Structural Concepts and Components

In Phase I, Microcosm demonstrated an all-composite cryogenic propellant tank fabricated out-of-autoclave. This revolutionary 42-inch LOX tank, tested with liquid nitrogen at 1.2 times maximum operating pressure, weighs 43% of one made of 2219 aluminum,and was produced for 15% of the cost. The design was scaled-up from our 10-inch IR&D tanks, one of which was the world's first all-composite LOX tank to be flown. Phase II refines the tank design and production process to achieve flight-quality for thelarger tanks. We first evaluate the Phase I tank, other SR-XM program tanks, and various material coupons. A more robust design will be developed, replacing the aluminum boss and fiberglass core with carbon-composite components. Carbon fabric coresdemonstrated at the 10-inch scale, were not used in Phase I due to thermal stresses between a scaled-up core and aluminum boss. Use of carbon-composite in both the boss and core material will essentially eliminate these thermal stresses and enable furtherscale-up. A Resin Transfer Molded (RTM) or Compression-Molded carbon-composite boss will be developed. The manufacturing process will be refined to improve consistency and repeatability. Three 42-inch tanks will be built and tested, including aflight-quality LOX tank to be delivered to AFRL.