Composite Technologies for Exploration (CTE)

The Composite Technology for Exploration (CTE) Project developed and demonstrated critical composite technologies with a focus on weight-saving, performance-enhancing bonded joint technology for Space Launch System (SLS)-scale composite hardware to support future NASA exploration missions. Joints have been called the Achilles heel of composite structures because current metallic bolted joints account for very significant increases in cost and weight. In addition to improvements with composite joints there was also a need for improvements in the analytical capabilities required to predict failure modes in composite structures. CTE matured composite technology and produced important innovations across the discipline areas of materials, design & analysis, and advanced manufacturing. The goal of this project was to advance composite technologies that provide lightweight structures to support future NASA missions. CTE also supported the SLS payload adapter by maturing composite bonded joint technology and analytical tools to enable risk reduction.

The CTE project started in FY17 and was a multi-Center project led by Marshall Space Flight Center (MSFC) and supported by Glenn Research Center (GRC), Goddard Space Flight Center (GSFC), and the Langley Research Center (LaRC). The project was funded by the GCDP with the Spacecraft Payload Integration and Evolution (SPIE) Office in the Space Launch System (SLS) Program providing funding support over the first three years. The CTE team established the design criteria working with SLS SPIE and selected a point design as the baseline for CTE joint development and analysis comparisons. This point design was chosen based on challenging loads and geometries relevant to SLS-scale composite structures. The CTE project successfully completed all project milestones by demonstrating design, manufacture, and test of both the longitudinal (L-joint) and Circumferential (C-joint) test articles. The project demonstrated an out-of-oven manufacturing process for the longitudinal bonded joints on the SLS Payload Adapter Manufacturing Demonstration Article (MDA) as risk reduction for the payload adapter project. Due to the work of the CTE project the composite bonded joint technology was successfully infused into the SLS payload adapter and baselined by the SLS Payload Adapter project to reduce weight and manufacturing time. The CTE C-Joint Scale Up testing demonstrated 3D woven joint technology manufacturing, load carrying capability, predictive capability of associated structural models, and collected data that will enable future advancements.
The composite bonded joint technology is applicable to SLS scale joints and structures as well as lunar lander scale structures and joints. The project supported two of the STMD strategic framework categories; Go – Rapid, Safe, & Efficient Space Transportation and Land – Expanded Access to Diverse Surface Destinations. The CTE project advanced composite technologies providing lightweight structures to support future NASA exploration missions. In particular, the CTE project demonstrated weight-saving, performance-enhancing bonded joint technology and reduced risks for the SLS payload adapter. Further, the project advanced the state of the art in the detailed analyses of composite bonded joints.

Improved the analytical capabilities required to predict failure modes in composite structures.

Supported SLS payload adapter by maturing composite bonded joint technology and analytical tools to enable risk reduction.

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