Properties of useful materials Tether properties and materials are dependent on the application. However, there are some common properties. To achieve maximum performance and low cost, tethers would need to be made of materials with the combination of high strength or electrical conductivity and low density. All space tethers are susceptible to space debris or micrometeoroids. Therefore, system designers will need to decide whether or not a protective coating is needed, including relative to
UV and
atomic oxygen. For applications that exert high tensile forces on the tether, the materials need to be strong and light. Some current tether designs use crystalline plastics such as
ultra-high-molecular-weight polyethylene,
aramid or
carbon fiber. A possible future material would be
carbon nanotubes, which have an estimated
tensile strength between , and a proven tensile strength in the range for some individual nanotubes. (A
number of other materials obtain in some samples on the nano scale, but translating such strengths to the macro scale has been challenging so far, with, as of 2011, CNT-based ropes being an order of magnitude less strong, not yet stronger than more conventional carbon fiber on that scale). For some applications, the tensile force on the tether is projected to be less than . Material selection in this case depends on the purpose of the mission and design constraints. Electrodynamic tethers, such as the one used on TSS-1R, may use thin copper wires for high conductivity (see
EDT). There are design equations for certain applications that may be used to aid designers in identifying typical quantities that drive material selection. Space elevator equations typically use a "characteristic length",
Lc, which is also known as its "self-support length" and is the length of untapered cable it can support in a constant 1
g gravity field. :L_c = \frac{\sigma}{\rho g}, where σ is the stress limit (in pressure units) and ρ is the density of the material. Hypersonic skyhook equations use the material's "specific velocity" which is equal to the maximum tangential velocity a spinning hoop can attain without breaking: :V = \sqrt{\frac{\sigma}{\rho}} For rotating tethers (rotovators) the value used is the material's 'characteristic velocity' which is the maximum tip velocity a rotating untapered cable can attain without breaking, :V_c = \sqrt{\frac{2\sigma}{\rho}} The characteristic velocity equals the specific velocity multiplied by the square root of two. These values are used in equations similar to the
rocket equation and are analogous to specific impulse or exhaust velocity. The higher these values are, the more efficient and lighter the tether can be in relation to the payloads that they can carry. Eventually however, the mass of the tether propulsion system will be limited at the low end by other factors such as momentum storage.
Practical materials Proposed materials include
Kevlar,
ultra-high-molecular-weight polyethylene,
carbon nanotubes and
M5 fiber. M5 is a synthetic fiber that is lighter than Kevlar or Spectra. According to Pearson, Levin, Oldson, and Wykes in their article "The Lunar Space Elevator", an M5 ribbon wide and thick, would be able to support on the
lunar surface. It would also be able to hold 100 cargo vehicles, each with a mass of , evenly spaced along the length of the elevator.
Shape Tapering For gravity stabilized tethers, to exceed the self-support length the tether material can be tapered so that the cross-sectional area varies with the total load at each point along the length of the cable. In practice this means that the central tether structure needs to be thicker than the tips. Correct tapering ensures that the tensile stress at every point in the cable is exactly the same. For very demanding applications, such as an Earth space elevator, the tapering can reduce the excessive ratios of cable weight to payload weight. In lieu of tapering a modular staged tether system maybe used to achieve the same goal. Multiple tethers would be used between stages. The number of tethers would determine the strength of any given cross-section.
Thickness For rotating tethers not significantly affected by gravity, the thickness also varies, and it can be shown that the area, A, is given as a function of r (the distance from the centre) as follows: :A(r) = \frac {M v^2} {T R} \mathrm{e} ^ { \frac {\delta} {T} \frac {v^2} {2} \left( 1-\frac {r^2} {R^2} \right) } where R is the radius of tether, v is the velocity with respect to the centre, M is the tip mass, \delta is the material density, and T is the design tensile strength.
Mass ratio Integrating the area to give the volume and multiplying by the density and dividing by the payload mass gives a payload mass / tether mass ratio of: :\frac M m = \sqrt { \pi } V_r \mathrm{e}^{ {V_r}^2 } \mathrm{erf} ( {V_r} ) This equation can be compared with the
rocket equation, which is proportional to a simple exponent on a velocity, rather than a velocity squared. This difference effectively limits the delta-v that can be obtained from a single tether.
Redundancy In addition the cable shape must be constructed to withstand micrometeorites and
space junk. This can be achieved with the use of redundant cables, such as the
Hoytether; redundancy can ensure that it is very unlikely that multiple redundant cables would be damaged near the same point on the cable, and hence a very large amount of total damage can occur over different parts of the cable before failure occurs.
Material strength Beanstalks and rotovators are currently limited by the strengths of available materials. Although ultra-high strength plastic fibers (
Kevlar and
Spectra) permit rotovators to pluck masses from the surface of the Moon and Mars, a rotovator from these materials cannot lift from the surface of the Earth. In theory, high flying,
supersonic (or
hypersonic) aircraft could deliver a payload to a rotovator that dipped into Earth's upper atmosphere briefly at predictable locations throughout the tropic (and temperate) zone of Earth. As of May 2013, all mechanical tethers (orbital and elevators) are on hold until stronger materials are available.
Cargo capture Cargo capture for rotovators is nontrivial, and failure to capture can cause problems. Several systems have been proposed, such as shooting nets at the cargo, but all add weight, complexity, and another failure mode. At least one lab scale demonstration of a working grapple system has been achieved, however.
Life expectancy Currently, the strongest materials in tension are plastics that require a coating for protection from UV radiation and (depending on the orbit) erosion by atomic oxygen. Disposal of
waste heat is difficult in a
vacuum, so
overheating may cause tether failures or damage. ==Control and modelling==