A unique titanium-lined, carbon fiber overwrapped Xenon storage pressure vessel was designed for an aerospace application. This tank has a nominal propellant volume of 1980 cubic inches and a nominal weight of 13.5 pounds. The operating pressure is 2500 psi, and the minimum burst pressure is 3750 psi. Due to limited space aboard the spacecraft, the tank was designed to fit within a conical envelope. This conical shape presented several major challenges for analysis, design and manufacture. Nonlinear material and geometric modeling techniques were used to analyze this tank. Stress analysis shows positive margins of safety for pressure cycle fatigue, vibration fatigue and minimum burst pressure over the design requirements. The liner was constructed from commercially pure (CP) titanium. CP titanium was chosen due to its relative high strength, excellent corrosion and oxidation resistance characteristics, superb weldability, good low and high cycle fatigue characteristics, and competitive manufacturing cost. The overwrap consists of high strength Torayca T1000GB carbon fiber and Shell Epon 826 cured resin system. Four composite layers were applied, two helical and two hoop wraps. A complete qualification program was conducted to verify the tank design, including two destructive burst pressure tests. A leak-beforeburst demonstration was also performed. The tank qualification program was successfully completed on 28 March 1996. Two tanks are required per spacecraft.
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