Numerical simulation and validation of MWCNT-CFRP hybrid composite structure in lightweight satellite design

Aluminum alloy is generally used in electronic housings of satellites in space avionics due to its remarkable mechanical, thermal, electrical, and radio-frequency shielding properties. This paper proposes a design for a lightweight multi-functional electronic housing made from plastic containing multi-wall carbon nanotubes (MWCNT) composite material. The structural design of housings was validated against a set of boundary conditions and requirements of launch and space environments as prescribed by European Cooperation for Space Standardization (ECSS) standards. The proposed concept for lightweight composite housing was designed with special emphasis on reducing machining operations. The composite housing offers a mass saving of similar to 25 % over a typical aluminum housing with similar mechanical performance in the three orthogonal directions. The modal frequency is greater than 100 Hz qualifying the design requirement for satellite electronic housings. Under si-nusoidal vibration loads, the structure shows no noticeable excitation in acceleration response graph, indicating no resonance in low-range frequencies from 5 to 100 Hz. Maximum stresses obtained from Quasi-static and random vibration loads are within the tensile strength limit in the three orthogonal directions. In addition, maximum deflection observed in electronic printed circuit boards is within the 1 mm design requirement.

Automated summary

This paper proposes a lightweight multi-functional electronic housing design made from plastic composite material, which offers similar mechanical performance to aluminum housings while reducing machining operations. The design meets the requirements for satellite electronic housings.