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 enormous autoclave capital equipment costs. In this proposed Phase I effort, Foster-Miller will demonstrate that autoclave equivalent mechanical properties can be obtained using its Ultrasonic Tape Lamination technology coupled with its novel out-of-autoclave processing approach, solid state curing. Preliminary data from work with Northrop Grumman on the second generation RLV cryotank manufacturing program already shows that this process is feasible by achieving 90 percent of the autoclave processed properties. Foster-Miller will utilize in house analytical equipment to perform the resin characterization essential for refining the UTL/solid state curing approach. Critical mechanical property testing will be performed to demonstrate autoclave property equity in the Phase I. Northrop Grumman will supply Foster-Miller with key logistical and tooling information to assess the cost saving potential of the refined UTL/solid state cure approach. The Air Force has shown significant interest in this technology and will be kept informed as UTL/solid state curing is developed in Phases I and II. (P-020642)