884. Aerospace Launch Vehicle Program Factors, Structures and Advanced Materials Cost-Performance Trade-Offs

Paper

Abstract

For a set of representative expendable-type aerospace launch vehicle structural components,
cost-performance tradeoffs including program factors, materials and construction technologies have been investigated. These investigations were primarily parametric.
The study was divided into two areas:
(1) Impact of program factors on the non-recurring and recurring manufacturing
cost for typical-expendable aluminum aerospace structures. The factors
included: quantity, production rate, separated facilities, facilities and tooling.
(2) Impact of changes in materials and construction, and safety factors on performance
(weight) and cost.
Investigation of the program factors was to identify primary cost drivers in the
manufacturing operation. Total quantities produced were found to have the greatest
influence on component cost. This was the direct result of high initial costs for facilities
and tooling to produce high reliability, minimum weight hardware. Advancements
in manufacturing technology appear to have little influence on reducing manufacturing
costs for future aluminum structures.
For the second area, aluminum integrally stiffened skin was used as the baseline
material and construction. Representative materials were chosen to span the advanced
material technologies. Materials included were aluminum, beryllium, and titanium for
the metals, boron and carbon fibers in an epoxy matrix for the resin composites, and
boron fibers in aluminum matrix for the metallic composites. The primary construction
was honeycomb. The advanced materials were lighter, but, with the exception of
carbon-epoxy, were substantially more costly than the baseline aluminum.