1. AAE 450 Spring 2008 Jesii Doyle 1/31/2008 Internal Structure, Mounting Materials Bulkhead Weight and Cost

2. AAE 450 Spring 2008 Bulkhead Weight and Cost  Assumptions –Max G-loading: 2G’s –Bulkhead position as shown in Figure 1 –Bulkhead loading as shown in Figure 1  Propulsion Options –LOX/LH2 –H2O2/RP-1 –HTPB/AP/Al *Dimensions and weights for each option provided by Dana Lattibeaudiere Structures Figure 1: Bulkhead Configuration Tank Engine External Skin Nozzle Bulkhead Bulkhead Inner Radius Nozzle Dia.

3. AAE 450 Spring 2008 Bulkhead Weight and Cost Structures Future Work  Internal support structure  CAD models - Internal structure

4. AAE 450 Spring 2008 Backup Slides  Prop. Specifications Structures

5. AAE 450 Spring 2008 Backup Slides  Prop. Specifications (Cont.)

6. AAE 450 Spring 2008 Backup Slides  MATLAB Code Results – Config. 2 LOX/LH2 Material Weight (kg)Cost (USD) Al 6061-T6160.2$442.20 Al 7075-T6121.2$334.45 Ti 6Al-4V137.6$29,353.00 Steel453.7$200.35 Fiberglass109.5$250,520.00 Carbon Fiber138.6$151,670.00 H2O2/RP-1 Material Weight (kg) Cost (USD) Al 6061-T62.3$6.35 Al 7075-T62.4$6.50 Ti 6Al-4V3.2$684.48 Steel4.7$2.09 Fiberglass2.3$5,269.20 Carbon Fiber2.1$2,305.80

7. AAE 450 Spring 2008 Backup Slides  MATLAB Code Results – Config. 2 (Cont.) HTPB/AP/Al Material Weight (kg) Cost (USD) Al 6061-T61.1$3.04 Al 7075-T61.1$3.12 Ti 6Al-4V1.5$328.02 Steel2.3$1.00 Fiberglass1.1$2,525.20 Carbon Fiber1.0$1,105.00

8. AAE 450 Spring 2008 Backup Slides  Global Governing Equations –Variables: Gs = Max. G-loading g = Gravitational constant = 9.80665 m/s^2 m = Weight applied to bulkhead (kg) rnozzle = Nozzle radius (m) w = Applied unit line load (Pa) a = Rocket stage radius (m) b = Inner bulkhead radius (m) t = Bulkhead thickness (m) –Requirements: Displacement <= Max. Displacement (y = -0.01m) Applied Stress <= Yield Stress

9. AAE 450 Spring 2008 Backup Slides  Governing Equations – Config. 2 –Calculation of Thickness Maximum Displacement E = Modulus of Elasticity (Pa) ν = Poisson’s ratio

10. AAE 450 Spring 2008 Backup Slides  Governing Equations - Config. 2 (Cont.) –Applied Stress Assume cantilever beam with square cross- section F.S. = Factor of Safety

11. AAE 450 Spring 2008 Backup Slides  Manufacturing Cost Estimations –Aluminum manufacturing: 1.2x Mat’l Cost –Steel manufacturing: 1.6x Aluminum –Titanium manufacturing: 2x Aluminum –Fiberglass structure manufacturing: 1.7x Aluminum Additional Safety Factor 3.0 Required –Carbon fiber manufacturing: 2x Aluminum

12. AAE 450 Spring 2008 Backup Slides  Bulkhead Configuration 1 Tank Engine External Skin Nozzle Bulkhead Inner Radius F Nozzle Diameter Stage Diameter

13. AAE 450 Spring 2008 Backup Slides  MATLAB Code Results – Config. 1 LOX/LH2 Material Weight (kg)Cost (USD) Al 6061-T6257.9$729.04 Al 7075-T6202.9$602.54 Ti 6Al-4V233.0$20,989.00 Steel744.3$388.69 Fiberglass177.1$198,880.00 Carbon Fiber227.6$104,060.00 H2O2/RP-1 Material Weight (kg) Cost (USD) Al 6061-T662.5$180.87 Al 7075-T647.5$146.37 Ti 6Al-4V54.6$4,926.90 Steel177.1$100.05 Fiberglass42.1$47,328.00 Carbon Fiber54.0$24,678.00

14. AAE 450 Spring 2008 Backup Slides  MATLAB Code Results – Config. 1 (Cont.) HTPB/AP/Al Material Weight (kg) Cost (USD) Al 6061-T621.4$86.37 Al 7075-T615.7$73.16 Ti 6Al-4V21.3$1,969.90 Steel60.7$73.29 Fiberglass16.5$18,591.00 Carbon Fiber17.8$8,189.40

15. AAE 450 Spring 2008 Backup Slides  Governing Equations – Config. 1 –Calculation of Thickness Maximum Displacement E = Modulus of Elasticity (Pa) ν = Poisson’s ratio

16. AAE 450 Spring 2008 Backup Slides  Governing Equations - Config. 1 (Cont.) –Applied Stress Assume cantilever beam with square cross- section F.S. = Factor of Safety

17. AAE 450 Spring 2008 Backup Slides  Manufacturing Cost Estimations –Cost/Rivet: $0.73/rivet –Labor hour/Rivet: 0.049 hr/rivet –Cost/Labor Hour: $52.00/hr –# Rivets = 6 * Circumference

18. AAE 450 Spring 2008 Backup Slides  References Cyr, Kelley, “NASA New Start Index Inflation Calculator,” Cost Estimating Web Site, NASA, May 2007. [http://cost.jsc.nasa.gov/inflation/nasa /inflateNASA.html. Accessed 1/28/08] Design Manual: Fiberglass Grating and Structural Products, Delta Composites, L.L.C., Houston, TX, 2007. Green, E.A., and Coulon, J.F., “Cost Considerations in Using Titanium,” AIAA Paper 67-400, Jun. 1967. Noton, Bryan R., “ICAM - Manufacturing Cost Design Guide,” AIAA Paper 81-0855, May 1981.

19. AAE 450 Spring 2008 Backup Slides  References (Cont.) Young, W.C., and Budynas, R.G., Roark’s Formulas for Stress and Strain (7th Edition), McGraw-Hill, 2002.