Development of Carbon Nanotube-based Composite
for Spacecraft Components
Suraj Rawal and James Brantley
Lockheed Martin Space Systems Company
Denver, CO 80201 USA
suraj.p.rawal@lmco.co
james.d.brantley@lmco.com
Abstract—Over the last decade, there have been significant
advancements in the material synthesis and processing aspects of
the carbon nanotube (CNT) technology, and the basic under-
standing of its multifunctional properties. Lockheed Martin
Space Systems has been evaluating CNTs, vapor-grown carbon
nanofibers (VGCF), and CNT sheets, grapheme-based nano-
composites, from different sources for incorporating them into
composite components of spacecraft structures. This paper
describes the use of CNT-based composite components such as
tubes and sandwich panels on the Juno spacecraft.
In the last two decades, several composite-based solutions
have also been investigated to minimize the Materials and
Processing steps and introduce electrical functionality to satisfy
electrostatic dissipation (ESD), grounding, and shielding
effectiveness (SE) requirements for spacecraft structures. A few
of these concepts have had very limited success, compared to the
highly-effective approaches such as an outer surface of thin
aluminum (Al) foil or electrically conductive coating. In this
investigation, several viable nanocomposite-based approaches
were evaluated for the spacecraft composite structure
applications. A few of these approaches offered the design
solution satisfying the ESD and outgassing requirements, and
provided good thermal conductivity. More specifically, the dry
CNT sheets were incorporated as the outermost ply on the
conventional composite layup, which were processed using state-
of-the-art (SOA) autoclave process for fabricating the tube
elements for the spacecraft. These tubes exhibited excellent
surface finish, enhanced surface conductivity, and improved
stiffness, compared to the state-of-the-art composite tubes.
Building upon this technology development effort, a few
flight-quality tubes and a flight-quality sandwich panel were
successfully fabricated and qualified for the Juno spacecraft.
Successful technology insertion of a CNT sheet for ESD
protection on the Juno spacecraft will pave the way for the
extensive use of CNT-based composite structures on future
spacecrafts, thus benefiting from CNT’s multifunctional
attributes such as electromagnetic shielding effectiveness,
thermal and electrical conductivity, and enhanced fracture
toughness and interlaminar properties.
Keywords—carbon nanotube; multifunctional properties;
electrostatic dissipation; composite structures; spacecraft.
978-1-4673-6396-9/13/$31.00 ©2013 IEEE
Nafiz Karabudak
Lockheed Martin Corporation
Corporate HQ, Bethesda, MD 20817 USA
nafiz.n.karabudak@lmco.com
I. INTRODUCTION
At the nanoscale, carbon nanotubes and graphene
nanoplatelets (GnP) materials offer a unique combination of
elastic modulus (0.8–3 Tpa), thermal conductivity (3000–6000
W/m-K), and electrical resistivity (3–20 µΩ-cm) properties [1-
4]. If these multifunctional properties could be translated from
nano to micro to macroscale composites with minimum loss in
parent properties, then it will make a revolutionary impact on
the design and manufacture of lightweight structures. Several
researchers have processed nanocomposites with 0.2–5
weight % of CNTs into different polymer matrix materials [5-
10]. The material properties of these nanocomposites do
exhibit 10%–35% improvement in properties such as modulus,
strength, impact resistance, thermal conductivity, and electrical
conductivity, compared to the matrix polymer. However, these
nanocomposites do not exhibit adequate enough properties for
spacecraft structural components.
A few investigators have also processed hybrid composites,
incorporating the CNT-based nanocomposites with conven-
tional carbon fiber composites, exhibiting moderate improve-
ment in multifunctional material properties. Recognizing the
current challenges in the development of hybrid composites to
attain significant (≥50%) increase in properties and perform-
ance, the key focus of this technical effort was to identify the
unique attributes, such as electromagnetic shielding (EMI) and
ESD characteristics of nanocomposites, that could be
implemented to demonstrate the benefits of CNT technology.
Leveraging upon the previous efforts in the development of
multifunctional CNT coatings [11] and graphene nanoplatelet
membranes [12], the objective of this project was to design and
fabricate CNT-based composite components that offer a cost-
effective solution and satisfy ESD requirements, and
potentially provide an equipotential ground plane of the
spacecraft structure.
Typically, the primary spacecraft composite honeycomb
structure is designed as an EMI tight shielding enclosure
(Faraday Cage). More specifically, the aluminum foil bonded
on composite substrate provides an electrically-conductive
surface for EMI shielding and ESD. In addition, the aluminum
surface layer also provides an electrical ground plane to ensure
that all components and interfaces are at an equipotential to
comply with system-level electromagnetic compatibility
13
(EMC)/EMI requirements (Table I) [13-15]. All structural and TABLE II. ELECTROMAGNETIC COMPATIBILITY REQUIREMENTS FOR
SPACECARFT SYSTEMS
mechanical parts, electronic boxes, and enclosures of the
spacecraft should be electrically bonded to each other to assure Nanocarbon Product Converted Source
a direct current resistance of less than 2.5 milliohm at each Allotrope Form Form
joint, as required for electrical grounding referencing reasons. NanoTechnology Lab,
MWNT Powder Nanocomposite
NC
All of the spacecraft composite surface materials (visible, Applied Sciences/
exterior) should be conductive in an ESD sense. These CNF Powder Nanocomposite Inc./NanoTechnology
composite structures shall be designed such that all exterior Lab, NC
structural surfaces have a surface resistance preferably less CNO Powder
CNO/MWNT NanoTechnology Lab,
than 106 Ohms per square. Presence of any resin-rich regions Sheet NC
CNT As-is Dry Sheet Nanocomp Inc.
on the composite surface could lead to differential charging of
(DWNT/MW Sheet or
spacecraft surfaces. Therefore, such composite surfaces are NT) Prepreg Sheet Tencate
often scuffed or abraded to expose the conductive carbon Graphene
GnP/MWNT GnP from: XG Sciences,
fibers, or an electrically-conductive surface coating is applied nanoplatelet Powder
sheet and Angstron Materials
to have a uniform partially conductive surface. The co- (GnP)
processing of an aluminum foil layer on composite surfaces,
and the scuffing of exterior surfaces, are often labor intensive double wall nanotube (DWNT), carbon nanoonions (CNO),
manufacturing steps. In the context of using hybrid composites and GnP are available in different product forms such as
for spacecraft structure, it will be ideal if CNT-based powder, platelet, or sheet from commercial sources. The
nanocomposites could eliminate the need for applying an nanocarbon materials available in the powder form from
aluminum foil layer on structural carbon/cyanate-ester (CE) Nanotechnology Lab (NTL), NC, USA, were dispersed in a
composites. polymer matrix to formulate nanocomposite coatings. Using
Spacecrafts encounter electron charging phenomena in the the proven paper-like continuous membrane manufacturing
operational space environment. Plasma conditions present in process, NTL provided several MWNT, CNF, and
these space environments are sufficient to yield particle CNO/MWNT and GnP/MWNT materials in the sheet form
penetration into exterior surfaces. Typical dielectric materials, (80–125 µm thick) with an areal density of ~40–45 gm/sq
including resin-rich layer on composite surface or low- meter (gsm). Nanocomp Technology Inc. (NCTI), NH, USA
electrical conductivity materials, are subject to electrical charge has a unique process to transform the as-deposited CNTs on a
accumulation, which may lead to damaging ESD or break- drum into non-woven sheets and mats. Thin CNT sheet (~ 20–
down. At this stage of nanotechnology, CNT-based nano- 30-µm-thick) material with an areal density of 15 gsm was
composites do not provide electrical conductivity equivalent to procured as a roll (1 m wide x 100 m length) from Nanocomp
a metallic surface layer for EMC/grounding purposes, but they Inc.
have the potential to satisfy EMI/ESD characteristics. This
paper presents specific materials and processes related to the B. Processing Approaches
development of an affordable and easy-to-use CNT Three different processing approaches were used to
nanocomposite-based ESD solution for spacecraft composite incorporate CNT-based nanocomposite onto SOA composite
structures. Leveraging on this development effort, CNT-based such as M55J/CE laminates or tubes. These approaches
composite components were fabricated and successfully included:
transitioned on to the Juno spacecraft which was launched in
August 2011. i) Spray deposit (or apply by brush) CNT-based nano-
composite on M55J/CE substrate.
II. MATERIALS AND TESTS ii) Co-cure CNT sheet/membrane as an outer ply of the
M55J/CE layup.
A. Nanocarbon Materials
iii) Prepare a CNT sheet/CE prepreg, and co-cure CNT
Table II lists different nanocarbon allotropes that have the prepreg as the outer most ply (on both sides of laminates)
potential to satisfy EMI and/or ESD requirements for to process CNT/ (M55J/CE) substrates.
spacecraft composite structures. These materials, including
multiwall nanotube (MWNT), carbon nanofiber (CNF),
C. Surface Resistivity, EMI, and ESD Evaluation Tests
Surface resistivity of each CNT-based as-processed
TABLE I. ELECTROMAGNETIC COMPATIBILITY REQUIREMENTS FOR membrane/sheet, nanocomposite coated substrates, and co-
SPACECRAFT SYSTEMS
cured CNT/composite laminates was measured by using a
EMC Control Requirements surface resistivity meter and four-point-probe tests. Initial
EMI or Radio Frequency screening tests were performed by a surface resistivity
– The DC Resistance across each joint ≤ 2.5 milliohms measurement (SRM)/return to ground (RTG) meter. On the
ESD SRM meter, 104 and 105 ohm/sq readings are indicated as
– Bonding Resistance ≤ 1.0 Ohm
– Surface Resistivity ≤ 106 Ohm/Sq conductive, and readings between 106 to 1012 ohm/sq are
Power Return and Shock Hazard indicated as static dissipative. Surface resistivity of each
– Ground Strap/Jump Wires ≤ 0.1 Ohm specimen was obtained at multiple locations to get the scatter
– Ground Strap (Length/Width) ≤ 5:1 in resistivity measurements. In each case, the measured surface

14
resistance in ohm/square was identical over the entire surface
indicating the uniform quality of the applied coating and its
electrical characteristics. In nearly all instances, the SRM
ohm/sq reading was less than 104 ohm/sq.
A four-point-probe test, using Keithley 4200 semi-
conductor characterization system via Keithley interactive test
environment software, was also used to determine the surface
resistivity of each sheet and CNT/composite. Each specimen
was placed in the four-point-probe test fixture that utilizes four
source measurements units (SMU) connected to four
autonomous gold probes extending through a Teflon base lying
parallel to the surface of the sample under test.
Simulating electron-charging phenomena in the space
environment, a preliminary assessment of CNT/(M55J/CE)
/CNT panel (Fig. 1) was also performed by conducting
electron-charging tests under vacuum conditions in the Plasma Fig. 1. Photograph of CNT/(M55J/CE) Panel in vacuum chamber for
Interaction Test facility. During the test, an electron flood beam electron charging tests.
was generated using a Kimball Physics 8104 Electron Gun
capable of operation up to 100 keV. Electron current densities
of ~1 nA/cm2 were utilized as per common design environ-
ments. Similarly, electron energy of 20 keV was used, along
with several lower energy levels of 2.5 keV, 5 keV, and 10
keV. In general, a test environment of 20 keV and 1 nA/cm2
represents most spacecraft design environments.
EMI shielding effectiveness (SE) dB tests were conducted
at the EMC test facility. Different CNT-based composite
panels, and composites with aluminum foil surface layer, were a) 20 to 200-MHz test set up b) 2 to 18-GHz test setup
tested over the frequency range from 20 MHz to 18 GHz Fig. 2. Electromagnetic shielding effectiveness testing of CNT composite
(Fig. 2). panels, Al foil composite panels, and Aluminum plates from 20 MHz to 18
GHz.
D. Mechanical Property Tests
Fig. 4a shows one of the CNT sheets (from NCTI) that
Using NCTI’s CNT sheet as an outer ply, eight CNT/
were examined at multiple locations on the sheet, and later on
(M55J/CE) tubular struts were fabricated, Compression testing
the as-processed CNT/composite laminates. Fig. 4b shows
was performed to determine the ultimate compressive strength
nearly uniform distribution of bundles of CNTs held together
primarily of M55J/CE composite. These tests also provided
by van-der-walls forces. In each case, the presence of residual
insight into the quality of adhesion of outer CNT ply to the
catalyst-type (e.g., iron, nickel or cobalt) impurity was quite
underlying laminates. Four M55J/CE composite sandwich
low. Fig. 4c shows two representative FIB images of the
panels (~50 cm x 50 cm x 1.3 cm) were also fabricated with
surface of the co-cured CNT sheet as an outer ply indicating
co-cured CNT prepreg ply on both of the outer surfaces.
dispersed CNT bundles within CE matrix. Microstructures
Flexure testing of the sandwich panel coupons was performed
indicate that during the SOA composite processing, the CE
to ascertain the quality of CNT/CE ply and underlying
wicks into the CNT sheet forming a very thin layer of resin on
M55J/CE substrate.
CNT bundles. Overall, each of the co-cured CNT sheets was
well adhered to the underlying M55J/CE substrate with no
III. RESULTS AND DISCUSSION significant resin-rich regions.

A. Microstructure
Using scanning electron microscopy, and focused ion beam
(FIB) imaging techniques, each nanocarbon-based sheet
material was examined. Fig. 3 shows the photomicrographs of
the representative regions. For example, MWNT showing
tangled distribution of MWNTs apparently held together by a) MWNT b) CNO c) Graphene Nanoplatelet
van-der-walls forces, CNO particles showing onion-skin like Fig. 3. Photomicrographs of MWNT, CNO, and Graphene Nanoplatelet in
structure, and GnPs well dispersed in the sheet along with the processed sheet materials.
MWNTs.

15
 thin, co-cured CNT sheet/M55J/CE. Each of the EMI shielding
effectiveness measurements over the 200 MHz to 18 GHz
indicated that the co-cured CNT M55J/CE panel exhibited
shielding effectiveness equivalent to the typical spacecraft
panel with aluminum foil-based M55J/CE composite or solid
aluminum plate. It must be recognized that each test was
performed in the identical test setup and conditions. Results of
a) NCTI’s CNT sheet b) CNT (as-received sheet) all these tests confirm that nanocarbon film-based composite
panels exhibit EMI shielding effectiveness in the acceptable
range for the spacecraft system requirements (including the
nickel nanostrand-based composite panel.
C. CNT Material Design Downselection
After successfully verifying that nearly all CNT-based
composites do satisfy the EMI and ESD requirements for the
spacecraft system, the challenge was to either prioritize or
down select the material and processes that would be
acceptable to spacecraft designers. Key elements of the down
selection criteria were as follows:
c) Co-cured CNT sheet layer i) Composite should be robust and reproducible to provide
acceptable EMI/ ESD performance.
Fig. 4. Photomicrographs of NCTI’s CNT sheet materials: a) as-received
sheet, b) FIB image of a representative region, c) FIB image of co-cured CNT ii) Provide ease of manufacturing (consistent with SOA
sheet revealing presence of CE resin wicked in to the distributed CNT processes), and provide cost savings.
bundles.
iii) Should preferably provide mass savings.
B. EMI/ESD Charcateristics iv) Should offer ≥SOA composite properties.
Table III lists the measured surface resistivity and average v) Cost-effective availability of material form with adequate
bulk electrical resistivity values of the bare M55J/CE material safety data sheets for approval by Employee
composite panel, nanocarbon-based sheets/membranes, and the Safety and Health Organization.
co-cured sheets on the composite panels. In each case, the co-
cured nanocarbon-sheet-based panel, exhibiting surface
resistivity values of <100 ohm/sq, satisfies the ESD require- TABLE III. MEASURED SURFACE RESISTIVITY OF CNT BASED
COMPOSITES
ments for spacecraft exterior surfaces. For example, the CNF-
spray-coated composite panel exhibited surface resistivity of CNT-based
Surface
Electrical
103 to 104, satisfying the ESD requirements. However, the Resistivity
Composite Process Resistivity
4-Point Probe
electron-charging experiments need to be performed to ensure Specimen
Ohm/sq
(Ohm-cm)
there are no resin-rich regions that could lead to charge build As-Processed (no
up and, consequently, ESD damage. The electron charging M55J/CE 108-1011 x
CNT)
tests performed at 20 keV of co-cured, thin CNT sheet/ CNF/(M55J/CE) Spray Coated 3
10 –10 4
x
(M55J/CE) panels indicated no observed surface potential
100%MWNT
values of less than –25 V were measured throughout. A few Sheet
~63-gsm Sheet 1–3 0.02
such panels were examined, and it was found that given the due Co-cured
MWNT/
care in processing, the CNT/composite surfaces did not exhibit (M55J/CE)
CNO/MWNT 20–25 x
any charge build up. Based on the results of several test Sheet
specimens and panels, the presence of thin CNT layer provides 60%CNO/
Sheet 2.5 0.025
40%MWNT
adequate electron mobility, and charges are distributed evenly
Co-cured
around the surface. Of the several nanocarbon-based panels CNO/ M55J/CE
CNO/MWNT
40–80 x
evaluated in the project, the NCTI’s CNT-based panels
CNT (NCTI) Sheet 0.271 8 x 10-4
exhibited consistently low surface resistivity and ease of
handling and processing. Co-cured Dry
CNT/(M55J/CE) 1–7 x
CNT Sheet
Fig. 5a shows the shielding effectiveness (dB) versus CNT Prepreg/ Co-cured CNT
10–30 x
(M55J/CE) Prepreg Outerply
frequency plots of four types of panels: 1) SOA M55J/CE 80%GnP/20%
composite laminate with outer layer of thin aluminum foil, Sheet 1.5–2 0.02
MWNT
2) thin, co-cured CNT sheet/M55J/CE laminate, 3) CNT/ Co-cured GnP
GnP/(M55J/CE) 20–30 x
(M55J/CE) sandwich panel, and 4) panel with a co-cured Sheet
nickel nanostrand-based film (areal density 120 gsm, not
discussed in this paper) on M55J/CE substrate panel. Similarly,
Fig. 5b shows the SE effectiveness testing of a solid plate and a

16

a) Four test panels: 1) Ni nanostrand/composite laminate, 2) CNT/composite
honey comb panel, 3) Al foil/composite laminate, and 4) CNT/composite
laminate.
b) Two test panels: 1) Solid aluminum plate, and 2) CNT/composite laminate.
Fig. 5. Shielding effectiveness plots showing nearly-equivalent performance
of different composite panels.
Of the different nanocarbon-based powders and sheets,
NCTI’s CNT sheet offered ease of manufacturing, as the sheet
material is readily available in the roll form, and CNT film can
be used as an outer ply and co-cured using conventional
composite manufacturing processes. As-processed CNT-based
laminates, tubes, and panels do not need to be scuffed to
expose conductive carbon fibers. Applying the CNT sheet as an
outer ply is quite consistent with composite layup processes,
compared to conducting extensive surface preparation of an
aluminum foil to bond it as an outer layer on composite
substrate for EMI/ESD. However, it must be recognized that Al
foil on composite substrate also provides faraday-cage and ease
of grounding at different joints/interfaces of the spacecraft bus
structure. Therefore, CNT sheet/layer can be used for
spacecraft components primarily to provide ESD, or in some
cases, ESD/EMI protection. Also, CNT sheet being thinner and
lower density than Al foil provides >50% mass savings in the
outermost layer of composite.
Using the results of this preliminary trade study, spacecraft
designers identified a few composite tubes and sandwich
panels to establish the materials and processing steps for proto-
flight or flight components.
17
D. CNT-based Materials and Processes for Protoflight
Composite Components
Consistent with conventional composite manufacturing
processes, CNT sheet materials specifications and processing
guidelines were established to produce tubes, laminates, and
sandwich panels. For example, tubes were manufactured by
applying the CNT sheet wrapped as an outer ply on the
underlying composite lay-up, and manufactured by conven-
tional autoclave process, thus yielding a well-consolidated
CNT-based composite tube. However, to manufacture
composite sandwich panels, it was best to use CNT/CE prepreg
as the outer ply on both sides of the sandwich panel and to co-
cure the assembly in the oven.
Using these materials and processing guidelines, a few
CNT/ (M55J/CE) composite tubes and sandwich panels were
fabricated. The ESD performance of each composite part was
verified to be consistent with the spacecraft structures require-
ments. For example, the surface resistivity values were
consistently ~1 to 10 ohm/sq. Compression testing of the
CNT/composite tubes (Fig. 6a) was conducted to ensure that
the average stiffness and strength values were equal to or better
than the baseline M55J/CE composite. The CNT/(M55J/CE)
sandwich panels were tested using the four-point bend/flexure
tests (Fig. 6b). Results of flexure tests indicated that the
average facing bending strength of CNT-based panels was
equivalent or better than M55J/CE panel without co-cured
CNT sheet.
E. CNT Technology Insertion on to Juno Spacecraft
After establishing the materials and processing guidelines,
and verification of ESD and mechanical performance, space-
craft designers felt confident to identify an opportunity to
process CNT-based composite parts for the Juno Spacecraft.
The following two types of composite parts were identified:
i) Tubular Struts: Rocket Engine Motor (REM) support struts
(15-cm-dia x 0.05-cm-wall thickness x 122-cm-long:
Quantity 2; and 15-cm-dia x 0.05-cm-wall thickness x 61-
cm long: Quantity 2). Fig. 7 shows the CNT sheet wrapped
as an outer ply on the underlying M55J/CE layup.
ii) One Engine Cover Sandwich Panel (~62-cm-dia, 10.3-cm-
high), as shown in Fig. 8. The engine cover was designed to
provide micro-meteoroid protection for the critical main
engine.
Specific layup for the engine cover panel is as follows:
• M55J/CE, 5 HS weave fabric
• 0.015-in. face sheet [+22.5-in., –22.5-in.]
• CNT (NCTI)/CE Outer ply (for ESD)
• 0.75-in. Flex Core, 2.1 pounds per cubic feet (pcf)
During the layup, trapezoidal gore sections of the
composite prepreg were cut at +/–22° off of warp direction.
Each of the gore sections were aligned along the radial
direction with about 2.54-cm overlap of adjacent gore section.

a) Compression Test b) Four-Point Bend Test
Fig. 6. Mechanical property testing of CNT/(M55J/CE) composite tubes and
sandwich panels.
Fig. 7. Layup of REM support strut with CNT outer layer on M55J/CE
composite.
Fig. 8. Configuration of Engine Cover Panel
Initially, the engineering development units of both the
REM support struts, and engine cover panel were processed,
and inspected for ESD, and mechanical performance. Results
of each test indicated that CNT-based composite parts,
exhibited properties quite consistent with the design require-
ments. Subsequently, the CNT-based REM struts, and engine
cover panels were fabricated as the flight hardware for the Juno
spacecraft bus structure. Fig. 9 shows the four REM support
struts (two at top, and two at bottom), installed on the Juno
spacecraft bus structure. Fig. 10 shows the engine cover panel,
with an aluminum lid, installed at the bottom of the spacecraft
engine. Each of these CNT composite parts satisfied all the
spacecraft system level tests.
The Juno spacecraft was launched on August 5, 2011, from
Cape Canaveral Air Force Station in Florida, USA. The Juno
mission is part of NASA’s New Frontiers Program where
scientists and industry partner to come up with projects to solve
certain science questions. The specific goals of the Juno
mission are to understand the origin and evolution of Jupiter.
With its array of instruments, scientists will use Juno to
investigate the existence of a solid planetary core, map the
planet’s magnetic field, determine the water content of the
atmosphere, and monitor the northern and southern auroras.
18
CNT REM
Strut
Fig. 9. CNT/(M55J/CE) composite struts supporting Rocket Engine Motor
(REM) on Juno spacecraft. Co-cured CNT layer provides ESD protection.
a) CNT Sheet outer ply on inner and outer surfaces of composite sandwich
panel.
CNT Engine
Cover Panel
b) Engine Cover panel installed on Juno Spacecraft structure
Fig. 10: Co-cured CNT-based composite sandwich structure as an engine
cover panel on Juno spacecraft to provide ESD Protection.
IV. CONCLUDING REMARKS
Advances in carbon nanotechnology offer an opportunity to
exploit the multifunctional properties such as the combination
of thermal, structural, and electrical attributes in composite
structures. In the last two decades, several composite-based
solutions have been investigated to develop a CNT-based
composite solution for spacecraft bus structure. More
specifically, using different nanocarbon allotropes, a few thin
membranes and sheets were fabricated and incorporated as an
outer ply on the composite substrate. In addition, a
commercially-available thin CNT sheet from NCTI, NH, USA
was also procured, and CNT/(M55J/CE) composite panels
were fabricated. Each of these nanocarbon sheet material-based
panels exhibited EMI shielding and ESD characteristics,
satisfying the typical spacecraft EMI/ESD requirements. In this
project, NCTI’s CNT sheet material was down selected for
design and fabrication of spacecraft composite components. It
was recognized that the use of the CNT sheet-based composites
with SOA manufacturing process offered cost and schedule
savings by eliminating the labor-intensive surface preparation
steps for composite surfaces, such as scuffing to expose
conductive carbon fibers, or apply an electrically-conductive
coating, film, or bond an Al foil to satisfy ESD requirements.
Proto-flight tubes, flat laminates, and sandwich panels, each
with a CNT outer ply on a composite substrate, were fabricated
using conventional composite manufacturing methods. Test
samples were prepared to conduct nondestructive inspection,
microstructural evaluation, mechanical property tests, and
EMI/ESD tests. Results of these tests indicated that the CNT/
(M55J/CE) composite parts exhibited excellent part integrity,
and measured mechanical properties were equivalent to the
baseline structural composite. In addition, these as-processed
composites consistently satisfy the ESD requirements for
spacecraft structures. Consequently, the spacecraft designers
identified two composite parts: REM support struts and engine
cover sandwich panel for the Juno spacecraft. Later, the tubes
with CNT outer ply on M55J/CE substrate were fabricated as
REM support struts. Also, two engine cover panels were
processed using the CNT/CE prepreg as an outer ply on the
M55J/CE substrate. Each of the CNT-based REM support
struts and Engine cover panels were subjected to component
level and system level tests. Each CNT/composite part satisfied
the mechanical and ESD requirements. Finally, the CNT-based
REM support struts and the engine cover panel were flown on
the Juno spacecraft which was launched successfully on
August 5, 2011. This opportunity was recognized as the first-
ever insertion of CNT-based composites on a spacecraft.
ACKNOWLEDGMENTS
This work was performed on the Lockheed Martin Space
System Company’s Independent Research and Development
Project, D-90D, under the task entitled, “Multifunctional
Materials and Composites.” Authors would like to express
special thanks to colleagues Jonathan Taylor, Nick Courtney,
and Sean Ley who were extremely helpful in fabrication,
testing, and insertion of CNT-based composites on the Juno
spacecraft. We sincerely thank Dr. David Lashmore and Jessica
Ravine of Nanocomp Technology Inc. and Nanotechnology
Laboratory, respectively, for several technical discussions
regarding processing of thin sheets of CNTs, MWNT, CNO,
and GnPs.
19
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