Project Overview
Objective: Identify the optimal material for constructing a satellite body capable of withstanding harsh space conditions while remaining lightweight, strong, and cost-effective. The project focused on evaluating mechanical properties, fatigue strength, electrical conductivity, and service temperature range of potential materials.
Design factors included strict constraints such as a 6-ton maximum weight, temperature resistance between -65°C and 125°C, and the need for low electrostatic conductivity to reduce charge buildup in orbit. The objective was to maximize fatigue strength while minimizing cost under these operating conditions:contentReference[oaicite:0]{index=0}.
Design Approach
The project team (Hunter Wagner, Dawson Scragg, and Jacob Dunne) used a systematic materials selection process inspired by Michael Ashby’s methodology. Multiple titanium alloys were screened and compared based on density, cost, fatigue strength, and service temperature range.
Through iterative analysis, Titanium Alloy Ti-15V-3Cr-3Sn-3Al (solution-treated and aged) was chosen as the optimal material. It offered a strong balance between high fatigue strength (6.36×10⁸ Pa at 10⁷ cycles), low density (4.43×10³ kg/m³), and thermal resilience (operational up to 487°C). The alloy also met requirements for low electrical conductivity—important for avoiding charge accumulation in satellite electronics:contentReference[oaicite:1]{index=1}.
Key Calculations and Results
- Outer radius (ro): 1.524 m
- Inner radius (ri): 1.4986 m
- Cross-sectional area (A): 0.24 m²
- Volume (V): 1.1027 m³
- Mass (M): 4885 kg (≈ 5.38 tons)
- Cost (C): $140,691 USD
- Maximum torsional stress (Tf): 196.7 MPa
These results confirmed that the selected titanium alloy met all strength and weight targets within acceptable cost limits for aerospace applications:contentReference[oaicite:2]{index=2}.
Why This Project is Important
Material selection is one of the most critical stages in aerospace design. In orbital environments, materials must resist thermal cycling, fatigue, and radiation exposure without excessive mass. This project highlights how systematic comparison of mechanical and thermal properties directly impacts performance, safety, and mission cost.
For satellite bodies, selecting a poor material can lead to catastrophic results—structural deformation, overheating, or charge accumulation damaging internal electronics. The careful analysis performed here mirrors industry-level selection processes used by aerospace manufacturers and government agencies like NASA.
What I Learned
This project deepened my understanding of how to compare and select materials for specific engineering environments. I learned how small variations in density, cost per kilogram, or modulus can drastically influence the feasibility of a design. I also gained practical experience using data-driven decision methods to balance multiple competing objectives—something engineers face constantly in the field.
Additionally, the work emphasized how material selection is not purely theoretical; it requires understanding fabrication, cost, and environmental performance together. This experience strengthened my foundation in both mechanical design and engineering economics.
Project Report
For the full presentation slides and data, view the project report below:
📄 View Presentation Report (PDF)