms-2019-0023 10.1016/j.jmrt.2022.09.085 10.1557/mrs.2015.278 10.1016/j.compositesb.2018.10.101 10.1016/j.trpro.2025.03.030 10.1080/09243046.2024.2369370 10.1016/j.matpr.2021.06.276 10.1007/s42114-024-00971-x 10.1533/9780857092229 10.1177/13694332231194686 10.1007/978-0-387-74365-3 10.3390/coatings14111456 10.1109/IROS47612.2022.9981191 10.3390/polym13213721 10.12968/S1478-2774(22)50461-5 10.1016/j.jallcom.2015.12.084 10.1016/j.wear.2020.203280 10.59287/iccar.736 10.1109/ICECS53924.2021.9665513 10.1016/j.matdes.2020.109140 10.1016/B978-0-08-102131-6.00001-3 10.1021/acs.iecr.8b04903 10.3390/polym16131912 10.1177/0021998312472217 10.1023/A:1004780301489 10.1109/AERO.2018.8396531 10.1002/adem.202402000 10.1016/j.jnucmat.2014.06.003 10.1007/s42823-022-00358-2 10.3390/polym15214333 10.3390/polym13152474 10.1016/j.ast.2018.06.020 10.1109/CIEES62939.2024.10811378 10.1016/j.jmapro.2020.05.042 10.1007/978-3-030-39062-4_20
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Keywords	carbon fibers truss structures finite element analysis computational aerodynamics aerospace engineering composite materials
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SubjectTerms	Aerodynamics Aerospace systems Altitude Aluminum Analysis Carbon fiber reinforced plastics Carbon fiber reinforcement Composite materials Computational fluid dynamics Corrosion resistance Design Drone aircraft Dynamic loads Epoxy resins Fatigue Fatigue life Fatigue testing machines Fiber orientation Finite element method High altitude Interfacial bonding Load Longerons Material properties Materials Optimization Polymers Prototyping Radiation Radiation tolerance Sensors Shear strength Simulation methods Structural integrity Tensile strength Thermal stability Trussed structures Unmanned aerial vehicles Wall thickness
Title	Structural and Material Optimization of a Sensor-Integrated Autonomous Aerial Vehicle Using KMU-3 CFRP
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