Light-weight and Low Cost Composite Cryotank

Lightweight and low cost cryotanks are an enabling technology for reusable space launch vehicles and hypersonic aircraft. Current state-of-the-art (SOTA) cryotanks are either metal lined composite overwrapped pressure vessels (COPVs) or linerless COPVs. Although a metal liner provides the desired sealing capability, a metal liner is not an optimal for a large size, lower pressure cryotank because they add unnecessary weight, cost, and manufacturing and operational risk. Linerless COPVs are the lightest weight option; however, current SOTA linerless composite cryotanks require thicker walls to limit the microstrain in the laminate that causes microcracks that lead to leaks. In order to meet DARPAs target performance weight and cost goals, the laminate thickness must be reduced. To address the space industrys need for lightweight and low cost cryotanks, SDC proposes a Phase I SBIR program to develop linerless composite cryotanks through the following innovations: 1) aligned CNT loaded resins to improve current SOTA cryo resin resistance to microcracking, 2) automated manufacturing for repeatability and reduced cost, and 3) embedded fiber optics for real time structural health monitoring. The estimated weight and cost savings due to using SDCs linerless cryotanks compared to current SOTA cryotanks is 67% and 50%, respectively.