铝双层板结构撞击损伤的板间距效应实验研究

为了研究空间碎片对航天器防护结构的超高速撞击损伤特性,采用二级轻气炮发射球形弹丸,对铝双层板结构进行了超高速撞击实验研究.弹丸直径为3.97 mm,撞击速度分别为(2.58±0.08)km/s、(3.54±0.25)km/s和(4.35±0.11)km/s,板间距为10~100 mm.实验得到了铝双层板结构在不同撞击速度区间的后板损伤模式.结果表明,弹丸撞击速度一定时,后板弹坑分布随前后板间距的不同而不同.前板背面返溅影响区和后板弹坑分布区随板间距的增大而增大,各弹坑分布区扩散角随板间距的增大而减小.     

Debris cloud expansion studies

Properties of fragment clouds produced by hypervelocity perforation of metal plates have been experimentally investigated. Replica model techniques have been applied. Targets consisted of steel dual-plate systems. Projectiles were hard metal spheres of tungsten carbide (3 mm, 7 mm and 10 mm diameter, HRc 79) and steel spheres (6 mm and 12 mm diameter, HRc 63) at velocities ranging between 2.3 km/s and 4.5 km/s. Cloud expansion velocities have been measured by means of in-flight flash X-ray photograph series. Maximum and minimum fragment velocities at front and rear side of clouds have been determined. From impact crater patterns on witness plates, and X-ray photographs of debris clouds, projectile and shield fragments have been identified. It has been found that plate perforation holes and debris cloud parameters scale geometrically for 6 mm and 12 mm diameter steel and 7 mm and 10 mm diameter hard metal spheres. For the 3 mm diameter hard metal spheres only the maximum debris cloud velocity v_rmax scales; all other parameters show deviations, indicating non-uniformity of the plate perforation process at different plate thicknesses. The shape of the inner part of debris clouds of steel spheres is different from that of hard metal spheres, caused by the density difference. For steel spheres the debris cloud shape is a convex lense, the shape of the hard metal fragments becomes in the rear nearly hemispherical. Increasing of the impact velocity causes an increasing of the expansion velocity and a flattening of the debris clouds.     

Generation of transient vibrations on aluminum honeycomb sandwich panels subjected to hypervelocity impacts

This paper presents the results of a set of experiments aimed at discovering the main features of impact-induced vibrations on all-aluminum honeycomb sandwich panels, representative of the GOCE satellite's top floor, which is exposed to the orbital debris environment. The activity focused on the characterization of the vibrations induced in the vicinity of internal payloads by hypervelocity impacts occurring on the vehicle's external shell. More than 30 tests were realized by launching 0.8–2.3 mm aluminum projectiles in the velocity range 4–5.5 km/s on targets with tri-axial accelerometer assemblies mounted on both the front and rear face of the panel, at a nominal distance of 150 mm from the impact point. It was found that a hypervelocity impact produces in both the front and rear side of the sandwich panel a vibration environment which can be described through the shock response spectrum (SRS) of three different types of waves that can be distinguished on the basis of the acceleration direction: out-of-plane, in-plane longitudinal and in-plane shear. The influence of projectile mass and velocity on SRS appeared to vary with frequency, with the most significant difference in the range between ∼10³ and ∼10⁴ Hz. The results of whole experimental set were used to derive an interpolation law through standard techniques of nonlinear fit. The empirical equation obtained makes it possible to predict the near-field vibration environment produced by hypervelocity impacts with debris having given size and velocity, reproducing all the test data with an average uncertainty of ±6 dB.     

椭球弹丸超高速撞击防护屏碎片云数值模拟

低地球轨道的各类航天器易受到微流星体及空间碎片的超高速撞击.本文采用AUTODYN软件进行了椭球弹丸超高速正撞击及斜撞击防护屏碎片云的数值模拟.给出了三维模拟的结果.研究了在相同质量的条件下,不同长径比椭球弹丸以不同速度和入射角撞击防护屏所产生碎片云的特性,并与球形弹丸撞击所应产生的碎片云特性进行了比较.结果表明:在相同的速度下,不同长径比椭球弹丸撞击的碎片云形状、质量分布和破碎程度是不同的,随撞击入射角的增加弹丸的破碎程度增大,滑弹碎片云的数量增加;随撞击速度的增加,弹丸的破碎程度也增加.     

Development of a lightweight space debris shield using high strength fibers

In order to protect space structure against space debris impacts, it is indispensable to develop a shield with high strength materials. A high strength fiber is one of potential materials from a viewpoint of strength, lightweight, and flexibility. The purpose of this study was to develop a new lightweight shield composed of high strength fibers against medium size debris impacts. We developed four kinds of shields using Vectran fibers, and hypervelocity impact tests were carried out by a railgun accelerator. The experimental results showed that the developed shield could stop the polycarbonate projectile with 13 mm in diameter, 1 gram in weight, and 6.9 km/sec in velocity. Adoption of the high strength fiber in the bumper materials may reinforce the protection capability and reduce the weight drastically.     

5A06铝合金单层板超高速撞击弹道极限分析

日益增长的空间碎片对在轨航天器的安全运行构成了严重威胁,毫米级空间碎片的防护已成为航天器结构设计必须考虑的问题之一.航天器的蒙皮是抵御空间碎片超高速撞击的最基本防护结构.采用数值仿真并结合试验验证的方法,对5 mm厚5A06铝合金单层板承受2A12铝合金球形弹丸正撞击下的弹道极限进行了研究.研究表明,在验证实验速度范围内,数值仿真结果与实验结果吻合良好;使用数值仿真对实验速度以上的区间进行拓展研究,获得了其弹道极限曲线和弹道极限方程;数值仿真和实验结果与已有经验方程对比表明,经验方程与具体材料的弹道极限有较大偏差,因此,应具体问题具体分析.     

Debris clouds produced by the hypervelocity impact of nonspherical projectiles

The significant features of debris clouds produced by the normal impact of spheres are described and compared with the features of debris clouds produced by the normal impact of nonspherical projectiles. Projectile shape and orientation at impact are shown to have a significant effect on the ability of a single-sheet bumper shield to promote the breakup of the projectile and the dispersion of the projectile fragments. The debris clouds produced by the normal impact of spheres are “relatively benign” in terms of their potential for damage to the rear wall of a spacecraft. Debris clouds produced by nonspherical projectiles contain one or more very large fragments at their leading edge that significantly threaten rear wall integrity.     

铝球弹丸超高速正撞击薄铝板穿孔尺寸研究

利用2017-T4铝球弹丸高速正撞击不同厚度的2A12铝合金板,模拟空间碎片对航天器防护屏的高速撞击作用,分析铝合金板撞击穿孔尺寸特征。铝球弹丸直径为3.18mm~6.35mm,弹丸直径与铝板厚度之比dp/t为1.00~9.96,撞击速度为1.50km/s~6.98km/s,得到了铝球弹丸高速正撞击铝板的穿孔经验公式。实验结果表明:薄铝板高速撞击穿孔直径扩张率与弹丸直径、铝合金板厚度及撞击速度有关。当弹丸直径与铝合金板厚度之比dp/t一定时,薄铝板撞击穿孔直径扩张率随着撞击速度的增大而增大;当撞击速度一定时,薄铝板撞击穿孔直径扩张率与dp/t呈非线性关系,且随着dp/t的增加,对薄铝板撞击穿孔直径扩张率的影响减弱。     

Performance of Whipple shields at impact velocities above 9 km/s

The results of 18 impact tests performed on Whipple shields were compared to the predicted ballistic limits of the shields in the region where the impact velocity of the threatening particle was high enough to produce melting and incipient vaporization of the particle. Ballistic limit equations developed at NASA Johnson Space Center were used to determine nominal failure thresholds for two configurations of all-aluminum Whipple shields. In the tests, 2017-T4 aluminum spheres with diameters ranging from 1.40 to 6.35 mm were used to impact the shields at impact velocities ranging from 6.94 to 9.89 km/s. Two different aluminum alloys were used for the rear walls of a simple Whipple shield. The results of 13 tests using these simple Whipple shields showed they offered better-than-predicted capability as impact velocity increased and that the strength of the rear wall material appeared to have a smaller-than-predicted effect on the shield performance. The results of five tests using three configurations of a scaled Space Station shield - a plain shield at 0 degrees, two shields with multilayer insulation in the space between the bumper and the rear wall (also at 0 degrees), and two tests with the plain shield at 45 degrees obliquity - showed that these shields met their predicted capabilities.     

Response of composite materials to hypervelocity impact

Investigation of composite materials response to hypervelocity impact by space debris has been carried out. In order to simulate hypervelocity impact, a unique laser driven flyer plate (LDFP) system was used, generating hypervelocity debris with velocities of up to 3 km/s. The materials studied in this research were Kevlar 29/epoxy and Spectra1000/epoxy thin film micro-composites (thickness of about 100 μm). Both Spectra and Kevlar fibers are used in long-duration spacecraft outer wall shielding to reduce the perforation threat. The micro-mechanical response of different composites was studied and correlated to the fiber, the matrix and the fiber/matrix interface properties. Visual and microscopic examinations of the damaged area identified fiber debonding as the prevailing failure mechanism. On the basis of a simple energy balance model it can be stated that for Spectra/epoxy composite the dominant mechanism is new surface creation, whereas for Spectra surface-treated fibers/epoxy the fiber pull out is the dominant mechanism. For Kevlar/epoxy fiber, pull out mechanism plays an important role.     

Projectile density, impact angle and energy effects on hypervelocity impact damage to carbon fibre/peek composites

This paper explores the effects of projectile density, impact angle and energy on the damage produced by hypervelocity impacts on carbon fibre/PEEK composites. Tests were performed using the light gas gun facilities at the University of Kent at Canterbury, UK, and the NASA Johnson Space Center two-stage light gas gun facilities at Rice University in Houston, Texas. Various density spherical projectiles impacted AS4/PEEK composite laminates at velocities ranging from 2.71 to 7.14 km/s. In addition, a series of tests with constant size aluminum projectiles (1.5 mm in diameter) impacting composite targets at velocities of 3, 4, 5 and 6 km/s was undertaken at incident angles of 0, 30 and 45 degrees. Similar tests were also performed with 2 mm aluminum projectiles impacting at a velocity of approximately 6 km/s. The damage to the composite was shown to be independent of projectile density; however, debris cloud damage patterns varied with particle density. It was also found that the entry crater diameters were more dependent upon the impact velocity and the projectile diameter than the impact angle. The extent of the primary damage on the witness plates for the normal incidence impacts was shown to increase with impact velocity, hence energy. A series of tests exploring the shielding effect on the witness plate showed that a stand-off layer of Nextel fabric was very effective at breaking up the impacting debris cloud, with the level of protection increasing with a non-zero stand-off distance.     

The effect of projectile properties on target cratering

The effect of projectile properties on target cratering is evaluated for two basic target designs: a simple, half-space target and a half-space target protected by a shield. The comparison of unshielded and shielded target impacts is based on empirical evaluations and emphasizes the velocity range of 4–6 km/sec. A wider velocity range, 0–8 km/sec, is considered for evaluations of projectile property effects. This paper examines the effects of projectile strength, density, shape, size, velocity and particulation. It was observed that the presence of a shield amplifies the influence of projectile density, shape and size but mitigates the influence of projectile velocity. For shielded target impacts the properties of the projectile debris cloud behind the shield were used to predict the crater damage to the target.     

高速粒子撞击作用下LF6合金多层靶结构防护能力研究

针对总厚度为４ｍｍ的ＬＦ６合金双层靶和总厚度为２ｍｍ的三层靶进行了直径为２ｍｍ,速度分别为５．８和７．２ｋｍ／ｓ的ＧＣｒ１５粒子 撞击试验,并对双层靶进行了不同前靶厚度和靶间距的撞击试验,试验结果表明：与同样碰撞条件下半无限体靶上产生的破坏情况相比,多层靶被击穿的总厚度远淖于半无限体靶上形成的弹坑深度,采用多层靶结构可显著提高材料的抗高速粒子撞击能力,并大大降低航天器抗高速粒子撞击的防护结构的重量     

弹丸超高速撞击半无限厚铝板数值模拟

微流星体及空间碎片的超高速撞击威胁着长寿命、大尺寸航天器的安全运行,导致其严重的损伤和灾难性的失效.撞击损伤特性研究是航天器防护设计的一个重要问题.本文采用AUTODYN软件的Lagrange法对半无限铝板的超高速斜撞击和与其具有相同法向速度的正撞击进行了模拟,给出了不同撞击角和不同法向速度下半无限厚铝板弹坑深度、宽度、长度的变化规律及多弹坑的形成过程,并与经验方程进行了比较分析.结果发现:随撞击角的增加,弹坑的深度和宽度减小,而弹坑的长度增加;随撞击速度的增加弹坑的直径和深度增加;在撞击角大于70度时出现多弹坑.     

Analysis of transient vibrations on complex targets representing elementary configurations of GOCE satellite

In order to analyze the propagation of shocks due to hypervelocity impact of micrometeoroids and space debris on spacecrafts, it was necessary to analyze the high-frequency shock-propagation-dynamic on complex structures representative of real spacecraft structure. Objective of this research is the GOCE satellite due to its highly accurate accelerometer very sensitive to the micro-vibration environment. After a detailed analysis of the most-probable shock-propagation-path within the satellite, several representative targets have been designed. Then an extensive test campaign has been conducted on these targets exploring a wide range of impact conditions. As a result, a database was established which correlates the impact conditions in the experimental range (0.6–2.3 mm projectiles at 2.5–5 km/s) with the shock spectra on selected locations on various types of structural models. The behaviour of structural joints was also analyzed under shock conditions that are not normally reproduced by pyroshock testing. The database represent a fundamental tool in order to validate the numerical analysis that will be used to assess the vibration environment, due to in-orbit micrometeoroids and space debris at the accelerometer location. This paper presents the test procedure applied and the general results achieved.     

Observations and simulations of the low velocity-to-hypervelocity impact crater transition for a range of penetrator densities into thick aluminum targets

Projectile/target impact crater systems involving soda-lime glass/1100 aluminum, ferritic stainless steel/1100 aluminum, and tungsten carbide/1100 aluminum (corresponding to projectile densities of 2.2, 7.89, and 17 Mg (m³) at impact velocities ranging from 0.56 to 3.99 km/s were examined by light metallography, SEM, and TEM. Plots of crater depth/crater diameter ratio (p/D _c) versus impact velocity exhibited anomalous humps with p/D _c ranging from 0.8 to 5.5 between 1 and 2 km/s, with hypervelocity threshold or steady-state values of p/D _c (>5 km/s) ranging from 0.4 to 1.0; with the p/D _c values increasing with increasing projectile density in each case. This hump-shaped regime, with exaggerated target penetration depths, appears to occur because projectiles remain relatively intact and unfragmented. The crater geometry begins to change when the projectile fragmentation onset velocity (>2 km/s) is exceeded and fragmentation increases with increasing impact velocity. Computer simulations and validation of these simulations were developed which fairly accurately represented residual crater shapes/geometries and correlated experimentally measured microhardness maps with simulated residual yield stress contour maps. Validated computer simulations allowed representative extrapolations of impact craters well beyond the laboratory where melting and solidification occurred at the crater wall, especially for hypervelocity impact (>5 km/s).     

Hypervelocity impact computations with finite elements and meshfree particles

The ability of computations to model characteristics of hypervelocity impact is demonstrated using an algorithm for the automatic conversion of distorted finite elements to meshfree particles. The Lagrangian formulation tracks material boundaries and properties without the errors typical in an Eulerian formulation as the material traverses large distances. A computation of a sphere impacting a bumper is shown to reproduce three regions in the debris cloud that are observed in tests: a front region composed of droplets of melted projectile and target, a middle region of fragmented projectile, and a back region of spalled projectile. Additional computations reproduce the observed traits that result from variations in the projectile shape and obliquity. The computation of a projectile impacting spaced plates demonstrates the ability of the method to model the damage to the rear plate of a Whipple shield for spacecraft protection.     

Simulation of hollow shaped charge jet impacts onto aluminium whipple bumpers at 11 km/s

The computational technique of Smoothed Particle Hydrodynamics (as implemented in the hydrocodes AUTODYN-2D and AUTODYN-3D) has been used to simulate the impact of hollow shaped charge jet projectiles onto stuffed Whipple bumper shielding. Due to limited availability of material models, the interim Nextel/Kevlar-Epoxy bumper was modelled as an equivalent thickness of aluminium. Stuffed Whipple bumper shields are used for meteoroid and debris impact protection of the European module of the International Space Station (the Columbus APM). A total of 56 simulations were carried out to investigate the impact processes occurring for shaped charge jet impact. Sensitivity studies were carried out on the influence of projectile shape, pitch, yaw and strength at 11 km/s to determine the range of debris cloud morphologies. The debris cloud structure was shown to be highly dispersed, and no projectile remnant was observed at the centre of the cloud. The mass of an aluminium sphere producing equivalent damage to a shaped charge jet projectile was in the range 1.5 to 1.75 times greater than the mass of the shaped charge jet projectile. Upon loading by the dispersed debris cloud, the interim bumper failed by spallation, producing fragments moving at 2 km/s or less. The fragments distorted the rear wall (pressure wall) of the shield but did not perforate it. The experimental data show rear wall deformation but to a lesser degree. Perforation of the rear wall, observed for one test, was not reproduced by the simulation. Nextel/Kevlar-epoxy material models are required to reproduce correctly the interim bumper failure under debris cloud loading.     

Cost effective honeycomb and multi-layer insulation debris shields for unmanned spacecraft

Ways to improve the tolerance of unmanned spacecraft to hypervelocity impact are presented. Two new honeycomb and multi-layer insulation (MLI) shields were defined: (1) double honeycomb, and (2) enhanced or toughened MLI (with additional Kevlar 310 and/or Betacloth layers). Following hypervelocity impact testing, a new ballistic limit threshold was defined, based on rear facesheet perforation and witness plate damage characteristics. At 12 km/s, the ballistic limit of single honeycomb was 0.58 mm (aluminium sphere), rising to 0.91 mm for double honeycomb, 1.00 mm for double honeycomb with MLI and 1.17 mm for double honeycomb with toughened MLI. A damage equation, based on the modified Cour-Palais equation with ESA constants, was compared with the data and found to be conservative. The impact angle exponent was increased in order to reduce the equation under-prediction for the oblique incidence data. An equivalent rear wall thickness was defined in order to distinguish between shield types above 7 km/s. The spacecraft survivability analysis showed that the double honeycomb and toughened MLI significantly reduced the number of perforating particles over the baseline single honeycomb design. The mass increase of these shields is approximately 1.2 kg/m² for double honeycomb and 0.8 kg/m² for toughened MLI.     

Direct observations and comparison of crater cross-section microstructures in copper targets for aluminium projectiles impacting at 1.4 and 6.7 km s−1

Light and transmission electron microscopy observations of impact crater-related microstructures in copper targets have revealed dramatic differences in the extent and type of microstructures. For a crater formed by a 6.4 mm diameter aluminium (1100) spherical projectile impacting at 1.4 km s^–1, a narrow (20 m) recrystallized zone extended axially outward from the crater wall, with dislocation cells which increased in size extending from this zone. By comparison, a crater formed by a 3.2 mm diameter aluminium (1100) spherical projectile impacting at 6.7 km s^–1 exhibited a recrystallization zone extending more than 200 m axially from the crater wall, a connecting zone of increasingly dense microbands, having an axial width of about 2000 m. This zone converged upon a region of dislocation cells which increased in size away from the crater wall. These observations highlight important microstructural differences in cratered metal targets in the hypervelocity impact regime in contrast to the lower-velocity regimes where shock-wave and related ultra-high-strain-rate effects are unimportant.