SIST-TP CEN/TR 17603-32-04:2022

Space engineering - Structural materials handbook - Part 4: Integrity control, verification guidelines and manufacturing

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 der Strukturwerkstoffe - Teil 4: Integritätskontrolle, Verifizierungsrichtlinien und Herstellung

Ingénierie spatiale - Manuel des matériaux structuraux - Partie 4 : Contrôle de l’intégrité, directives de vérification et fabrication

Vesoljska tehnika - Priročnik o strukturnih materialih - 4. del: Nadzor integritete, smernice za preverjanje in proizvodnja

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
• Public Enquiry End Date: 20-Oct-2021
• Publication Date: 09-Feb-2022
• ICS: 49.140 - Space systems and operations
• Technical Committee: I13 - Imaginarni 13
• Current Stage: 6060 - National Implementation/Publication (Adopted Project)
• Start Date: 31-Jan-2022
• Due Date: 07-Apr-2022
• Completion Date: 10-Feb-2022
• Mandate: M/496 - Mandate addressed to CEN, CENELEC and ETSI to develop standardisation regarding space industry (Phase 3 of the process)
• Ref Project: CEN/TR 17603-32-04:2022 - Space engineering - Structural materials handbook - Part 4: Integrity control, verification guidelines and manufacturing

Overview

SIST-TP CEN/TR 17603-32-04:2022 - Space engineering - Structural materials handbook - Part 4: Integrity control, verification guidelines and manufacturing is a technical report focused on ensuring the structural integrity of space hardware built from polymer matrix composites and other structural materials. Part 4 (Clauses 33–45) of the eight-part Structural Materials Handbook (SMH) provides practical guidance on damage tolerance, inspection methods, manufacturing controls and verification practices relevant to space systems.

Key topics and technical coverage

The report combines design-oriented guidance with detailed non-destructive testing (NDT) and verification techniques. Major topics include:

• Damage tolerance and fracture control
  • Definitions of damage events, tolerance criteria, residual strength, safe-life and fail-safe considerations.
  • Use of fracture mechanics and test/analysis strategies for composites.
• Defect characterisation and standardisation
  • Types of defects in composite laminates and their effects on static and dynamic loads.
• Inspection, quality assurance and verification
  • Quality assurance during fabrication, inspection planning, maintenance and repair guidelines.
  • Definition and documentation of inspection procedures for thin and thick laminates.
• Non‑destructive testing (NDT) techniques
  • Wide survey of NDT methods: visual inspection, dye-penetrant, ultrasonic (including guided waves and laser ultrasonics), acoustic emission, holography, shearography, thermography, X‑ray radiography, computed tomography (CT), eddy current, microwave methods, neutron/gamma radiography and specialized NDT for adhesive bond defects.
  • Advances in large-area scanning, data processing, imaging and smart condition-monitoring technologies.
• Manufacturing aspects
  • Integration of inspection and verification into manufacturing flows, proof testing and mitigation strategies (e.g., tougher laminates, lay-up optimisation).
• References and normative guidance
  • Cross‑references to ECSS and relevant MIL standards where applicable.

Practical applications & who should use it

This part of the SMH is designed for professionals involved in the lifecycle of spacecraft structures:

• Aerospace structural and materials engineers designing composite components
• Manufacturing engineers and process planners implementing QA and verification
• NDT specialists and inspection technicians selecting and applying methods
• System integrators, certification authorities and program managers responsible for verification and flight acceptance
• Repair and maintenance teams addressing in‑flight or ground handling damage

Use cases include inspection planning for flight hardware, selecting appropriate NDT methods for composite assemblies, defining verification campaigns, implementing damage-tolerant designs, and establishing manufacturing quality control.

Related standards and context

Part 4 is one of eight SMH parts (TR17603-32-01 to TR17603-32-08). The full handbook complements aerospace standards such as ECSS documents and referenced MIL standards. For terminology, consult Part 8 (Glossary).

Standards Content (Sample)

SLOVENSKI STANDARD
01-marec-2022
Vesoljska tehnika - Priročnik o strukturnih materialih - 4. del: Nadzor integritete,
smernice za preverjanje in proizvodnja
Space engineering - Structural materials handbook - Part 4: Integrity control, verification
guidelines and manufacturing
Raumfahrttechnik - Handbuch der Strukturwerkstoffe - Teil 4: Integritätskontrolle,
Verifizierungsrichtlinien und Herstellung
Ingénierie spatiale - Manuel des matériaux structuraux - Partie 4 : Contrôle de l’intégrité,
directives de vérification et fabrication
Ta slovenski standard je istoveten z: CEN/TR 17603-32-04:2022
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 17603-32-04

RAPPORT TECHNIQUE
TECHNISCHER BERICHT
January 2022
ICS 49.140
English version
Space engineering - Structural materials handbook - Part
4: Integrity control, verification guidelines and
manufacturing
Ingénierie spatiale - Manuel des matériaux structuraux Raumfahrttechnik - Handbuch der Strukturwerkstoffe -
- Partie 4 : Contrôle de l'intégrité, directives de Teil 4: Integritätskontrolle, Verifizierungsrichtlinien
vérification et fabrication und Herstellung

This Technical Report was approved by CEN on 22 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 17603-32-04:2022 E
reserved worldwide for CEN national Members and for
CENELEC Members.
Table of contents
European Foreword . 26
Introduction . 27
33 Aspects of damage tolerance . 28
33.1 Introduction . 28
33.1.1 Damage tolerance . 28
33.1.2 Damage events . 28
33.1.3 Damage tolerance criteria . 28
33.2 General guidelines . 29
33.2.1 Fracture control . 29
33.2.2 Durability . 29
33.2.3 Damage . 29
33.2.4 Defects in composites . 29
33.2.5 Impact damage . 32
33.3 Damage tolerance criteria . 33
33.3.1 General . 33
33.3.2 Load paths . 34
33.3.3 Environment . 34
33.3.4 Damage . 34
33.3.5 Residual strength . 35
33.3.6 Safe-life . 35
33.3.7 Fail-safe . 35
33.3.8 Stiffness . 35
33.3.9 Loads . 35
33.3.10 Environmental factors . 35
33.3.11 Inspection . 35
33.3.12 Summary . 36
33.4 Defect standardisation . 36
33.4.1 General . 36
33.4.2 Types of defects . 37
33.5 Effect of macroscopic defects on static load . 39
33.5.1 Composite failure . 39
33.5.2 Use of fracture mechanics . 39
33.5.3 Multi-angle laminates . 39
33.6 Test and analysis . 40
33.6.1 General . 40
33.6.2 Constituent tests . 42
33.6.3 Lamina tests. 43
33.6.4 Laminate tests . 43
33.6.5 Structural element and component tests . 43
33.6.6 Structural sub-component or full-scale tests . 43
33.6.7 Delamination . 43
33.7 Other features of damage-tolerance design . 45
33.7.1 Acoustic fatigue . 45
33.7.2 Proof testing . 45
33.7.3 Metallic parts . 45
33.7.4 Thermal and meteoroid protection system . 45
33.7.5 Impact dynamics – crashworthiness . 45
33.7.6 Flammability, toxicity and off-gassing . 45
33.7.7 Lightning protection . 46
33.8 Improving damage tolerance with higher toughness laminates . 46
33.8.1 General . 46
33.8.2 Material-related aspects . 46
33.8.3 Lay-up aspects . 47
33.9 References . 47
33.9.1 General . 47
33.9.2 ECSS documents . 48
33.9.3 MIL standards . 48
34 Inspection and quality assurance . 49
34.1 Introduction . 49
34.2 Fabrication and quality assurance . 49
34.2.1 Quality assurance . 49
34.3 Inspection, maintenance and repair . 50
34.3.1 Inspection and maintenance . 50
34.3.2 Repairs . 51
34.4 Inspection . 51
34.4.1 Basic considerations . 51
34.5 Definition of inspection procedures . 52
34.5.1 Procedures . 52
34.5.2 Thin composite laminates. 53
34.5.3 Thick composite laminates . 53
34.6 Non-destructive inspection techniques . 54
34.6.1 Introduction . 54
34.6.2 Damage tolerant designs . 54
34.6.3 Advances in NDT . 54
34.6.4 Techniques . 55
34.6.5 Smart technologies for condition monitoring . 56
34.7 Defects and anomalies for detection . 56
34.7.1 General . 56
34.7.2 Emphasis of NDT development . 57
34.8 Overview of NDT techniques . 57
34.8.1 Selection of NDT technique . 57
34.8.2 Detection of defects . 58
34.9 Traditional contact NDT techniques . 64
34.9.1 General . 64
34.9.2 Visual inspection . 64
34.9.3 Dye penetrant . 64
34.9.4 Magnetic particle . 64
34.9.5 Mechanical resonance or impedance . 64
34.10 Ultrasonic techniques . 65
34.10.1 Introduction . 65
34.10.2 Modes of examination . 66
34.10.3 Ultrasonic signal presentation . 66
34.10.4 Data and image processing . 66
34.10.5 Equipment calibration . 67
34.10.6 Large area scanning . 67
34.10.7 Acousto-ultrasonics . 68
34.10.8 Lamb wave (guided wave) . 69
34.10.9 Rayleigh wave techniques . 70
34.10.10 Backscattering techniques . 70
34.10.11 Transducer technology . 71
34.10.12 Air-coupled techniques (non-contact) . 74
34.11 Acoustic emission . 77
34.12 Laser ultrasonics . 78
34.12.1 General . 78
34.12.2 Basic principles . 79
34.13 Holography . 80
34.13.1 Introduction . 80
34.13.2 Laser interferometric techniques . 81
34.13.3 Vibration, pressure and thermal loading . 82
34.13.4 Electronic imaging . 82
34.13.5 Examination of space structures . 83
34.14 Laser shearography . 84
34.14.1 Introduction . 84
34.14.2 Basic technique . 84
34.14.3 Characteristics of shearography . 85
34.15 Thermography . 86
34.15.1 Introduction . 86
34.15.2 Techniques . 87
34.15.3 Heat sources and pulse duration . 91
34.15.4 Detection capabilities . 91
34.15.5 Limitations of thermography . 92
34.16 X-ray radiography . 93
34.16.1 Introduction . 93
34.16.2 X-ray techniques . 94
34.16.3 Digital radiographic system developments . 95
34.16.4 Defect resolution . 98
34.17 Computer tomography . 98
34.17.1 Introduction . 98
34.17.2 Basic technique . 98
34.17.3 Attributes of CT scanning . 99
34.17.4 Micro-tomography . 100
34.18 Eddy currents . 100
34.18.1 Introduction . 100
34.18.2 Developments in eddy current techniques . 101
34.19 Other NDT techniques . 102
34.19.1 General . 102
34.19.2 Microwave . 103
34.19.3 Heat and photosensitive agents . 103
34.19.4 Electrical impedance . 103
34.19.5 Acoustic microscopy . 103
34.19.6 Nuclear magnetic resonance (NMR) . 104
34.19.7 Neutron radiography . 104
34.19.8 Gamma radiography . 104
34.19.9 D sight - Diffracto sight . 104
34.20 NDT for adhesive bond defects. 105
34.20.1 General . 105
34.20.2 Disbonds, voids and porosity . 105
34.20.3 Cohesion and adhesion . 106
34.21 NDT for space applications . 106
34.21.1 Introduction . 106
34.21.2 Developments in inspection . 107
34.21.3 Summary of NDT techniques . 107
34.22 Rupture tests . 109
34.22.1 Application . 109
34.23 Test related items . 110
34.23.1 General . 110
34.23.2 Major items . 110
34.23.3 Qualification tests . 111
34.24 Structural test reports . 122
34.25 Analysis and test documents . 123
34.26 References . 125
34.26.1 General . 125
34.26.2 ECSS documents . 137
35 Objective of verification . 138
35.1 Introduction . 138
35.1.1 General . 138
35.1.2 Composite structures . 138
35.1.3 Composite materials . 138
36 Procurement specifications for raw materials . 140
36.1 Introduction . 140
36.1.1 Guidelines . 140
36.2 Specification methods . 140
36.2.1 Fiche sheet principle . 140
36.2.2 Specific material specification . 141
36.3 Guidelines on resin procurement . 141
36.3.1 Scope. 141
36.3.2 Basic information to be provided by the supplier . 142
36.4 Guidelines on carbon and other fibre prepreg procurement . 146
36.4.1 Scope. 146
36.4.2 Description and classification of prepreg . 146
36.4.3 Prepreg charachteristics for qualification and batch testing . 147
36.4.4 Laminate Characteristics . 150
36.4.5 Test methods . 151
36.5 References . 152
36.5.1 ECSS documents . 152
36.5.2 ESA publications . 152
37 Philosophy of assessment of design allowables . 153
37.1 Introduction . 153
37.2 Carbon fibre reinforced plastics . 153
37.2.1 Design values . 153
37.3 Definition of design allowables . 154
37.3.1 'A' basis allowable . 154
37.3.2 'B' basis allowable . 154
37.4 Development procedure. 154
37.5 Test data . 154
37.5.1 Material . 154
37.5.2 Data . 155
37.6 References . 159
37.6.1 General . 159
38 Manufacturing techniques . 160
38.1 Introduction . 160
38.1.1 Processing techniques . 160
38.1.2 Process selection . 160
38.2 Process selection criteria . 161
38.3 Hand lay-up . 161
38.3.1 General . 161
38.3.2 Wet lamination . 162
38.3.3 Prepreg lay-up . 165
38.4 Autoclave moulding . 169
38.4.1 Use . 169
38.4.2 Basic process . 169
38.4.3 Bag moulding methods . 170
38.4.4 Features of bag moulding. 173
38.4.5 Bagging techniques . 174
38.4.6 Tool materials . 175
38.4.7 Cure schedules . 177
38.5 Filament winding . 178
38.5.1 Basic process . 178
38.5.2 Applications. 178
38.5.3 Winding process . 179
38.5.4 Mandrels . 180
38.5.5 Sandwich constructions . 180
38.5.6 Tape winding . 181
38.6 Filament-winding machines . 181
38.6.1 General . 181
38.6.2 Polar winding . 181
38.6.3 Helical winding . 183
38.7 Resin transfer moulding . 184
38.7.1 General . 184
38.7.2 Basic process . 184
38.7.3 Applications. 185
38.7.4 Fibre preforms . 185
38.7.5 Resin injection . 186
38.7.6 Process variables . 187
38.7.7 Process advantages . 187
38.8 Pultrusion . 188
38.8.1 Use . 188
38.8.2 Basic process . 188
38.8.3 Pull-forming . 189
38.9 Table rolling . 189
38.9.1 Tubular sections . 189
38.10 Pressure and mechanical forming . 190
38.10.1 General . 190
38.10.2 Fibre metal laminates . 190
38.10.3 Thermoplastic composites . 190
38.11 Injection moulding . 191
38.11.1 General . 191
38.11.2 Short fibre composites . 191
38.12 Radiation curing . 192
38.12.1 Process developments . 192
38.12.2 EB electron beam curing . 193
38.12.3 Microwave . 197
38.12.4 UV curing . 198
38.13 Preform technology . 198
38.13.1 General . 198
38.13.2 Braids. 199
38.13.3 Commingled fibre performs . 199
38.14 Fibre placement . 200
38.14.1 Introduction . 200
38.14.2 Advantages . 203
38.14.3 Repeatability in lay-up and properties . 204
38.14.4 Mixed materials in the same lay-up . 205
38.14.5 Major advantages of fibre placement compared with other
technologies . 206
38.14.6 Examples of European launcher and satellite structures made by
fibre placement . 207
38.15 Out of autoclave . 208
38.15.1 Introduction . 208
38.15.2 Aerospace structural parts . 208
38.15.3 Composite materials . 209
38.15.4 Tooling . 209
38.16 References . 210
38.16.1 General . 210
38.16.2 ECSS standards . 216
39 Machining techniques . 217
39.1 Introduction . 217
39.2 Basic rules . 217
39.2.1 General . 217
39.2.2 Equipment . 217
39.3 Routing . 218
39.3.1 Carbon/epoxy composites . 218
39.3.2 Aramid/epoxy composites . 218
39.3.3 Trimming and bevelling . 219
39.4 Sanding . 220
39.4.1 General . 220
39.4.2 Fit or trim . 220
39.4.3 Bonding . 221
39.4.4 Aramid/epoxy composites . 222
39.5 Sawing . 222
39.5.1 Basic rules . 222
39.5.2 Bandsawing . 222
39.5.3 Circular sawing . 223
39.5.4 Sabre sawing . 224
39.6 Countersinking . 225
39.6.1 General . 225
39.6.2 Carbon and glass reinforced epoxy . 225
39.6.3 Aramid/epoxy composites . 225
39.7 Counterboring . 226
39.8 Milling . 227
39.8.1 Basic Rules . 227
39.8.2 Plunge-cut milling . 227
39.9 Drilling . 228
39.9.1 Basic problems . 228
39.9.2 Drill bits for composites . 229
39.10 Orbital drilling . 231
39.10.1 Introduction . 231
39.10.2 Advantages . 232
39.10.3 Drilling parameters . 232
39.10.4 Equipment . 232
39.10.5 Application examples . 233
39.11 References . 234
39.11.1 General . 234
39.11.2 ECSS standards . 234
40 Manufacturing costs. 235
40.1 Introduction . 235
40.2 Cost drivers . 236
40.2.1 General . 236
40.2.2 Project cost drivers . 236
40.2.3 Mass for cost budgets . 236
40.2.4 Materials selection . 236
40.2.5 Design for manufacturing . 237
40.2.6 Manufacturing expertise . 237
40.2.7 Tooling and consumables . 237
40.2.8 Processing times . 237
40.2.9 Labour costs . 238
40.2.10 Part count . 238
40.2.11 Unit numbers . 238
40.2.12 Product life and sourcing . 239
40.3 Cost optimisation . 239
40.3.1 Load-carrying structures. 239
40.4 Cost advantages of composites . 244
40.4.1 Material costs . 244
40.4.2 Manufacturing costs . 244
40.5 Satellite thrust cylinders . 244
40.6 Launcher fairing cylinders . 245
40.6.1 General . 245
40.6.2 Potential fairing designs . 245
40.6.3 Selection of designs . 249
40.6.4 Process and material trade-off . 250
40.7 Thermoplastic versus thermoset . 252
40.7.1 General . 252
40.7.2 Recurring spacecraft components . 253
40.7.3 Thermoplastic composites in aircraft . 258
40.7.4 Conclusions . 260
40.8 Automation . 260
40.9 Cost analysis methods . 261
40.10 References . 261
40.10.1 General . 261
41 Repair of composites . 263
41.1 Introduction . 263
41.2 Damage classification . 263
41.2.1 Life-histories of composite structures . 263
41.2.2 Inspection and criticality of damage . 263
41.2.
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