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composite-propellant-tank's Introduction

composite-propellant-tank

Prototyping lightweight composite LOX and IPA tanks for LV4.

The good: the current PSAS CF airframe technology seems to offer fantastic tank factors if they can be used as propellant tanks, even given extremely conservative mass growth assumptions. This could give us the mass ratios to get LV4 above the von Karman line. Early conceptual design analysis for LV4 suggests that 280x700 mm modules are optimal.

The bad: Composites are hard...

  • Lack of established design criteria for composite tanks
  • Galvanic corrosion of composites in contact with metals
  • Composites degrade under extreme temperatures
  • Composites degrade in the presence of mositure
  • Difficult to detect defective adhesive bonds in composite structures
  • Difficult to maintain hermetic seals
  • Difficult to incorperate cutouts
  • Significant problems with CTE mismatch when used in conjunction with metallic structures

The Ugly: Proof-of-Concept Composite Fuel Tank designed and built by 2017 PSAS Capstone Team. Currently undergoing testing and refinement.

Summary of 2017 Tank Capstone Project Design Artifacts

  • Analysis

    • Calculations (Hand Calculations and Python Scripts)
    • Finite Element Analysis (Code, Results, and Documentation)
  • Design

    • CAD (Current and Archive)
    • Design Ideas
  • Documents

    • AIAA (Paper Abstract)
    • Materials (MDS and Property info
    • ME492 (Capstone Docs)
    • ME493 (Capstone Docs)
    • Research Documents (Literature Review Documents)
    • OSGC (Oregon Space Grant Award Info)
    • Presentations (Resources for project presentation)
    • Resource Documents (How Tos and Readme Docs for Git, Jupyter, etc.)
    • Safety (docs related to chemical safety)
    • Team Documents (Team Agenda, Meeting notes, Contacts, etc.)
    • Templates (Experiment Templates)
    • Doc Readme and Standards of Documentation
    • Media (Photos and Videos)
  • Manufacturing (Procedural documents)

  • Testing (Test results and procedures)

composite-propellant-tank's People

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composite-propellant-tank's Issues

Cryo-Test PTFE

We need to test PTFE samples with our adhesive and at cryogenic temperatures.

Stress analysis on Flat End Cap design

Back of the envelope calculations & analysis on Flat end cap, to determine how thick it needs to be to meet FS=2, as well as any bolt sizing changes to meet FS.

Move to github

We need to move all relevant information from google drive to GitHub.

Further LN2 Testing

Need to develop further LN2 tests, procedures, safety. Need to schedule appropriate time for said items.

Document types

Suggestion: Use markdown files or something else that GitHub can natively render where possible instead of non-free .docx files for project documentation.

Composite Propellant Tank Layup Procedure

  • Need to develop clear, well-defined, easily reproducible layup procedure for manufacturing the tank. (With focus on documentation/reproducibility for future teams)
    -Potential issues? Tough layup tasks or parts to incorporate? Securing liner, sealant, etc...
    -Start documenting things early once we get all parts here and begin prototyping, much can be reiterated/recycled from LV3 airframe.
    -Need a professional, clear, well-defined document before closing.

Gasket/Template Laser Cutting

Arrange time with MELT to get test PTFE cut to see if lasering gaskets is feasible. Cut gaskets, cut templates for layup procedure

Heat Transfer Analysis Refinement

Further refining heat transfer analysis to better understand overall heat xfer through tank, better represent temperatures at each interface etc..

Optimize Shrink-fit endcap / Compressed PTFE Design

-Need to determine ideal thickness of PTFE liner and corresponding initial endcap inset diameter that preserves mechanical seal during chill and fill process.
-Need to find reliable Elastic Mod and stress/strain behavior for given PTFE material at room and Cryo temps.
(Waiting on Manufacturer)
-Create optimization and FEA model for given interface.

FEA full modeling analysis

Begin developing full FEA model of the tank under current designs in order to locate stress concentrations due to pressure loads and thermal stresses. Will be able to use this to help determine thickness of lapping portion of ring design or any other necessary changes due to failure/stress concentrations.

LOX testing procedures & obtaining LOX

Need to develop testing procedures, safety, & location for experiments, as well as how/where/when we can obtain LOX. (Get in touch with liquid fuel test stand team as they are already working on this)

Calculations for end cap/mating ring

Calculate dimensions necessary for shrink fit

Contact surface area between end cap and matting ring if we were to do a shrink fit.
radius of end cap for shrink fit
etc

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