Combining honeycomb structures with carbon/carbon (C/C) composites provides significant benefits, such as enhanced load-bearing strength, reduced weight, minimal thermal expansion, and no moisture absorption. These characteristics make such structures particularly suited for space applications. Carbon fiber reinforced composites, with their versatile design capabilities, emerge as an ideal material for satellite bearing platforms. In this study, three continuous carbon fiber woven structures are designed, and an integrally woven ortho-hexagonal C/C honeycomb structure was fabricated through performing Chemical Vapor Infiltration (CVI) process on honeycomb preform. A multiscale damage model is used to analyze and compare the properties related to out-of-plane compression, shear in the L-direction, and shear in the W-direction across these three C/C honeycomb structures. Results indicate that the plain-woven C/C honeycomb structure demonstrates the most favorable mechanical properties, with the highest compressive modulus and shear strength under various loading conditions. Damage initially occurred in single-layer honeycomb walls with void defects, with ultimate failure appearing predominantly in the middle regions of all walls. These findings establish the plain-woven structure as the preferred choice for satellite bearing platforms due to its outstanding mechanical characteristics, providing stability and strength crucial for space applications.
FuLPingRTingL, et al.Application of carbon-carbon composite for load-carrying cylinder in lunar optical telescope. In: International symposium on photoelectronic detection and imaging 2011 - space exploration technologies and applications, 2011.
2.
NavarroRBurgeJHBlechaL, et al.Analytical optimization and test validation of the submicron dimensional stability of the CHEOPS space telescope's CFRP structure. In: Advances in optical and mechanical technologies for telescopes and instrumentation II, 2016.
3.
ZhuZTianALiuB, et al.Design and evaluation of flexible support based on space mirror. Appl Sci2024; 14. DOI: 10.3390/app14051927.
4.
KazemianRFanaieNMousavi-BafrouyiSMS, et al.Experimental investigation on flexural behavior and energy absorption of lightweight sandwich panels with aluminum honeycomb core embedded by thin-ply carbon-glass fibers/epoxy face sheets. Structures2024; 60. DOI: 10.1016/j.istruc.2024.105961.
5.
WangZG. Recent advances in novel metallic honeycomb structure. Compos B Eng2019; 166: 731–741. DOI: 10.1016/j.compositesb.2019.02.011.
6.
OnyiboECSafaeiB. Application of finite element analysis to honeycomb sandwich structures: a review. Reports in Mechanical Engineering2022; 3: 283–300. DOI: 10.31181/rme20023032022o.
7.
LinXCLiSLLiWX, et al.Thermo responsive self ceramifiable robust aerogel with exceptional strengthening and thermal insulating performance at ultrahigh temperatures. Adv Funct Mater2023; 33: 2214913. DOI: 10.1002/adfm.202214913.
8.
MohammadiHAhmadZPetrůM, et al.An insight from nature: honeycomb pattern in advanced structural design for impact energy absorption. J Mater Res Technol2023; 22: 2862–2887. DOI: 10.1016/j.jmrt.2022.12.063.
9.
LeVTHaNSGooNS. Advanced sandwich structures for thermal protection systems in hypersonic vehicles: a review. Compos B Eng2021; 226: 109301. DOI: 10.1016/j.compositesb.2021.109301.
10.
DuDHLiangXYLiWJ, et al.A novel integrated forming strategy based on chemical vapor infiltration for C/C honeycomb with variable stiffness. J Sandw Struct Mater2024; 26: 1265–1287. DOI: 10.1177/10996362241278215.
11.
FuYCSadeghianP. Bio-based sandwich beams made of paper honeycomb cores and flax FRP facings: flexural and shear characteristics. Structures2023; 54: 446–460. DOI: 10.1016/j.istruc.2023.05.064.
12.
ZhuXJXiongCYinJH, et al.Experimental study and modeling analysis of planar compression of composite corrugated, lattice and honeycomb sandwich plates. Compos Struct2023; 308: 116690. DOI: 10.1016/j.compstruct.2023.116690.
13.
WangZXChenXJYuGC, et al.Improving shear strength of carbon fiber composite honeycombs with the surface microprinting technology. Compos Struct2023; 304: 116420. DOI: 10.1016/j.compstruct.2022.116420.
14.
LiuRYYaoGFShaLM, et al.Study on mechanical properties of polyurethane-enhanced triply periodic minimal composite structures inspired by rachis microstructure. Compos Sci Technol2023; 242: 110197. DOI: 10.1016/j.compscitech.2023.110197.
15.
ZhaoZYLiuCWangHJ, et al.Crushing behavior of curved Nomex honeycombs under combined shear-compression loads. Int J Mech Sci2022; 228: 107480. DOI: 10.1016/j.ijmecsci.2022.107480.
KimMKimY. A thermo-mechanical properties evaluation of multi-directional carbon/carbon composite materials in aerospace applications. Aerospace2022; 9. DOI: 10.3390/aerospace9080461.
18.
TakeyaHKumeMHahnSE, et al.Development of ultra-light-weight mirror with carbon/carbon composites for optical-IR astronomy. Optical, Infrared, and Millimeter Space Telescopes2004; 1: 2.
19.
FabioPLutz-NivetMLemaireH. Development of Carbon-Carbon sanswich panels. Proceedings of the 9th international symposium on materials in a space environment Noordwijk, The Netherlands, 2003.
20.
SalvoMCasalegnoVVitupierY, et al.Study of joining of carbon/carbon composites for ultra stable structures. J Eur Ceram Soc2010; 30: 1751–1759. DOI: 10.1016/j.jeurceramsoc.2009.12.013.
21.
GuoLJWangHCYangYP, et al.A multi-scale damage model and mechanical behavior for novel light-weight C/C honeycomb sandwich structure. J Mater Res Technol2023; 25: 2097–2111. DOI: 10.1016/j.jmrt.2023.06.101.
22.
GuoLJWangHCLiW, et al.Multi-scale damage modeling and out-of-plane shear behavior of carbon/carbon honeycomb structure. Thin-Walled Struct2023; 192. DOI: 10.1016/j.tws.2023.111103.
23.
GuoLJZhangFCLiWJ, et al.Effect of void defects on mechanical behavior and failure features of C/C honeycomb structure. Thin-Walled Struct2024; 199. DOI: 10.1016/j.tws.2024.111745.
24.
LiaoXLiHXuW, et al.Study on the thermal expansion properties of C/C composites. J Mater Sci2007; 42: 3435–3439. DOI: 10.1007/s10853-006-1123-3.
25.
MichalowskiJMikociakDKonsztowiczKJ, et al.Thermal conductivity of 2D C–C composites with pyrolytic and glass-like carbon matrices. J Nucl Mater2009; 393: 47–53. DOI: 10.1016/j.jnucmat.2009.05.004.
26.
GuoYNGil PérezMSerhatG, et al.A design methodology for fiber layup optimization of filament wound structural components. Structures2022; 38: 1125–1136. DOI: 10.1016/j.istruc.2022.02.048.
27.
BeheraBKDashBP. An experimental investigation into the mechanical behaviour of 3D woven fabrics for structural composites. Fibers Polym2014; 15: 1950–1955. DOI: 10.1007/s12221-014-1950-9.
28.
SunTJiangRSunH, et al.Multiscale uncertainty propagation analysis and reliability optimization of the CFRP crossbeam of the twist beam axle. Int J Mech Sci2023; 242. DOI: 10.1016/j.ijmecsci.2022.108022.
29.
QianYBaoQLiZ, et al.Numerical investigation on the mechanical behaviors of 2D woven composites under complex in-plane stress states. Compos Struct2023; 315. DOI: 10.1016/j.compstruct.2023.117008.
30.
LiuYJHuangCYXiaH, et al.Research on development of 3D woven textile-reinforced composites and their flexural behavior. Mater Des2021; 212. DOI: 10.1016/j.matdes.2021.110267.
31.
LiuYJXiaHNiQQ. Experimental investigation on low-velocity impact performance of 3D woven textile composites. Appl Compos Mater2022; 29: 121–146. DOI: 10.1007/s10443-021-10005-0.
32.
JiaoWChenLXieJ, et al.Effect of weaving structures on the geometry variations and mechanical properties of 3D LTL woven composites. Compos Struct2020; 252. DOI: 10.1016/j.compstruct.2020.112756.
33.
LiangHRLiWJWangLY, et al.Effect of meso‐structure characteristics on surface emissivity of 2.5D Woven ablative composite for thermal protection. Polym Compos2023; 44: 3209–3220. DOI: 10.1002/pc.27312.
34.
HeCWGeJRQiDX, et al.A multiscale elasto-plastic damage model for the nonlinear behavior of 3D braided composites. Compos Sci Technol2019; 171: 21–33. DOI: 10.1016/j.compscitech.2018.12.003.
35.
GaoZYChenL. A review of multi-scale numerical modeling of three-dimensional woven fabric. Compos Struct2021; 263. DOI: 10.1016/j.compstruct.2021.113685.
36.
ZhouYLuZXYangZY. Progressive damage analysis and strength prediction of 2D plain weave composites. Compos B Eng2013; 47: 220–229. DOI: 10.1016/j.compositesb.2012.10.026.
37.
ZhaoZQLiuPChenCY, et al.Modeling the transverse tensile and compressive failure behavior of triaxially braided composites. Compos Sci Technol2019; 172: 96–107. DOI: 10.1016/j.compscitech.2019.01.008.
38.
ZhengTGuoLCDingJF, et al.An innovative micromechanics-based multiscale damage model of 3D woven composites incorporating probabilistic fiber strength distribution. Compos Struct2022; 287. DOI: 10.1016/j.compstruct.2022.115345.
39.
HongYYanYTianZY, et al.Mechanical behavior analysis of 3D braided composite joint via experiment and multiscale finite element method. Compos Struct2019; 208: 200–212. DOI: 10.1016/j.compstruct.2018.10.017.
40.
SiddiqueSHHazellPJWangHX, et al.Lessons from nature: 3D printed bio-inspired porous structures for impact energy absorption – a review. Addit Manuf2022; 58: 103051. DOI: 10.1016/j.addma.2022.103051.
41.
JiaoPMuellerJRaneyJR, et al.Mechanical metamaterials and beyond. Nat Commun2023; 14. DOI: 10.1038/s41467-023-41679-8.
42.
AiSGFangDNHeRJ, et al.Effect of manufacturing defects on mechanical properties and failure features of 3D orthogonal woven C/C composites. Compos B Eng2015; 71: 113–121. DOI: 10.1016/j.compositesb.2014.11.003.
43.
WeiKLShiHBLiJ, et al.A new progressive damage model for predicting the tensile behavior of the three-dimensional woven carbon/carbon composites using micromechanics method. Int J Damage Mech2021; 31: 294–322. DOI: 10.1177/10567895211035496.
44.
LindePde BoerH. Modelling of inter-rivet buckling of hybrid composites. Compos Struct2006; 73: 221–228. DOI: 10.1016/j.compstruct.2005.11.062.
45.
ShanCWDangJYanJQ, et al.Three-dimensional numerical simulation for drilling of 2.5D carbon/carbon composites. Int J Adv Des Manuf Technol2017; 93: 2985–2996. DOI: 10.1007/s00170-017-0653-y.
