Multi-level computational framework for assessment of damage evolution in satellite subsystems during launch

Purpose Main purpose of this research was to set up specialised numerical-experimental approaches for rapid re-design, testing and optimisation of micro- and nanosatellite components to boost new paradigms for faster and less risk-averse space mission developments. Design/methodology/approach The new numerical approach is tailored for rapidly integrated and tested spacecrafts for which critical stress-strain fields and damage mechanisms must be efficiently analysed at various levels and length scales. These range from macroscopic loads imposed by the rocket onto the satellite and its critical subsystems all the way down to damage evolution at micro scales. Findings The applicability of the new experimental-numerical approach has been tested on a real case scenario derived from the first Slovenian microsatellite mission NEMO-HD that required re-design of an optical backend subsystem due to a failure of a joint during pre-launch vibration testing. The proposed approach proved to be excellent for explaining failure causes and justifying applied re-design changes. The derisking approach was found to be very successful because the satellite continues to operate reliably after reaching more than 30.000 orbit cycles in the seventh successful year of remote sensing operations. Originality/value The coupling between the scales is achieved through mesh substructuring and boundary conditions based on the finite element method, while the bridging of scales is facilitated by phenomenological damage mechanics models and a very original implementation of FE2 method where digital twin microstructures for real engineering materials for space applications are homogenised at selected integration points of macro elements.