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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Veröffentlicht in:Polymers Jg. 17; H. 16; S. 2175
Hauptverfasser: Nurgizat, Yerkebulan, Uzbekbayev, Arman, Fedorov, Igor, Bebenin, Andrey, Karypov, Andrey
Format: Journal Article
Sprache:Englisch
Veröffentlicht: Switzerland MDPI AG 08.08.2025
MDPI
Schlagworte:
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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Zusammenfassung: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.
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ISSN:2073-4360
2073-4360
DOI:10.3390/polym17162175