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A titanium-lined, composite overwrapped pressure vessel (COPV) for helium pressurant storage was designed for a commercial spacecraft. This tank has a nominal propellant volume of 81.4 liters (4,967 cubic inches)

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Alt 03.05.10, 17:14
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Standart Design And Manufacture Of A Composite Overwrapped Pressurant Tank Assembly

A titanium-lined, composite overwrapped pressure vessel (COPV) for helium pressurant storage was designed for a commercial spacecraft. This tank has a nominal propellant volume of 81.4 liters (4,967 cubic inches) and a nominal weight of 11.7 kg (25.8 pounds). The maximum expected operating pressure is 331 bar (4,800 psi). Proof pressure requirement is 414 bar (6,000 psi), and the minimum burst pressure is 497 bar (7,200 psi).
The pressurant tank design is based on a flight-qualified pressurant tank to take advantage of its design and flight heritage. To minimize risk, the pressurant tank is designed to use only existing manufacturing technology, processes, and procedures. Manufacturing cost is minimized by using existing tooling to the fullest extent.
Nonlinear material and geometric modeling techniques were used to analyze this tank. Stress analysis showed positive margins of safety for pressure cycle fatigue, vibration fatigue and minimum burst pressure over the design requirements. Qualification testing verified the design margins and showed the design analyses to be conservative.
The liner is constructed from commercially pure titanium. This material was chosen due to heritage and for its superb manufacturability, relative high strength, excellent corrosion and oxidation resistance characteristics, good low and high cycle fatigue characteristics, and competitive manufacturing cost.
The overwrap consists of high strength Torayca T1000G carbon fiber and Epon 826 cured resin system. Several composite layers are applied, including helical and hoop wraps.
A complete qualification program was conducted to verify the tank design, including a destructive burst pressure test. The tank successfully completed qualification testing on 03 April, 2002. The production program is in progress. Over 10 flight tanks have been manufactured to date.

INTRODUCTION
A Helium pressurant storage pressure vessel with unique characteristics is needed for a commercial spacecraft. This tank must be high performance, light-weight, and designed to withstand severe operational loads. Additionally, this tank must be built with existing technology to minimize manufacturing cost and program risk. A titanium-lined, carbon fiber overwrapped tank was designed and manufactured to meet such a need. A sketch of this tank is shown in Figure 1.
1.JPG
The tank is mounted to the spacecraft by polar bosses located on the tank centerline axis. The ported end is the fixed end with a threaded attachment to mount onto the spacecraft structure. The blind end stinger boss, mounted on a slip joint bearing, is designed to accommodate the tank's axial growth during pressurization. Two pressurant tanks are required for the spacecraft.
This pressurant tank was designed to the requirements listed in Table 1 below:

Walter H. Tam and Paul S. Griffin Pressure Systems, Inc. and Arthur C. Jackson Jackson Consulting
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Dosya tipi: pdf AIAA2002-4349 Astrolink Pres.pdf (272,7 KB (Kilobyte), 6x kez indirilmiştir)
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assembly, composite, design, manufacture, overwrapped, pressurant, tank

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