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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Vydáno v:Polymers Ročník 17; číslo 16; s. 2175
Hlavní autoři: Nurgizat, Yerkebulan, Uzbekbayev, Arman, Fedorov, Igor, Bebenin, Andrey, Karypov, Andrey
Médium: Journal Article
Jazyk:angličtina
Vydáno: Switzerland MDPI AG 08.08.2025
MDPI
Témata:
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
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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
URI https://www.ncbi.nlm.nih.gov/pubmed/40871122
https://www.proquest.com/docview/3244051023
https://www.proquest.com/docview/3246301331
https://pubmed.ncbi.nlm.nih.gov/PMC12389304
Volume 17
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