Electron Beam Additive Manufacturing of Upper Stage Propellant Tanks

This program is significant in that it represents a leap forward in electron beam (Ebeam) processes as well as liquid propellant tank designs. Mainstream will demonstrate the technical feasibility of Ebeam additive manufacturing (AM) for upper-stage liquid propellant tanks with Mainstream’s EBEAM facility by fabricating test coupons and subscale prototype components from novel materials. We will begin by modeling the proposed Ebeam AM method with an iterative process of beam parameter determination and Integrated Computation Materials Engineering (ICME) inputs. We will use this model and advanced material analysis instruments and techniques to fabricate and characterize the microstructures and mechanical properties of produced parts. These results will be used to evaluate complex structures/materials to design mission-specific liquid-propellant tanks that provide the greatest weight and cost savings ratio. Approved for Public Release | 18-MDA-9817 (23 Oct 18)