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Development of a lean production process for a thermoplastic composite upper stage propellant tank

Brandt, Lars and Deden, Dominik and Bruckner, Fabian and Engelschall, Manuel and Mayer, Monika and Schuster, Alfons and Nieberl, Dorothea and Frommel, Christoph and Krebs, Florian and Jarka, Stefan and Fischer, Frederic and Larsen, Lars-Christian (2020) Development of a lean production process for a thermoplastic composite upper stage propellant tank. SAMPE Europe Conference 2020, 30. Sept.- 01. Okt., Amsterdam, Niederlande.

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Private space flight disrupted the international launcher industry with an innovative spirit, tremendous funding and the objective to provide low cost access to space. In order to stay a relevant competitor the European launcher industry has to increase its launchers performance while reducing the manufacturing costs. The Center for Lightweight Production Technology (ZLP) of the German Aerospace Center (DLR) in Augsburg developed an innovative and data driven manufacturing process for a liquid hydrogen propellant tank. To account for the complex interior of the tank (e.g. fill level indicators and propellant management devices ) an integral design with thermoplastic CFRP LM-PAEK material was developed. Components were manufactured individually in an automated fiber placement (AFP) process and subsequently assembled by ultrasonic welding. This allows a reduction of complexity in individual parts and ensures easy installation of systems inside the tank. Throughout manufacturing inline quality assurance methods are used, the data is coupled with machine parameters and automatically evaluated. The paper gives an overview of the design approach, processes and methods to manufacture a scaled propellant tank demonstrator.

Item URL in elib:https://elib.dlr.de/140218/
Document Type:Conference or Workshop Item (Speech)
Title:Development of a lean production process for a thermoplastic composite upper stage propellant tank
AuthorsInstitution or Email of AuthorsAuthor's ORCID iDORCID Put Code
Brandt, LarsUNSPECIFIEDhttps://orcid.org/0009-0007-8608-0759UNSPECIFIED
Deden, DominikUNSPECIFIEDhttps://orcid.org/0000-0001-8959-8720UNSPECIFIED
Mayer, MonikaUNSPECIFIEDhttps://orcid.org/0000-0002-4448-9501UNSPECIFIED
Schuster, AlfonsUNSPECIFIEDhttps://orcid.org/0000-0002-7444-366XUNSPECIFIED
Frommel, ChristophUNSPECIFIEDhttps://orcid.org/0000-0002-3717-1087UNSPECIFIED
Krebs, FlorianUNSPECIFIEDhttps://orcid.org/0000-0001-6033-801XUNSPECIFIED
Fischer, FredericUNSPECIFIEDhttps://orcid.org/0000-0001-5421-4336UNSPECIFIED
Larsen, Lars-ChristianUNSPECIFIEDhttps://orcid.org/0000-0002-4450-8581UNSPECIFIED
Refereed publication:Yes
Open Access:Yes
Gold Open Access:No
In ISI Web of Science:No
Keywords:Produktion, Thermoplast, CFK, AFP, krygoner Tank
Event Title:SAMPE Europe Conference 2020
Event Location:Amsterdam, Niederlande
Event Type:international Conference
Event Dates:30. Sept.- 01. Okt.
Organizer:Sampe Europe
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Space
HGF - Program Themes:Space Transportation
DLR - Research area:Raumfahrt
DLR - Program:R RP - Space Transportation
DLR - Research theme (Project):R - Reusable Space Systems and Propulsion Technology
Location: Augsburg
Institutes and Institutions:Institute of Structures and Design > Automation and Production Technology
Deposited By: Brandt, Lars
Deposited On:11 Jan 2021 09:40
Last Modified:05 Dec 2022 14:37

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