ATTRITABLE CERAMIC MIRROR FOR SPACE APPLICATION
Provided herein is a lightweight satellite component such as an optical mirror for aerospace applications and methods of making such lightweight components. The optical mirror comprises a graphite body and a SiC reflective layer formed on and integrated with the graphite body. The optical mirror is designed for demise upon re-entry into the Earth's atmosphere.
1 . A satellite component comprising:
a graphite body having a first outer surface coated with silicon carbide (SiC); and
a second outer surface positioned below the first outer surface, the second outer surface comprising exposed graphite.
2 . The satellite component of claim 19 , wherein the satellite component is a satellite payload comprising an optical mirror wherein:
the graphite body comprises a face plate and a support base;
the first outer surface coated with SiC is a reflective layer integrally formed on an outer surface of the face plate; and
the second outer surface is a bottom surface of the support based positioned beneath the face plate.
3 . The satellite component according to claim 2 , wherein at least a portion of the bottom surface of the support base is not coated with SiC.
4 . The satellite component according to claim 2 , wherein the SiC reflective layer is deposited on the outer surface of the face plate using chemical vapor deposition.
5 . The satellite component according to claim 2 , wherein the support base comprises a sidewall along a perimeter of the support base, the sidewall comprising graphite.
6 . The satellite component according to claim 5 , wherein the bottom surface comprises a plurality of ribs defining a plurality of openings, the sidewall comprising a plurality of access holes extending through the sidewall from an outer surface of the support body through the sidewall to the openings.
7 . The satellite component according to claim 6 , wherein the openings comprise exposed graphite and further comprising a bottom cover at least partially covering the bottom surface of the support base.
8 . The satellite component according to claim 2 , wherein the bottom surface comprises a plurality of ribs defining a plurality of openings, at least a portion of the plurality of ribs or a portion of the plurality of openings comprises the exposed graphite.
9 . The satellite component according to claim 8 , wherein the plurality of openings forms a series of circular ribs, a grid, an iso-grid, a tessellation, or a honeycomb structure.
10 . The satellite component according to claim 9 , wherein at least a portion of the plurality of the ribs or a portion of the openings is coated with SiC.
11 . The satellite component according to claim 2 , wherein the graphite body comprises an integrated graphite face plate and support base and the reflective layer is formed directly on the graphite of the face plate.
12 . The satellite component according to claim 2 , wherein the bottom surface includes a plurality of first portions coated with SiC, the plurality of first portions being separate from each other by a second portion of the bottom surface that is not coated with SiC.
13 . The satellite component according to claim 1 , wherein the second outer surface is configured to break into the plurality of first portions upon disintegration of the satellite component.
14 . The satellite component of claim 1 , wherein the satellite component is a structural strut.
15 . A method for making a satellite component, comprising:
providing a graphite body comprising a face plate and a support base, wherein the support base is positioned beneath the face plate and integrated with the bottom surface of the face plate; and
depositing a layer of SiC using chemical vapor deposition on the outer surface of the face plate, wherein a bottom surface of the support base positioned beneath the face plate comprises exposed graphite.
16 . The method according to claim 15 , further comprising:
applying a mask to the support base to prevent deposition of SiC onto a portion of the support base covered by the mask; and
removing the mask to expose the exposed graphite.
17 . The method according to claim 15 , further comprising:
depositing a layer of SiC using chemical vapor deposition on the bottom surface of the support base; and
mechanically removing a portion of the SiC deposited on the bottom surface of the support base to expose the exposed graphite.
18 . The method according to claim 15 , wherein the bottom surface comprises a plurality of ribs defining a plurality of openings, at least a portion of the plurality of ribs or a portion of the plurality of openings comprises the exposed graphite.
19 . The method according to claim 18 , wherein the plurality of openings forms a series of circular ribs, a grid, an iso-grid, a tessellation, or a honeycomb structure.
20 . The method according to claim 18 , wherein at least a portion of the plurality of the ribs or a portion of the openings is coated in SiC.