Post Flight Analysis of an in situ Consolidated Thermoplastic Rocket Module with Integrated Fiber Optic Temperature Sensors

Kurzfassung

As part of a high-altitude research rocket mission, the Chair of Carbon Composites of Technical University Munich developed and implemented a manufacturing concept for a thermoplastic fiber composite module of a high-altitude research rocket. In the manufacturing concept, the Automated Fiber Placement process is combined with press-formed long-fiber-reinforced thermoplastic structures. The AFP-laminate and its joint to the LFT-structure is realized by in situ consolidation. The developed module is more than 40% lighter than the conventional aluminum modules and was launched in March 2019 as a structural part of the REXUS-23 rocket at an altitude of 75.42 km. The rocket had a “hard landing” as the main parachute did not open properly which led to considerable additional loads. The module was analyzed via computer tomography to investigate flight- or impact-induced defects. The concept was able to prove its airworthiness being the first in situ consolidated structural component of a rocket mission.