Form 9.B Project Summary

Chron: 971949

Proposal Number: 20.01-7653

Project Title: This proposal has not been assigned a title Advanced Low Density Tooling and Fabrication Processes for Reusable Launch Vehicles

Technical Abstract (Limit 200 words)

NASA launch vehicles such as X-33 and X-34 depend largely on composite technology to reduce launch weight. Composite cryogenic tanks have been fabricated and tested for liquid hydrogen storage (DC-XA Clipper Graham), but new innovations are required to produce LOX compatible composite structures. Innovative technologies are proposed herein to form LOX compatible liners for composite lines, ducts and cryotanks, The liners are produced in conjunction

with lightweight tooling foam mandrels which greatly reduce the weight of composite structure fabrication. The LOX compatible liners are applied either directly on foam mandrels and then overwrapped, or the liner can be appplied internally to the composite structure. Innovative thermal spray processes are used to form the liners out of non-metallics (i.e., fluoropolymers - FEP) and metal (i.e., aluminum). Tooling foam formulations will be demonstrated that dramatically reduce tooling cost and weight.

Potential Commercial Applications (Limit 200 words)

Applications include cryogenic storage vessels, ducts, manifolds, brewing tanks, water storage tanks, fuel oil and hot water tanks, medical and residential oxygen tanks, gas cylinders, hazardous waste containers, and protecting spacecraft from atomic oxygen. Tremendous potential in tooling for molds, mandrels, dies, and complex free form metal components near net shape.

Name and Address of Principal Investigator (Name,

Organization Name, Mail Address, City/State/Zip)

Timothy McKechnie

Plasma Processes Inc.

4914 D Moores Mill Road

Huntsville , Al 35811

Name and Address of Offeror (Firm Name, Mail Address,

City/State/Zip)

Timothy McKechnie

Plasma Processes Inc.

4914 D Moores Mill Road

Huntsville , Al 35811