The new Vega satellite launcher, which recently completed its maiden flight for the European Space Agency (ESA), is the first in what's expected to be a new class of launch vehicles with carbon-fiber composite shells. The Vega is designed to be a compact tool for economic launches into polar and low-Earth orbits for the multiple European satellites used for scientific and earth observation missions.
Design engineers are applying carbon-fiber reinforced (CFR) composites to satellite launch vehicles for the same reason they're using this material in cars, planes, and wind turbines: a higher strength-to-weight ratio than metals. That means you can make a large object lighter or a small one stronger. In the case of launch vehicles, keeping the vehicle small and making it stronger as satellites get bigger is the primary gain.
On Feb. 13, the first Vega satellite launcher, incorporating carbon-fiber composites, began its maiden flight from the Guiana Space Centre. (Source: S. Corvaja/European Space Agency)
The launcher was designed and developed in Italy by the Avio Group, the program's prime contractor. Unlike most other small satellite launchers, the Vega can send multiple payloads into orbit on a single trip. It will transport mainly lower-cost satellites weighing 300-2,500kg and is expected to ease the strain on the rest of the satellite infrastructure, which serves larger, more costly satellite launches.
"Vega is the first launcher that is entirely made of carbon fiber [composites], with advanced digital controls and high configuration flexibility that make it capable of launching satellites of different sizes and functionalities in the same mission," Francesco Caio, Avio's CEO, said in a press release.
Wow! I have many years experience in the aerospace industry. I have seen composites used, long ago, for upper stages, which operate in space. I have not seen that done for the while launcher. It should not be suprising considering what is being done for aircraft. This is really interesting and a real breakthrough.
naperlou, I was also surprised to see composites in a launcher. It just goes to show how tough carbon fiber composites can be. The fact that Vega has already completed its maiden flight says a lot.
I'd be interested to learn if the range-safety package had to be scaled up or down for the material change. The range-safety package is (usually) an explosive designed to rip open the booster in a controlled manner in case of loss of control. This permits the propellant to burn at altitude and at zero pressure (instead of in the thrust chamber).
Is it easier or more difficult to split the side of a composite booster?
Do these materials pose a risk once made airborn? Carbon fibers are certainly more dangerous than other materials (biologically) so if they atomize they may cause issues.
But even as a bulk material, will carbon fibers simply burn up or remain as a large object falling to earth and pose a blunt object risk?
TJ, those are interesting questions. I didn't find a lot of technical detail about the design. However, there's some info at this link (even though it's called a press kit):
Chuck, composites have been used in launchers before, but not for the entire shell. The reasons for their use are basically the same ones as in other aerospace apps: light weight and toughness. CFR composites just keep getting stronger. Here's some info from Hexcel:
3drob, if by airborne you mean more or less in flight, then no--CFR composites have been used in aircraft for several decades, including military aircraft:
@3drob: Inhalation of carbon fibers is not really all that dangerous, at least as far as inhalation of foreign substances goes. (When it comes to carbon nanotubes, it may be a different story). At any rate, the airborne concentration of carbon fibers produced by re-entry of a launch vehicle is likely to be extremely small -- the earth's atmosphere is really big, and fibers are likely to be widely dispersed by the time they reach ground level. Inhalation hazards are more of a concern for people working in composites manufacturing, where it is important to have adequate personal protective equipment.
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