Upper stage flight experiment (USFE) integral structure development effort

ocused composite tankage development program that is targeted to existing and future aerospace applications. AFRL/VS is developing a wide range of tank concepts that include linerless cryogenic tankage, self-healing cryogenic tankage, hydrogen peroxide compatible tankage, volumetrically efficient toroidal (donut shaped) geometries, and more. This paper will summarize the Upper Stage Flight Experiment (USFE) composite integral structure development effort. The integral structure refers to the stage skirt and the propellant tankage. These two parts are bonded together to form an integral structure. The USFE tank is the worldʹs first composite, common-bulkhead, medium-pressure vessel designed to be Class 1 Compatible with high concentrations of hydrogen peroxide. Lightweight hydrogen peroxide compatible tankage development is becoming increasingly important to the international aerospace community because it provides considerable benefits. Peroxide can be stored unpressurized and is relatively non-toxic, which makes it safer to handle and store compared to oxidizers such as hydrazine. In addition to being a viable bi-propellant oxidizer, hydrogen peroxide can also serve as a monopropellant for an attitude control system (ACS). Peroxide is not cryogenic, therefore, it does not require an on-board cryocooler, which makes it easier to meet mass budgets and to mitigate technical risk. Storability and ease of handling make high concentration hydrogen peroxide an ideal propellant for reusable launch vehicle (RLV) responsive upper stage applications.