1、 Standard AIAA S-081A-2006 Space Systems Composite Overwrapped Pressure Vessels (COPVs) AIAA standards are copyrighted by the American Institute of Aeronautics and Astronautics (AIAA), 1801 Alexander Bell Drive, Reston, VA 20191-4344 USA. All rights reserved. AIAA grants you a license as follows: Th
2、e right to download an electronic file of this AIAA standard for storage on one computer for purposes of viewing, and/or printing one copy of the AIAA standard for individual use. Neither the electronic file nor the hard copy print may be reproduced in any way. In addition, the electronic file may n
3、ot be distributed elsewhere over computer networks or otherwise. The hard copy print may only be distributed to other employees for their internal use within your organization. AIAA S-081A-2006 Standard Space Systems Composite Overwrapped Pressure Vessels (COPVs) Sponsored by American Institute of A
4、eronautics and Astronautics Abstract This standard establishes baseline requirements for the design, fabrication, test, inspection, operation and maintenance of composite overwrapped pressure vessels (COPVs) containing a separate metallic liner. These vessels are used for pressurized, hazardous or n
5、on-hazardous liquid or gas storage in space systems including spacecraft and launch vehicles. These requirements when implemented on a particular system will assure a high level of confidence in achieving safe and reliable operation. AIAA S-081A-2006 ii Library of Congress Cataloging-in-Publication
6、Data Space systems-composite overwrapped pressure vessels (COPVS) / sponsored by American Institute of Aeronautics and Astronautics ; approved by American National Standards Institute. p. cm. Rev. ed. of: American national standard space systems. 2000. “ANSI/AIAA S-081A-2006.“ Includes bibliographic
7、al references. ISBN 1-56347-842-0 (hardcopy) - ISBN 1-56347-843-9 (electronic) 1. Space vehicles-Equipment and supplies-Standards-United States. 2. Ballistic missiles-Equipment and supplies-Standards-United States. 3. Pressure vessels-Standards-United States. I. American Institute of Aeronautics and
8、 Astronautics. II. American National Standards Institute. III. American national standard space systems. TL795.A48 2006 629.472-dc22 2006010888 Published by American Institute of Aeronautics and Astronautics 1801 Alexander Bell Drive, Reston, VA 20191 Copyright 2006 American Institute of Aeronautics
9、 and Astronautics All rights reserved No part of this publication may be reproduced in any form, in an electronic retrieval system or otherwise, without prior written permission of the publisher. Printed in the United States of America AIAA S-081A-2006 iii Contents Foreword v 1 Scope. 1 2 Tailoring
10、. 1 3 Applicable Documents . 1 4 Vocabulary . 1 4.1 Acronyms and Abbreviated Terms . 1 4.2 Terms and Definitions 3 5 General Requirements . 7 5.1 System Analysis Requirements . 7 5.2 General Design Requirements . 7 5.2.1 Loads, Pressures, and Environments Requirements . 7 5.2.2 Strength Requirements
11、 8 5.2.3 Stiffness Requirements 8 5.2.4 Thermal Requirements 8 5.2.5 Margin of Safety Requirement . 8 5.2.6 Fatigue-Life Requirements . 9 5.2.7 Damage-Tolerance Life (Safe-Life) Requirements 9 5.2.8 Leak-Before-Burst Requirements 9 5.2.9 Stress-Rupture Life Requirements . 9 5.2.10 Mechanical Damage
12、Control Requirements 9 5.3 Materials Requirements . 10 5.3.1 Metallic Materials . 10 5.3.2 Composite Materials 10 5.4 Fabrication and Process Control Requirements 11 5.4.1 Liner Fabrication and Process Control . 11 5.4.2 Overwrap Fabrication and Process Control . 12 5.4.3 Corrosion and Corrosion Con
13、trol . 12 5.4.4 Embrittlement Control 12 5.5 Quality Assurance Requirements 12 5.5.1 Inspection Plan 12 5.5.2 Inspection Techniques . 12 5.5.3 Inspector Certification Program . 13 5.5.4 Acceptance Proof Test. 13 5.5.5 Data Documentation 13 5.6 Operations and Maintenance Requirements 13 AIAA S-081A-2
14、006 iv 5.6.1 Operating Procedures 13 5.6.2 Safe Operating Limits 14 5.6.3 Special Pre-launch Inspection and Pressure Testing 14 5.6.4 Inspection and Maintenance 14 5.6.5 Repair and Refurbishment . 14 5.6.6 Storage 15 5.6.7 Handling and Transportation Control . 15 5.7 Data Retention . 15 6 Verificati
15、on Requirements 15 6.1 Verification by Analysis 16 6.1.1 Stress Analysis 16 6.1.2 Fatigue Analysis 17 6.1.3 Damage-Tolerance Life (Safe-Life) Analysis . 17 6.1.4 LBB Analysis 17 6.2 Verification By Testing . 18 6.2.1 Fatigue Testing 18 6.2.2 Damage-Tolerance Life (Safe-Life) Testing . 18 6.2.3 LBB T
16、esting . 19 6.2.4 Mechanical Damage Testing . 20 6.2.5 Margin-of-Safety Testing 20 6.3 Acceptance Test Requirements . 20 6.3.1 Non-Destructive Inspection 20 6.3.2 Proof Testing . 21 6.3.3 Leak Testing 21 6.4 Qualification Test Requirements 21 6.4.1 Pressure Cycle Testing 22 6.4.2 Vibration/External
17、Load Testing . 22 6.4.3 Burst Testing 22 7 Bibliography . 24 Tables Table 1 Design Requirements Verification Matrix . 16 Table 2 Qualification Pressure Testing Requirements . 23 AIAA S-081A-2006 v Foreword This version of S-081 was developed in conjunction with launch-site operators and range safety
18、 authorities including the U.S. Air Force (USAF) 45th Space Wing, NASA Centers, and the Federal Aviation Administration (FAA) to ensure consistency and/or compatibility with local regulatory requirements that will be imposed on the space system customer. For space systems that operate on commercial
19、and federal ranges, it is necessary that the latest safety requirements document, e.g., AFSPCMAN 91-710 (which supercedes EWR 127-1), be identified as a compliance document, even though there is commonality with this AIAA standard. The requirements in this standard, as well as launch-site and range
20、safety requirements are intended to be tailored for specific missions by adding, deleting and modifying them as necessary to satisfy the manufacturer, customer and launch-site/range safety requirements. Launch-site/range safety approval of all requirements and the method of implementation or complia
21、nce are mandatory. Moreover, manufacturers that are engaged in the development of composite technologies for space systems are highly encouraged to involve the appropriate range safety authority and/or launch-site operator in the initial development process to ensure that the prototype design and de
22、monstration testing incorporate their input. The AIAA Aerospace Pressure Vessels Standards Working Group operates within the AIAA Structures Committee on Standards. It was formed in March 1996 with an emphasis on inclusion of aerospace prime companies, pressure vessel suppliers, and all applicable g
23、overnment agencies. Deliberations focused on adapting the standard to address commercial procurement of aerospace composite pressure vessels. One of the goals of the project is to provide a performance standard which can easily be used by commercial launch and re-entry vehicle operators in seeking l
24、icenses from the FAA/AST. Another goal is to assist the U.S. Department of Defense in its transition to procuring aerospace items on a commercial basis to the maximum extent possible. At the time of approval, the members of the AIAA Aerospace Pressure Vessels Standards Working Group were (* denotes
25、voting member): Henry Babel* The Boeing Company Keith Beckman* NASA Johnson Space Center Harold Beeson White Sands Test Facility Robert Biggs* Lockheed Martin Corporation James Chang* The Aerospace Corporation Marcus Darais* ATK Thiokol Tom DeLay* NASA Marshall Spaceflight Center John Dollberg NASA
26、Kennedy Space Center Wayne Frazier NASA Headquarters Marcus Gregg NASA Marshall Spaceflight Center Owen Greulich* NASA Headquarters Paul Griffin ATK Pressure Systems Michael Hersh MSH Consulting Michael Higgins* Carleton Technologies Jim Hurdle* General Dynamics/Armament and Technical Products AIAA
27、S-081A-2006 vi David Huff USAF 45th Space Wing Sri Iyengar* Lockheed Martin Corporation Jamil (Jim) Kabbara* FAA/AST-300 Lorie Grimes-Ledesma Jet Propulsion Laboratory Richard G. Lee Management to uncover unexpected system response characteristics; to evaluate design changes; to determine interface
28、compatibility; to prove qualification and acceptance procedures and techniques; to establish accept/reject criteria for non-destructive inspection (NDI); or any other purpose necessary to establish the validity of the design and manufacturing processes Dynamic Envelope the space or volume allocated
29、to a component which includes allowance for all displacements and deflections associated with the limit load Environments the environmental exposures (including humidity, temperature, vibration, acoustic, and radiation levels), which the COPV is subjected to after completion of manufacture and final
30、 inspection Elastically Responding Regions of the Liner a region of the liner of a COPV that responds elastically during autofrettage and at all pressures up to and including the acceptance proof pressure Fatigue the process of progressive localized permanent structural change occurring in a materia
31、l subjected to fluctuating stresses and strains at some point or points and which may culminate in cracks, or complete fracture after a sufficient number of fluctuations (cycles) Fatigue Life the number of cycles of applied external loads and/or pressurization that the unflawed pressurized item can
32、sustain before failure of a specified nature could occur AIAA S-081A-2006 5 Flaw a local discontinuity in a structural material such as a crack, void, delamination, etc. NOTE Flaws are the result of manufacturing defects. Flaw (Crack) Shape (a/2c or a/c) the shape of a surface flaw (crack) or a corn
33、er flaw (crack) in the liner where “a” is the depth and “2c” or “c” is the length of the flaw (crack) Hazard an existing or potential condition that may result in a mishap Hazardous Fluid/Material a liquid or gas that may be toxic, reactive, flammable, or may cause oxygen deficiency either by itself
34、 or in combination with other material Impact Damage an induced anomaly in the composite shell of a COPV which is caused by an object striking a vessel or vessel striking an object Launch-Site Operator the organization that governs and approves the safety requirements for the launch site Launch-Site
35、/Range Safety Authority the (government) entity that is responsible for the safety review and approval of a contractors design, analysis, and test program; hazard and risk assessments; and operating and maintenance procedures for meeting range safety requirements Leak-Before-Burst (LBB) a design app
36、roach in which, at and below MEOP, potentially pre-existing flaws in the metallic liner, should they grow, will grow through the liner and result in pressure-relieving leakage rather than burst or rupture NOTE LBB only applies to the liner and does not apply to the composite overwrap. Limit Load the
37、 maximum expected external load or worst-case combination of loads, which a structure may experience during the performance of specified missions in specified environments NOTE When a statistical estimate is applicable, the limit load is that load not expected to be exceeded at 99% probability with
38、90% confidence. Liner a component of a COPV upon which the composite material is applied NOTE In this document, the liner includes all bosses Loading Spectrum a representation of the cumulative loading anticipated for the COPV under all expected operating environments including significant transport
39、ation and handling loads. Margin of Safety (MS) MS =Allowable Load (Yield or Ultimate)Limit Load Factor of Safety (Yield or Ultimate) 1 NOTE 1 Load may mean force, stress, or strain. NOTE 2 Definition applies to a single loading condition (mechanical, thermal, or pressure). AIAA S-081A-2006 6 Maximu
40、m Expected Operating Pressure (MEOP) the maximum pressure at which the system or component actually operates in an actual application, it includes the effects of temperature, transient peaks, vehicle acceleration, and relief valve tolerance Maximum Ground Operating Pressure (MGOP) the maximum pressu
41、re to which a pressure vessel will be pressurized after loading with a specified fluid as part of the vehicle ground processing pre-launch checkout Mechanical Damage an induced anomaly in the composite shell of a COPV, which is caused by surface abrasion, cut or impact Mechanical Damage Control Plan
42、 (MDCP) a document that captures the mechanical damage threats to a COPV during manufacturing, transportation and handling, and integration into a space system up to the time of launch/re-launch, reentry and landing, as applicable, and the steps taken to mitigate the possibility of damage due to the
43、se threats Pressure Vessel a container designed primarily for the storage of pressurized fluids which (1) contains stored energy of 14,240 foot pounds (19,310 joules) or greater, based on adiabatic expansion of a perfect gas, or (2) contains gas or liquid which will create a mishap (accident) if rel
44、eased, or (3) will experience a MEOP greater than 100 psi (700 kPa) Procuring Authority the organization which places a manufacturer on contract to design, qualify, test and fabricate the COPV Proof Factor a multiplying factor applied to the limit load or MEOP to obtain the proof load or proof press
45、ure for use in the acceptance testing Pressurized Structure a structure or tank designed to carry vehicle structural loads while containing pressurized fluids EXAMPLE A typical example is the main propellant tank of a launch vehicle. Qualification Tests the required formal contractual tests used to
46、demonstrate that the design, manufacturing, and assembly have resulted in a design that conforms to specification requirements Residual Stress the stress that remains in a structure after processing, autofrettage, fabrication, assembly, testing, or operation; for example, welding induced residual st
47、ress Service Life the period of time or number of cycles which starts with acceptance proof testing with the associate determination of the state or nature of pre-existing flaws based on NDI or flaw-screening proof test and continues through all subsequent exposure to environments, including as appl
48、icable, handling, storage, transportation, service environments, refurbishment, re-testing, reentry or recovery from orbit, and reuse NOTE In the case that a launch-site pressure test will be performed, the service life includes this pressure cycle. Stress-Corrosion Cracking a mechanical-environment
49、al induced failure process in which sustained tensile stress and chemical attack combine to initiate and propagate a crack or a crack-like flaw in a metallic part of a COPV Stress Intensity Factor (K) a parameter that characterizes the stress-strain behavior at the tip of a crack contained in a linear elastic, homogeneous, and isotropic body AIAA S-081A-2006 7 Stress Rupture Life the minimum time during which the composite structure maintains structural integrity considering the combined effects of stress level(s), time at stress level(s), and associated
