Design, fabrication and test of a liquid hydrogen titanium honeycomb cryogenic test tank for use as a reusable launch vehicle main propellant tank

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Scientific paper

Reusable Launch Vehicles (RLV's) utilizing LOX\LH2 as the propellant require lightweight durable structural systems to meet mass fraction goals and to reduce overall systems operating costs. Titanium honeycomb sandwich with flexible blanket TPS on the windward surface is potentially the lightest-weight and most operable option. Light weight is achieved in part because the honeycomb sandwich tank provides insulation to its liquid hydrogen contents, with no need for separate cryogenic insulation, and in part because the high use temperature of titanium honeycomb reduces the required surface area of re-entry thermal protection systems. System operability is increased because TPS needs to be applied only to surfaces where temperatures exceed approximately 650 K. In order to demonstrate the viability of a titanium sandwich constructed propellant tank, a technology demonstration program was conducted including the design, fabrication and testing of a propellant tank-TPS system. The tank was tested in controlled as well as ambient environments representing ground hold conditions for a RLV main propellant tank. Data collected during each test run was used to validate predictions for air liquefaction, outside wall temperature, boil-off rates, frost buildup and its insulation effects, and the effects of placing a thermal protection system blanket on the external surface. Test results indicated that titanium honeycomb, when used as a RLV propellant tank material, has great promise as a light-weight structural system.

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