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Completed TRL 4 (started at 2, targeting 4)
We propose a novel composite cryogenic fuel tank to solve the issues of current thermosetting composites by capitalizing on the inherent crack-resistance, toughness and unlimited out-time of thermoplastic polymers. The breakthrough over the current metallic cryogenic tank is about 25% cost savings and 30% weight reduction at the 10-meter-diameter scale. After completing this project, the STMD program will enable advanced space exploration missions currently prohibited by thermoset resins as well as deliver about 30% cost and weight savings. We anticipate that lack of feasible thermoplastic materials could delay our project so MD simulation will be used to accelerate selection of materials for experimentation. Novel thermoplastic composite technology could provide reliable lightweight cryogenic fuel storage systems that can extend cryogenic storage duration from hours to years.
Reliable lightweight cryogenic fuel storage systems are important for NASA space exploration missions, because it can extend cryogenic fuel storage duration from hours to years. In addition, this technology enables increased efficiency, reduced weight, and improved capability for lightweight cryogenic propellant usage for both Artemis and future Mars exploration missions.
NASA identified manufacturability issues caused by the out-time limitation of thermoset material as the main challenge preventing the use of composite cryotanks. Thermoplastic resins have no out-time limitations. Recently, civilian aircraft manufacturing companies, military industries and DOD (DARPA) have made intensive efforts toward developing fabrication processes that would realize the benefits of thermoplastic resins in airframes. The proposed work enables increased efficiency, reduced weight, and improved capability for thermoplastic airframes as well as for cryogenic tanks.
By the end of the first year of tier 2, the technical requirements are defined and the candidate thermoplastic materials are selected by both MD simulation and experimental validation. The tier 1 study (May – July 2022) results confirmed higher cryogenic mode II fracture toughness (400% higher) of the candidate thermoplastic composites over the SOA baseline epoxy system, and provide a basic guideline for the tier 2 study. The new technology enables a broad range of missions such as landers, ascent stages, in-space transfer vehicles, habitats, and in-situ resource utilization (ISRU) operations and encompasses both in-space and extraterrestrial destination operation conditions. About 60% of the dry mass of a launch vehicle is due to the fuel and oxidizer tanks. The novel lightweight composite cryotank is expected to achieve about 30% weight and 25% cost savings over state-of-the-art (SOA) aluminum lithium alloy cryotanks at the 10-meter diameter scale, thereby enabling long-duration advanced human or robotic space exploration missions. In addition to NASA missions, potential customers include department of defense (DOD), military and civilian aerospace industries. The new technology enables a broad range of missions such as landers, ascent stages, in-space transfer vehicles, habitats, and in-situ resource utilization (ISRU) operations and encompasses both in-space or extraterrestrial destination operation conditions.
NASA has expended significant budget and time to develop a high-performance cryotank based on lightweight composites made with thermoset resins. Significant technology gaps remain due to manufacturing limitations imposed by thermoset resins. A new alternative approach is to utilize thermoplastic resins instead of thermoset materials. ‘In-silico’ molecular dynamics (MD) simulations can accelerate the material selection and development by screening for the most promising candidate materials and by providing molecular insight into the behavior of candidate materials. In parallel and coordination with simulations, engineers at LaRC develop coupon-level test methods to measure key performance parameters such as cryogenic toughness (resistance to microcracking), permeability to liquid oxygen (LOX) and liquid hydrogen (LH2) cryogenic fuels, and thermal expansion properties, and develop novel light weight composite materials for cryogenic applications.
Lightweight novel thermoplastic composite technology could extend cryogenic storage durations from hours to years. A tier I study confirmed that cryogenic mode II fracture toughness of the candidate thermoplastic composites exceeded that of the SOA baseline epoxy system by 400%, and the significant advancement is expected to achieve significant weight and cost savings over SOA metallic cryotanks.
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