MetPreg Fiber Reinforced Aluminum for Hard Upper Torso Spacesuit Components

Currently, NASA is seeking new technologies to be incorporated into their Hard Upper Torso (HUT) design for spacesuits that will be used in off-planet applications. This next generation of spacesuits will require technologies that are stronger and more durable than the current state-of-the-art materials that were used for previous space exploration. Touchstone proposes to replace the existing HUT materials with a lightweight high-strength metal matrix composite (MMC), known commercially as MetPreg. MetPreg is a fiber reinforced aluminum (FRA) composite composed of continuous alumina fibers within a pure aluminum matrix. Metal matrix composites such as MetPreg offer unmatched durability, and composite-adjacent strength to weight ratios, both of which are critical in remote and off-planet applications. Additionally, these materials permit repair, recycling, and remanufacturing opportunities that are seldom considered with traditional epoxy (thermoset) aerospace composites. Therefore, a metallic structure will provide many benefits in off-planet situations, especially regarding durability, maintenance, repair and off-gassing. Phase I of this study intends to prove the ability of MetPreg to be thermally formed into shaped coupons and maintain strength properties. As part of this study, Touchstone plans to manufacture 10 tensile samples and 5 hemispherical shaped coupons. 5 of the tensile samples will be tested to the appropriate ASTM standard and the 5 remaining samples are planned to be delivered to NASA for future vendor testing. 5 Hemispherical coupons will be manufactured to prove the ability to form coupons of MetPreg and manufactured for use within NASA HUTs and for use in future testing. All testing and learnings from this study will be supplied to NASA at its completion.
Benefits: Metal matrix composites such as MetPreg offer unmatched durability and composite-adjacent strength to weight ratios, both critical qualities in remote and off-planet applications. These materials permit repair, recycling, and remanufacturing opportunities that are seldom considered with traditional epoxy (thermoset) aerospace composites. Therefore, a metallic structure will provide many benefits in off-planet situations, especially regarding durability, maintenance, repair and off-gassing. MetPreg has no storage requirements and has no effective expiration date, simplifying the logistical requirements of a repair job. Furthermore, MetPreg patches can be welded onto the surface of the Hard Upper Torso components, allowing for quick repair. Weight reduction of aluminum HUTs is critical as historic suits with an aluminum HUT have significantly exceeded mass requirements set forth for Block 2 suits. Spacesuit weight reduction is critical as it reduces fatigue on the astronaut and can allow for additional weight to be allocated to other components such as the life support system. Previous aluminum HUTs were constructed from aluminum 6061-T6 which has an ultimate tensile strength (UTS) of 45 ksi, whereas MetPreg has a UTS of 210 ksi, which highlights a strength improvement of more than 4.5 times that of aluminum 6061-T6. Touchstone intends to continue its practice of engaging with a wide variety of industries with trade shows, corporate presentations, and engaging with already existing customers. Ease of market penetration will rely on Touchstone’s established long-term relationships with companies in this industry, such as NASA, Boeing, Lockheed Martin, SpaceX, Blue Origin and Sierra Space. Any possible user who is looking for a lightweight material with high temperature resistance, high strength, high durability, and low maintenance will benefit from the use of this product. The US Navy will likely be early adopter of the complex MetPreg geometries for applications of repair within and around corners. In addition, there are likely customers within the aerospace industry of any aircraft or spacecraft that needs curved surfaces without the maintenance challenges associated with polymer matrix composites.