Development and Characterization of the Integrally Stiffened Cylinder (ISC) Process for Launch Vehicles and Aircraft Fuselage Structures

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Development and Characterization of the Integrally Stiffened Cylinder (ISC) Process for Launch Vehicles and Aircraft Fuselage Structures

W. Tayon / M. Domack / J. Wagner / K. Taminger / E. Hoffman / S. Newman

Over the past decade, NASA Langley has led development of the Integrally Stiffened Cylinder (ISC) Process, a near-net shape, flow-forming technology. This innovative process is being evaluated for launch vehicle and commercial aircraft manufacturing. A thick-walled, cylindrical preform is flow-formed in a single operation into a thin-walled barrel with longitudinal stiffeners. The one-piece, stiffened barrels offer a direct replacement for conventional multi-piece welded or riveted structures. A cost-benefit analysis for launch vehicles estimated that the ISC process offers up to a 50% reduction in manufacturing costs and a 10% reduction in mass. NASA, the European Space Agency (ESA), and industry partners have teamed to manufacture 10-ft. diameter aluminum ISCs. The intent is to demonstrate the commercial viability of the process at a scale relevant to the commercial launch and aircraft industries. Development activities will be presented, including process scale-up, formability assessment, microstructural analysis, and mechanical property testing.