Breaking the Sound Barrier: Carbon Fiber and E105 Epoxy 20,000 Feet Up

Austin Schader MatE 330 April 26, 2011

Background
When Calpoly Space Systems set their sights on breaking the 20,000 foot barrier in their next rocket launch, they knew they would need an advanced material. They selected E105 Resin and 205 Hardener from West Systems reinforced with carbon fiber prepreg sheets (Figure 1).

flutter that occurs when the high flight wind speed matches the natural frequency of the material.

Science
Carbon contains very strong covalent bonds in its hexagonal structure in each plane of hexagons, but weak bonds between each planes. During processing the strong planes are aligned in different directions depending on the application to create strength in the desired orientation. Additionally the fibers are processed to diameters of 10 m or smaller which minimizes surface defects promoting strength. These factors make carbon fiber one of the strongest materials (Figure 2).

Figure 1 - Carbon Fiber nose cone and fin can.1 Carbon fiber provides both a strong and stable nose cone and an excellent surface finish.

Carbon fiber was invented in 1879 by Thomas Edison for use in light bulb filaments. These fibers had high temperature resistance but a lower tensile strength and elastic modulus than modern carbon fibers2. Modern production began in the 1960s spurred by military requirements for aerospace applications such as high strength, high stiffness, and low density. Epoxys birth began when Russian Chemist Prileschajev synthesized epoxied groups from olefin precursors in the early 1900s3. A thermoset, epoxies provide a matrix for carbon fiber that creates excellent adhesion to fibers, low shrinkage in curing, and a wide variety of properties, as many resins and hardeners are available3. West Systems was founded in 1969 and produces epoxies for a variety of uses.

Figure 2 - Tensile Strength of common aerospace composites5.

E105 Epoxy from West Systems is an aromatic epoxide resin utilizing 205 Hardener. This combination allows for a shorter B-Stage (working time) and a very highly cross-linked polymer matrix for the carbon fiber. This high degree of crosslinking causes the matrix to become both stiffer and stronger. Together with carbon fiber a light, chemically resistant, strong, high dampening ability, and stiff material is created.

Application
The Calpoly Space Systems rocket is 15 tall, 6.25 inches in diameter, and weighs just under 50kgs4. The nose cone is 24 long. The overall surface finish must be as smooth as possible. During flight the nose cone experiences 8-9 Gs and must withstand wind speeds well over 600 mph4. In addition dampening ability must be maximized so the rocket does not experience

References
1.Carbon fiber fin: U.S. Rockets 2011, Cited 4/22/2011 http://vserv.com/usr/crr54mm.htm

2. History Carbon Fiber: Illstreet.Com 2011, Cited 4/22/2011http://www.carbon-fiber-hood.net/cf-history 3.Hempel: Hempel 2011 http://www.hempel.com/Internet/inecorporatec.nsf/ 4. CPSS information & Specs. R. Bauer, Aero 3rd Year, 4/22/2011 5.Tensile Strength: Bike 2011 Cited 4/22/2011
http://www.bikehps.com/bst/acg/tensile_strength.gif