Ultrasonic Tape Laminated Cryogenic Tank Structures Processed Outside Autoclave

Recent designs for large aerospace structures especially cryotank structures for the second and third Generation Reusable Launch Vehicle (RLV) are driving the aerospace community to develop out-of-autoclave composite manufacturing processes to save an estimated $30 million in autoclave capital equipment costs. In the Phase I effort, this process was demonstrated to produce excellent quality laminates typical for most of the thin regions of cryotank structure. In this proposed Phase II effort, Foster-Miller will further refine its Ultrasonic Tape Lamination (UTL?) technology coupled with its novel out-of-autoclave processing approach, controlled state curing, and demonstrate that reinforced regions cryotank structure can be fabricated with this novel methodology. The proposed Phase II program will also advance the state of art for the UTL? equipment by developing key articulation control mechanisms for complex contour fabrication. Foster-Miller will fabricate and deliver the resulting advanced UTL? head to NASA at the conclusion of the Phase II program. Foster-Miller will also fabricate a cylindrical demonstrator using both the advanced UTL? equipment and the refined controlled state curing technique. Northrop Grumman and Alliant TechSystems (ATK) supported the Phase I program, and both have agreed to cost share in the proposed Phase II program. (P-030587)