Structural and Material Optimization of a Sensor-Integrated Autonomous Aerial Vehicle Using KMU-3 CFRP.

Area of Science:

• Materials Science and Engineering
• Aerospace Engineering
• Composite Materials

Background:

• Aerospace systems require robust materials for extreme environmental conditions, particularly for high-altitude pseudo-satellites (HAPS).
• Sustained operations at altitudes up to 30 km necessitate advanced materials capable of withstanding stratospheric conditions.

Purpose of the Study:

• To select and apply composite materials for aerospace systems operating in extreme environments, focusing on HAPS.
• To develop a lightweight, structurally sound autonomous aerial vehicle (AAV) for high-altitude, long-duration missions.

Main Methods:

• Utilized KMU-3 composite material (high-modulus carbon fibers in 5-211B epoxy matrix) for truss structure development.
• Evaluated mechanical, thermal, and aerodynamic properties via finite element method (FEM) simulations and computational fluid dynamics (CFD) analysis.
• Developed and tested a novel thermal bonding technique for composite joints and validated designs through experimental prototyping.

Main Results:

• Ultra-thin (0.1 mm wall thickness) KMU-3 truss structures demonstrated structural integrity under dynamic loads, achieving a lightweight design (45 kg).
• The novel thermal bonding technique yielded joints with 40 MPa shear strength and >10^6 cycles fatigue life.
• Optimized fiber orientation and epoxy matrix provided excellent resistance to mechanical stresses and radiation, with stable properties from -60 °C to +80 °C.

Conclusions:

• Validated lightweight (45 kg) ultra-thin truss structures using KMU-3 composite material are suitable for next-generation HAPS.
• The developed materials and bonding techniques support extended mission durations in harsh stratospheric conditions.
• This research provides a robust framework for designing advanced autonomous aerial vehicles for extreme altitude operations.