CEN/TR 17603-32-06:2022

Space engineering - Structural materials handbook - Part 6: Fracture and material modelling, case studies and design and integrity control and inspection

The structural materials handbook, SMH, combines materials and design information on established polymer matrix composites with provisional information on the emerging groups of newer advanced materials and their composites. Design aspects are described, along with factors associated with joining and manufacturing. Where possible, these are illustrated by examples or case studies.
The Structural materials handbook contains 8 Parts.
A glossary of terms, definitions and abbreviated terms for these handbooks is contained in Part 8.
The parts are as follows:
Part 1 Overview and material properties and applications                    Clauses 1 ‐ 9
Part 2 Design calculation methods and general design aspects    Clauses 10 ‐ 22
Part 3 Load transfer and design of joints and design of structures    Clauses 23 ‐ 32
Part 4 Integrity control, verification guidelines and manufacturing    Clauses 33 ‐ 45
Part 5 New advanced materials, advanced metallic materials, general design aspects and load transfer and design of joints    Clauses 46 ‐ 63
Part 6 Fracture and material modelling, case studies and design and integrity control and inspection    Clauses 64 ‐ 81
Part 7 Thermal and environmental integrity, manufacturing aspects, in‐orbit and health monitoring, soft materials, hybrid materials and nanotechnoligies   Clauses 82 ‐ 107
Part 8 Glossary   
NOTE: The 8 parts will be numbered TR17603-32-01 to TR 17603-32-08

Raumfahrttechnik - Handbuch zu Strukturmaterialien - Teil 6: Modellierung von Brüchen und Materialien - Fallstudien, Design, Integritätskontrolle, Inspektionen

Ingénierie spatiale - Manuel des matériaux structuraux - Partie 6 : Modélisation des matériaux et de leur rupture, études de cas, inspections et contrôle de l’intégrité

Vesoljska tehnika - Priročnik o strukturnih materialih - 6. del: Modeliranje zlomov in materialov, študije primerov ter načrtovanje in nadzor integritete in inšpekcijski pregled

Priročnik o strukturnih materialih, SMH, združuje informacije o materialih in oblikovanju uveljavljenih polimernih matričnih kompozitov z začasnimi informacijami o nastajajočih skupinah novejših naprednih materialov in njihovih kompozitov. Opisani so vidiki oblikovanja, skupaj z dejavniki združevanja in proizvodnje. Kjer je mogoče, so podani primeri ali študije primerov.
Priročnik o strukturnih materialih vsebuje 8 delov.
Slovar izrazov, opredelitve in okrajšave izrazov za te priročnike so v 8. delu.
Deli so:
1. del: Pregled in lastnosti materialov ter aplikacije                    Točke 1–9
2. del: Metode za izračun zasnove in splošni vidiki zasnove    Točke 10–22
3. del: Prenos obremenitve ter projektiranje spojev in konstrukcij    Točke 23–32
4. del: Nadzor integritete, smernice za preverjanje in proizvodnja    Točke 33–45
5. del: Novi napredni materiali, napredni kovinski materiali, splošni konstrukcijski vidiki ter prenos obremenitve in oblikovanje sklepov    Točke 46–63
6. del: Modeliranje zlomov in materialov, študije primerov, načrtovanje in nadzor integritete ter inšpekcijski pregled    Točke 64–81
7. del: Toplotna in okoljska celovitost, proizvodni vidiki, spremljanje stanja materialov v orbiti, mehki materiali, hibridni materiali in nanotehnologije   Točke 82–107
8. del: Slovar   
OPOMBA: Teh 8 delov je označenih s številkami od TR17603-32-01 do TR 17603-32-08.

General Information

• Status: Published
• Publication Date: 11-Jan-2022
• ICS: 49.140 - Space systems and operations
• Technical Committee: CEN/CLC/TC 5 - Space
• Drafting Committee: CEN/CLC/TC 5/WG 6 - Upstream standards
• Current Stage: 6060 - Definitive text made available (DAV) - Publishing
• Start Date: 12-Jan-2022
• Due Date: 29-Dec-2022
• Completion Date: 12-Jan-2022
• Mandate: M/496 - Mandate addressed to CEN, CENELEC and ETSI to develop standardisation regarding space industry (Phase 3 of the process)
• Ref Project: SIST-TP CEN/TR 17603-32-06:2022 - Space engineering - Structural materials handbook - Part 6: Fracture and material modelling, case studies and design and integrity control and inspection

Overview

CEN/TR 17603-32-06:2022 - Space engineering: Structural materials handbook, Part 6 - provides guidance on fracture and material modelling, illustrated case studies, and recommendations for design, integrity control and inspection of advanced structural materials used in spacecraft. Part 6 covers Clauses 64–81 and is one installment of an 8‑part Structural Materials Handbook (TR17603-32-01 to TR17603-32-08) that together address material properties, design methods, joints, manufacturing, environmental performance and a glossary (Part 8).

Key topics and technical requirements

Part 6 focuses on the behaviour and modelling of advanced structural materials and practical integrity processes. Main technical topics include:

• Fracture behaviour and failure modes for particulate and fibre‑reinforced metals, ceramic matrix composites (CMC) and metal matrix composites (MMC).
• Damage mechanisms: microcracking, porosity effects, fibre/matrix interface failure, void nucleation and growth, and self‑similar damage growth.
• Fracture mechanics parameters and test methods: toughness measures, specimen considerations, R‑curves and defining conservative design values.
• Material modelling approaches for polymer composites, MMCs and CMCs - guidance on model use and limitations for design and life prediction.
• Thermo‑mechanical fatigue (TMF), creep and residual stresses, including effects of coefficient of thermal expansion (CTE) mismatch and thermal history.
• High‑temperature structures and thermo‑structural design: materials selection, heat management and life expectancy considerations for re‑entry, propulsion and aerospace thermal environments.
• Integrity control, verification and inspection: non‑destructive inspection strategies, verification guidelines and links between manufacturing defects and in‑service performance.
• Case studies illustrating application of modelling, testing and inspection to real design problems.

Practical applications and target users

This technical report is intended for professionals involved in spacecraft structure life‑cycle engineering:

• Aerospace materials and structural engineers applying fracture mechanics and predictive models.
• Design authorities and certification bodies needing conservative design values and verification approaches.
• Manufacturers and NDT/inspection teams planning quality control and maintenance inspections.
• Testing laboratories and researchers developing models or validating fracture and TMF behaviour for advanced composites and high‑temperature components.

Typical applications include spacecraft primary and secondary structures, high‑temperature components (thermal protection, propulsion interfaces), composite joints and lifetime assessments.

Related standards and linkage

Part 6 complements the rest of the Structural Materials Handbook series:

• Part 1: overview and material properties
• Part 2–5: design methods, joints, manufacturing and advanced materials
• Part 7: environmental, in‑orbit monitoring and novel materials
• Part 8: glossary and definitions

Relevant search keywords: CEN/TR 17603-32-06:2022, SIST-TP CEN/TR 17603-32-06, structural materials handbook Part 6, fracture and material modelling, integrity control, inspection, space engineering, composites, CMC, MMC, thermo‑mechanial fatigue.

Standards Content (Sample)

SLOVENSKI STANDARD
01-marec-2022
Vesoljska tehnika - Priročnik o strukturnih materialih - 6. del: Modeliranje zlomov
in materialov, študije primerov ter načrtovanje in nadzor integritete in inšpekcijski
pregled
Space engineering - Structural materials handbook - Part 6: Fracture and material
modelling, case studies and design and integrity control and inspection
Raumfahrttechnik - Handbuch zu Strukturmaterialien - Teil 6: Modellierung von Brüchen
und Materialien - Fallstudien, Design, Integritätskontrolle, Inspektionen
Ingénierie spatiale - Manuel des matériaux structuraux - Partie 6 : Modélisation des
matériaux et de leur rupture, études de cas, inspections et contrôle de l’intégrité
Ta slovenski standard je istoveten z: CEN/TR 17603-32-06:2022
ICS:
49.140 Vesoljski sistemi in operacije Space systems and
operations
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

TECHNICAL REPORT CEN/TR 17603-32-06

RAPPORT TECHNIQUE
TECHNISCHER BERICHT
January 2022
ICS 49.140
English version
Space engineering - Structural materials handbook - Part
6: Fracture and material modelling, case studies and
design and integrity control and inspection
Ingénierie spatiale - Manuel des matériaux structuraux Raumfahrttechnik - Handbuch zu Strukturmaterialien -
- Partie 6 : Modélisation des matériaux et de leur Teil 6: Modellierung von Brüchen und Materialien -
rupture, études de cas, inspections et contrôle de Fallstudien, Design, Integritätskontrolle, Inspektionen
l'intégrité
This Technical Report was approved by CEN on 29 November 2021. It has been drawn up by the Technical Committee
CEN/CLC/JTC 5.
CEN and CENELEC members are the national standards bodies and national electrotechnical committees of Austria, Belgium,
Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy,
Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Republic of North Macedonia, Romania, Serbia,
Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom.

CEN-CENELEC Management Centre:
Rue de la Science 23, B-1040 Brussels
© 2022 CEN/CENELEC All rights of exploitation in any form and by any means Ref. No. CEN/TR 17603-32-06:2022 E
reserved worldwide for CEN national Members and for
CENELEC Members.
Table of contents
European Foreword . 25
Introduction . 26
64 Behaviour of advanced composites . 27
64.1 Introduction . 27
64.2 Summary of material behaviour . 28
64.2.1 Metal matrix composites. 28
64.2.2 Inorganic ceramic matrix composites . 29
64.3 Significant behavioural characteristics . 29
64.3.1 General . 29
64.3.2 Modulus mismatch . 29
64.3.3 Matrix-to-reinforcement interface . 30
64.3.4 In-situ fibre strength . 31
64.3.5 CTE mismatch . 31
64.3.6 Thermal history and residual stresses . 32
64.3.7 Multiple cracking . 32
64.3.8 Thermo-mechanical fatigue (TMF) . 32
64.4 Basic fracture characteristics . 32
64.4.1 General . 32
64.4.2 Particulate reinforced MMC . 33
64.4.3 Fibre reinforced MMC . 34
64.4.4 Fibre reinforced CMC . 35
64.4.5 Defining design values . 35
64.5 Failure criteria for CMC . 36
64.5.1 Introduction . 36
64.5.2 Design aspects . 36
64.6 References . 39
64.6.1 General . 39
65 Particulate reinforced metals . 40
65.1 Introduction . 40
65.1.1 Materials . 40
65.1.2 Composites . 40
65.1.3 Particulate reinforcement . 41
65.2 Damage mechanisms . 42
65.2.1 Unnotched specimen . 42
65.2.2 Notched specimen . 43
65.2.3 Influence of particles . 43
65.2.4 Composite performance . 44
65.3 Failure modes and fracture behaviour. 44
65.3.1 Matrix effects . 44
65.3.2 Failure mode studies . 45
65.3.3 Particulate shape and aspect ratio . 45
65.3.4 Particulate fracture . 47
65.3.5 Void nucleation and growth . 47
65.3.6 Fracture toughness . 48
65.4 Thermo-mechanical fatigue (TMF) and creep . 49
65.4.1 Residual stresses . 49
65.4.2 Temperature . 49
65.4.3 Superplasticity . 49
65.4.4 Applications. 49
65.5 References . 49
65.5.1 General . 49
66 Fibre reinforced metals . 52
66.1 Introduction . 52
66.1.1 Materials . 52
66.2 Damage mechanisms . 53
66.2.1 General . 53
66.2.2 Effect of lay-up . 53
66.3 Failure modes . 54
66.3.1 General . 54
66.3.2 Matrix dominated failure . 54
66.3.3 Fibre-dominated damage . 54
66.3.4 Self-similar damage growth . 54
66.3.5 Fibre-matrix interfacial failures . 55
66.4 Thermo-mechanical and creep response . 55
66.4.1 General . 55
66.4.2 Application . 56
66.5 References . 56
66.5.1 General . 56
67 Inorganic ceramic matrix composites . 58
67.1 Introduction . 58
67.1.1 General . 58
67.1.2 Matrix . 59
67.1.3 Interface . 59
67.1.4 Fibres . 59
67.2 Damage mechanisms . 59
67.2.1 Material effects . 59
67.2.2 Microcracking . 59
67.2.3 Porosity . 61
67.2.4 Manufacturing and in-service effects . 62
67.2.5 Crack propagation . 62
67.3 Fracture behaviour . 63
67.3.1 Toughness parameters . 63
67.3.2 Test specimens . 68
67.3.3 'R' curves . 68
67.4 References . 70
68 Modelling advanced materials . 71
68.1 Introduction . 71
68.1.1 Polymer composites . 71
68.1.2 Metal matrix composites. 71
68.1.3 Inorganic ceramic matrix materials . 71
68.1.4 Summary of models . 72
68.2 Particulate reinforced metals . 73
68.2.1 Use of models . 73
68.3 Fibre reinforced metals . 73
68.3.1 Use of models . 73
68.4 Inorganic ceramic matrix composites . 74
68.4.1 Use of models . 74
68.5 References . 77
68.5.1 General . 77
69 High-temperature structures . 79
69.1 Introduction . 79
69.1.1 Applications. 79
69.1.2 Performance . 79
69.1.3 High-temperature materials . 79
69.1.4 Development approach . 80
69.2 Functions . 80
69.2.1 General . 80
69.2.2 Aerodynamic heating . 81
69.2.3 Propulsive power generation . 82
69.3 Operating environments. 83
69.4 Integration . 83
69.5 Heat management . 84
69.6 Life expectancy . 84
69.6.1 General . 84
69.6.2 Launcher . 84
69.6.3 Spaceplane . 84
69.6.4 Satellite . 85
69.7 Materials selection . 85
69.8 Manufacturing . 85
69.9 Applications . 86
69.9.1 Future reusable launch vehicles . 86
69.9.2 Flight-vehicle dependent . 87
69.9.3 Non-vehicle dependent . 91
69.9.4 Summary of European capabilities . 94
69.10 References . 95
69.10.1 General . 95
70 Thermo-structural designs . 97
70.1 Introduction . 97
70.1.1 General . 97
70.1.2 Single mission . 97
70.1.3 Reusable vehicles . 98
70.2 Spaceplanes . 98
70.2.1 Hermes . 98
70.2.2 HOPE. 98
70.2.3 Single- and two-stage-to-orbit . 99
70.3 Hermes . 99
70.4 HOPE . 100
70.5 HOTOL . 104
70.6 SÄNGER . 106
70.7 National aerospace plane (NASP) . 107
70.8 Demonstrator panels . 109
70.8.1 General . 109
70.8.2 NASP . 109
70.9 Nose cones. 109
70.9.1 General . 109
70.9.2 Shuttle orbiter . 109
70.9.3 Hermes . 111
70.9.4 HOPE. 113
70.9.5 NASP . 113
70.9.6 HOTOL . 113
70.9.7 SÄNGER . 114
70.9.8 X-38 . 114
70.10 Wing leading edges (WLE) . 115
70.10.1 General . 115
70.10.2 Shuttle orbiter . 115
70.10.3 Buran . 115
70.10.4 Hermes . 117
70.10.5 HOPE. 118
70.10.6 Others . 118
70.11 Box sections . 119
70.11.1 NASP . 119
70.11.2 Hermes . 119
70.12 Cryogenic tanks . 120
70.13 Heat shield designs . 120
70.14 Air inlet-intakes . 123
70.15 Earth re-entry capsules . 124
70.16 Manned re-entry vehicles . 126
70.17 Deep space missions . 127
70.17.1 CNSR ROSETTA: Earth return capsule . 127
70.18 Mars landers . 128
70.18.1 General . 128
70.18.2 NASA Pathfinder/MESUR network landers . 128
70.18.3 MARSNET . 129
70.19 Cassini-Huygens . 129
70.19.1 General . 129
70.19.2 C-C aerobrake (heat shield) . 129
70.19.3 Nose cap front shield with AQ60 . 130
70.20 Planetary probes . 130
70.21 Aerobrake designs . 130
70.21.1 General . 130
70.21.2 NASA/ESA Cassini-Huygens mission . 130
70.22 PRORA: USV – unmanned space vehicle . 132
70.22.1 Background . 132
70.22.2 USV programme . 133
70.22.3 USV systems and flight test beds . 134
70.22.4 External configuration of FTB_1 and FTB_2. 135
70.22.5 External configuration of FTB_3 . 136
70.23 X-38 Body flap . 138
70.23.1 Background . 138
70.23.2 Body flaps . 140
70.23.3 Mechanical fasteners . 141
70.23.4 CMC to metal attachment . 142
70.23.5 Ceramic bearings . 143
70.23.6 Ceramic seals . 144
70.24 X-38 Nose cap . 145
70.24.1 Background . 145
70.24.2 Concept . 146
70.24.3 Thermal profiles . 146
70.24.4 Flexible insulation design . 147
70.24.5 Integration and qualification testing . 148
70.24.6 Summary . 150
70.25 Aerobrake: Deployable CMC decelerator . 151
70.25.1 Background . 151
70.25.2 Mars ISRU mission ‘in-situ resource unit’ . 152
70.25.3 Mars ISRU mission – Concept . 152
70.25.4 Mars ISRU mission – Environmental aspects . 155
70.26 References . 155
70.26.1 General . 155
71 Thermal protection systems . 160
71.1 Introduction . 160
71.1.1 Application . 160
71.1.2 European development programmes . 161
71.1.3 Concepts . 162
71.1.4 Non load-carrying TPS . 164
71.1.5 Load-carrying TPS . 164
71.1.6 Reusable structures . 165
71.2 Cooling modes . 166
71.2.1 General . 166
71.2.2 Passive TPS . 166
71.2.3 Active cooling concepts . 167
71.3 Early re-entry capsules . 168
71.4 Ablative designs . 170
71.4.1 General . 170
71.4.2 Programmes . 171
71.4.3 Materials . 171
71.5 Space Shuttle orbiter . 174
71.5.1 General . 174
71.5.2 Materials and configurations . 175
71.5.3 In-Service TPS Performance . 179
71.6 Buran . 179
71.6.1 General . 179
71.6.2 Materials and configurations . 181
71.7 Advanced carbon reinforced composites . 181
71.7.1 Carbon-carbon composites . 181
71.7.2 ACC - Advanced carbon-carbon . 181
71.7.3 Aerospatiale - Aerotiss® 2.5D . 182
71.7.4 Carbon-silicon carbide composites . 183
71.8 Durable metallic TPS . 185
71.8.1 General . 185
71.8.2 Multiwall TPS . 186
71.8.3 Developments . 187
71.9 Titanium-based composites . 189
71.9.1 NASP . 189
71.10 Internal multiscreen insulation (IMI) . 189
71.10.1 Concept . 189
71.10.2 Development and characterisation . 192
71.10.3 Potential applications . 194
71.11 Flexible external insulation (FEI) . 195
71.11.1 General . 195
71.11.2 Design concept . 195
71.11.3 Key features . 195
71.11.4 Product range . 196
71.11.5 Hermes . 197
71.11.6 MSTP programme . 198
71.11.7 ARD programme . 201
71.11.8 Future reusable vehicles . 201
71.11.9 Verified performance . 202
71.11.10 IFI - Internal flexible insulation development . 203
71.12 CMC shingles . 205
71.12.1 Hermes design concept . 205
71.12.2 TETRA/X-38 programme panels . 207
71.12.3 SPFI - Surface protected flexible insulation . 209
71.13 Heat pipes . 220
71.13.1 General . 220
71.13.2 Shuttle-type heat pipe cooled wing leading edge . 222
71.13.3 Sodium-Hastelloy-X heat pipe for advanced space transportation
system . 222
71.13.4 Refractory metal-CMC heat pipe for NASP . 223
71.14 Cooled panels . 224
71.14.1 General . 224
71.14.2 Demonstrator units . 225
71.14.3 Active cooling on NASP . 226
71.15 Beryllium TPS . 228
71.15.1 General . 228
71.15.2 Cassini-Huygens heat shield: Phase A configuration . 228
71.16 Aerobrakes . 230
71.17 Heat shields . 230
71.17.1 General . 230
71.17.2 SEPCORE® TPS concept. 230
71.17.3 Ceramic heatshield assembly (CHA) . 231
71.17.4 MIRKA - Micro re-entry capsule . 239
71.17.5 ALSCAP - Alternative low-cost, short-manufacturing-cycle ceramic
assessment programme . 241
71.18 Aeroshell . 244
71.18.1 General . 244
71.18.2 Semi-integrated aeroshell TPS (S.I.A.T) . 244
71.18.3 Demonstrator aeroshell design. 244
71.19 Cryogenic tanks . 250
71.19.1 General . 250
71.19.2 European programmes . 251
71.19.3 Concepts: TPS panel array . 252
71.19.4 Concepts: LH tank cryogenic insulation . 252
71.20 TPS mass budgets . 254
71.20.1 Allocation . 254
71.20.2 Examples . 255
71.21 TPS verification . 255
71.22 Polymer foam cryogenic insulation . 255
71.22.1 General . 255
71.22.2 Polymer foam characteristics . 255
71.22.3 Properties . 256
71.22.4 Materials . 257
71.22.5 Ranking of polymer foam cryogenic insulation . 259
71.22.6 Further work . 261
71.23 High temperature insulation (HTI) . 261
71.23.1 Background . 261
71.23.2 Development factors . 262
71.23.3 Development apoproach . 263
71.23.4 Materials . 266
71.23.5 Testing . 266
71.23.6 Summary . 270
71.24 References . 270
72 SPF/DB titanium designs . 280
72.1 Introduction . 280
72.1.1 General . 280
72.1.2 Aircraft components . 280
72.1.3 Space applications . 280
72.2 Basic SPF/DB process . 281
72.2.1 Superplastic forming . 281
72.2.2 Diffusion bonding . 281
72.3 Process attributes . 283
72.4 Titanium alloys . 284
72.5 Aluminium alloys . 285
72.6 Access doors and ducting . 286
72.6.1 General . 286
72.6.2 Slat track/jack cans . 286
72.6.3 Underwing access doors . 287
72.6.4 Other SPF/DB components . 288
72.7 Spars and stiffened panels . 288
72.8 Struts and cylinders . 289
72.9 Leading edges and lateral fins . 289
72.10 Firewalls . 290
72.11 Pressure vessels . 290
72.12 Cost aspects . 291
72.13 European facilities . 291
72.14 References . 291
72.14.1 General . 291
73 Propulsion technologies . 293
73.1 Introduction . 293
73.2 Propulsion unit requirements . 293
73.2.1 Launcher engines . 293
73.2.2 Shuttle engines . 293
73.2.3 Spaceplane engines . 293
73.2.4 Thrusters . 294
73.2.5 Nozzles . 294
73.3 Fuels. 294
73.3.1 General . 294
73.3.2 Solid propellants . 294
73.3.3 LH/LOX . 294
73.3.4 Monopropellants . 295
73.3.5 Bipropella
...