Carbon Fiber TRAC Boom Research

Project Description

Overview

In the fall of 2023, I assisted Dr. Anthony Waas in the study of TRAC composite booms. These are boom structures for the space environment which can coil for compact storage before being expanded to use in space. We explored a novel manufacturing method using asymetric carbon fiber construction.

The Engineering Challenge

The asymetric carbon fiber construction of the booms allowed them to be manufactured without a mold in a flat layup, after which they would fold outward due to their asymetric coefficients of thermal expansion. I identified a key design concern which was the temperatures experienced by these structures in space. This would vary from -200C to +120C and because the structure was dependent on thermal expansion to give it shape, this would have a massive impact on the strength of the booms in these different regimes.

Process

In order to test this, I designed and constructed a thermal test chamber where we varied the temperature and observed boom deflection. We then manufactured a number of booms to have a variety of deflections at room temperature, where we tested their properties in order to determine their viability.

Outcomes

It was determined that this construction of TRAC boom was not applicable for the space environment due to its instability at high temperatures. Further work could be done to determine if coatings or other methods could be used to reduce the heating of the booms in direct sunlight. We concluded that the cost of these methods would likely override the cost savings of moldless TRAC boom construction.

Personal Takeaways

Where I Succeeded

Where I Failed

What I Learned

In this research, I learned a significant amount about composite manufacturing