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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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• Tank Test Article

• MSFC Test Facility

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• LN2 Pre-test series

• LH2 Cyclic Test

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• Burst Test

• Post·Test Evaluation

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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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• 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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• 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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• 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

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• 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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• 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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