Big science and industry join forces to innovate new space technologies

Space exploration has led to many societal benefits that have vastly improved quality of life on Earth. The first satellites contributed critical knowledge and capabilities for telecommunications, global positioning, and advances in weather forecasting. Successful space exploration encompasses a broad range of missions requiring advanced systems and capabilities that will accelerate the development of many critical technologies, including advanced materials and structural concepts. Research innovating the materials behind space technologies as well as their manufacturing methods will pave the way for more successful space missions and applications for use on Earth. In 2016, the global space economy totalled $345 billion (€296 / £262 billion) worldwide; developing innovative technologies is key to ensuring Europe continues to play an important role in this global and highly competitive sector.   

Pooling European science and engineering resources for industry, across research techniques, is critical for innovation in space research, technology and its applications. This ethos is echoed in an agreement signed by the ILL and ESRF, establishing the intent to collaborate with leading European space companies OHB System AG and MT Aerospace AG to further the field. As the world’s flagship neutron and synchrotron facilities, ILL and ESRF will unite their best-in-class resources, facilities and expertise to tackle challenges together with OHB System AG and MT Aerospace AG experts in the field of advanced characterisation of aerospace materials and fabrication processes. Together, the two sister companies boast more than 85 years of heritage in aerospace programs. Satellites by OHB System AG cover the whole range of satellite applications - from telecommunications, Earth observation, navigation, reconnaissance to exploration and science. MT Aerospace AG, a technological leader in light-weight metal and composite engineering, develops and delivers key components for Ariane launchers, aeronautics and space vehicles.

Requirements for space missions are broad and can include high-performance materials for vehicle structures, propellant tanks and propulsion systems; lightweight, deployable and inflatable structures for space infrastructures and crew habitats; and systems for reducing launch mass and volume of parts such as antennae and booms to be deployed in space. These requirements also therefore present several materials challenges – amongst which they also need to be durable and functional in a hostile environment.

Advanced characterisation of aerospace materials and fabrication processes

To help further these studies, scientists and engineers are developing smarter materials and components to make more efficient devices and systems for space deployment. Mastering the methodologies that lead to new and better materials requires a detailed knowledge of their structure at the atomic or molecular level. As ILL’s neutrons are non-destructive and can explore deep inside matter, they are an ideal probe for most materials. ESRF’s high-energy non-destructive X-rays go far beyond lab-based X-ray beams, with their ability to penetrate deeply in large structures and provide atomic to micron-scale structural data using a huge range of techniques, including in-situ micro- and nano-computed tomography (CT). 

Together the collaborators will conduct prototype manufacturing of new materials, progressing from multi-parameter studies through to qualifying models for testing and flight approval. Without the knowledge from the deep-penetrating techniques provided by ESRF and ILL, many of these steps would have to be repeated from the beginning, wasting time and resources. Working with ILL and ESRF will give OHB System AG and MT Aerospace AG access to a Non-Destructive Investigation (NDI) tool which will enable investigation of large complex parts such as brackets, valves or tank and structures on the one hand, and electronic components and circuit boards on the other.

The cooperation with ILL and ESRF is an important cornerstone for competitive manufacturing technologies

Roland Schneider, Vice President and Head of Technology Programs, MT Aerospace AG

“Europe operates the most powerful network of large scale materials characterisation facilities, among which the ESRF and ILL are the world-leading flagships for probing matter with X-rays and neutrons. Employing these tools for the benefit of Europe's space industry is an enormous opportunity to further develop Europe's competitiveness in this technology sector. The agreement with OHB System and MT Aerospace is laying the pioneering groundwork for fully seizing this opportunity”, says Professor Helmut Schober, Director of the ILL.

“It is essential for a satellite manufacturer to permanently innovate and develop new concepts, new systems and processes. The use of new materials and corresponding manufacturing processes represent key levers to improve performance, reliability, or cost efficiency of our space products. Since the quality requirements for our products are so challenging, the verification of material quality in all steps of space systems implementation plays an increasingly important role. The new methods and technologies developed by our scientific partners will help us stay at the forefront of satellite technology and systems”, says Andreas Lindenthal, COO of OHB System AG.

“The cooperation with ILL and ESRF is an important cornerstone within our development activities for competitive manufacturing technologies. The agreement will enable a most effective and innovative collaboration between space engineers and researchers in various future development projects. Neutron beams and synchrotron rays are outstanding investigation methods for new materials for satellites and launch systems. They give a much better understanding of material behaviour in correlation with modern manufacturing processes”, adds Roland Schneider, Vice President and Head of Technology Programs, MT Aerospace AG.

Joining forces to tackle challenges

ILL will provide OHB System AG and MT Aerospace AG users with unique access to a complete world-leading suite of highly-specialised neutron instruments, supported by the expertise and know-how of experienced scientific and technical staff. The ILL’s extensive range of sample environment facilities accurately mimic real working conditions: extreme temperatures and pressures, magnetic fields, mechanical constraints and therefore will play an essential role in the analysis of the in-operando industrial processes critical to accelerating their innovations. A dedicated group of engineers and scientists will also assist with all aspects of the project, from defining the problem, through data analysis and final experimental reporting.

A Memorandum of Understanding was signed between all Parties, to express their intention to establish potential collaborations in the field of advanced characterisation of aerospace materials and fabrication processes for peaceful means, in areas mutually agreed.