CompositesWorld

SEP 2017

CompositesWorld

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SEPTERMBER 2017 60 CompositesWorld WORK IN PROGRESS composite case we've ever built," says Slaughter. In turn, the size of the casing's joined segments, and the loads it will experience in operation, also required a robust joint design. After it is completed, the casing for the CASTOR 300 segment will be subject to several full-scale tests. In one test, the case is locked in a fixture, filled with water, and the water is pressurized, using a mechanical piston. e case must withstand these high pressures to be cleared for operation — specifi- cally, for the NGL, a test pressure of >1,280 psi. In a separate test, using another fixture, engineers induce dynamic transverse and shear loads on the case like those induced by propulsion in an actual launch. Lastly the solid propellant, a mixture of oxidizer, fuel and binding polymer, is loaded into the case for static testing. e "live" motor is hori- zontally attached to a test stand abutting a thrust block to prevent movement, and then is fired. To date, the Air Force and Orbital ATK have invested a combined US$200 million on the NGL project. Orbital is currently producing and installing tooling with plans, upon successful completion of the final phase of testing, to begin full-scale manu- facturing in late 2018 or early 2019, with certification test flights planned for 2021. Launching into heavy orbital traffic e NGL development work is coming amid a flurry of new commercial space hardware activity as the main players in this arena seek to provide larger payload delivery capability with shorter turnaround times. In June, Space Exploration Technologies Corp. (SpaceX, Hawthorne, CA, US) delivered a 2,722 kg payload to the International Space Station via its Falcon 9 rocket, set a goal of two launches per month this year and is conducting tests on a larger version of Falcon 9, the Falcon Heavy. United Launch Alliance (ULA, Centennial, CO, US) is testing and building the new Vulcan line of launchers to replace its workhorse Atlas V and Delta IV rockets. Orbital ATK's initial plans for the NGL entail capturing four or five US national security satellites a year, projecting a cost reduction to the US government of US$600 million over 10 years via manu- facturing economies of scale and other process and procurement improvements. If it does, and if work on the NGL, thus far, is an indication, it will, composites will be a key to its success. Read this article online | short.compositesworld.com/OATK-EELV Michael R. LeGault is a freelance writer located in Houston, TX, US, and the former editor of Canadian Plastics magazine (Toronto, ON, Canada). mlegault@compositesworld.com PRESENTERS PRESENTED BY zoltek.com CHRIS THOMAS Director of Automotive Business USA EVENT DESCRIPTION: ere is a misconception that manufacturing carbon fiber parts can be prohibitively expensive. is webinar will focus on utilizing low cost manufacturing techniques to turn an economical carbon fiber into an affordable part that maintains advanced properties needed in automotive and other industries. We will explore specific manufacturing techniques along with the pros and cons of each. Our team of experts will help you find solutions to the challenges you face.. PARTICIPANTS WILL LEARN: • Common Challenges to Traditional Manufacturing Processes • Three Manufacturing Methods to Prevent These Challenges • How These Processes Can Be Put to Work For You How to Produce Affordable Carbon Fiber Automotive Parts September 27, 2017 • 2:00 PM EST REGISTER TODAY FOR WEBINAR AT: http://short.compositesworld.com/Zoltek927 TOBIAS POTYRA Director of Automotive Business for Europe

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