ross messinger and john pulley the boeing company … · structure, structural dynamics, and...
TRANSCRIPT
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Reusable Cryogenic Tanks
Thermal-Mechanical Cyclic Test of a Composite Cryogenic Tank for Reusable Launch Vehicles
Ross Messinger and John Pulley The Boeing Company
Huntington Beach, California
For 44th AIAAlASME/ASCE/AHS/ASC
Structure, Structural Dynamics, and Material Conference Special Session: Cryogenic Propellant Tanks and Integrated Structures for a Next Generation Reusable Launch Vehicle
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https://ntrs.nasa.gov/search.jsp?R=20030062263 2018-09-01T12:25:00+00:00Z
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• Tank Test Article
• MSFC Test Facility
• Test Plan
• LN2 Pre-test series
• LH2 Cyclic Test
• Repair
• Burst Test
• Post·Test Evaluation
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TaD' Slluctulal CIIDli,UlalillD .--__ ----:..R:.::e~usable Cryogenic Tanks
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Cryo-Insulation
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MIIC CryllgBnic IlluctUIB 'Bsllacility
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8-8 Tanlt TII61 SIIIUP
Vent Lines
MSFC·buUt Composite Intertank
Heritage Rockwell-built 8-ft Composite Tank
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Hydraulic Struts for Axial Load
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Cyclic 111S1 Plan and ACCIIRlPlishRlllnts Reusable Cryogenic Tanks
• Eight LN2 Pre-tests completed • Cold shock • Proof pressure (LN2) • Ascent axial load • Landing axial load • 10 simulated LN2 cycles
• 26 of 200 LH2 Test cycles completed - Fill and pressurize to over 40 psi - Apply over 600 Iblin axial launch load - Reduce pressure and load - Apply heat to TPS surface (Entry) - Apply over 800 Ib/in axial landing load - Repeat
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'isualfnsPBctilln Of Tanlt IntBrillr AftBr 5 eyefBS
• With the sump cover off, an inspection of the inside of tank was performed
• No visually apparent anomalies were observed in the tank skin
• A "tap test" of the bond of each of the 60 stringers from the lower end to the mid frame revealed no obvious soft areas or disbonds
• Visual inspection of each of the tension and shear clips common to the lower frame showed no clip or fastener failures or apparent movement
• While not conclusive of tank health, no change in tank appearance was evident through 5 cycles
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SlrainDa,a Reusable Cryogenic Tanks
• Large translation of the strain data was observed from some gages but not others, but since the data was linear, the behavior was concluded to be a gage or calibration issue rather than a structural problem
• Only four gages survived through all 26 LH2 cycles and burst test
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.LH2 Cycle Test - 28047
Cycle No. I
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Pressure (%)
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Large translation In strain results i I Pressure (psig)
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TPI TIJRlPlJratul1J Data Reusable Cryogenic Tanks -'-rolf
• Thermal data obtained on wall, within TPS, within insulation, and at all ' interfaces
• Adhesive bondline temperatures generally remained within established maximum and minimum limits
• Cryopumpin9, caused by liquid air evaporating away from the tank wall surface and blowing through the insulation, was evident locally
Evidence of I cryopumping iIi'
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Typical cryo fill temp. results
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Acoustic Emission Data Reusable Cryogenic Tanks
• Significant number of AE signals recorded during each LH2 or LN2 filling due to cold shock induced thermal stresses
• Tank pressurization (tension membrane load) caused a large number of AE hits
• Matrix cracking or crazing monitored at the beginning of the test series, with no structural integrity damage
• Fewer AE signals were detected during each subsequent equivalent cycle (Kaiser effect)
• A distinct peak of AE hits occurred when the pressure increased from the cyclic test pressure to burst pressurQo_~~~"~~~~. __ ~!:'''~'om ;,,;.: LH2 Cycle 1 AE data
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Sensor and installation in cryoi nsu lation
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Vacuum bag being removed from external patch along stri ngar 51.
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Burst location at stringer 51
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• Microscopy and C-scans revealed good tank wall consolidation
• Minimal microcracking (max. 2-ply depth) in the tank wall were found
• Blade-stringers were cracked in noodle area (probably due to thermal stresses)
• Some stringer flanges dis-bonded from the tank wall (probably due to burst test)
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Conclusion and RlJcoD/D/llndations Reusable Cryogenic Tanks
- Designed, built, and cyclic tested flight-weight graphite/epoxy LH2 tank under NASA MSFC Cooperative Agreement
-Integrated structure, cryo-insulation and TPS system with SHM instrumentation successfully demonstrated
-Eight LN2 Pretest Series tests completed -26 LH2 simulated mission cycles completed • Burst test demonstrated robust design
• Next building block in development of composite cryotanks for RLVs is fabrication and cyclic test of an even larger tank, with integrated wing and thrust structure, to demonstrate low-cost producibility and operability, and long-life, complex-loading capability
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