3D Printed/Additively Manufactured Titanium Alloy Fuel Tank: A Major Leap in the Space Industry
By Mufaddal Shakir
8/28/20252 min read
3D Printed/Additively Manufactured Titanium Alloy Fuel Tank: A Major Leap in the Space Industry
The Korea Institute of Industry Technology (KITECH) has achieved a significant breakthrough in the world of additive manufacturing by managing to 3D print a titanium alloy fuel tank for space travel application. This collaborative project was led by the Korea Aerospace Research Institute (KARI), KP Aviation Industries, Hanyang University, and AM Solutions.
A space rocket fuel tank is one of the most important components of a space vehicle. The majority of today's launch vehicles use liquid-fueled rockets. The fuel tank is designed to store this liquid fuel at extremely low temperatures (cryogenic conditions). The fuel tank must be lightweight and mechanically strong, capable of surviving extreme temperatures, pressures, chemical reactivity, and structural vibrations. The rocket fuel tanks are usually developed using the forging process, which is a time-consuming manufacturing technique. Thus, scientists have found a way to 3D print the fuel tank, which could save the manufacturing time.
3D printing of fuel tank
The fuel tank was 3D-printed using the Directed Energy Deposition (DED) technique, in which the fuel tank was created by melting and depositing Ti64 titanium alloy using a high energy source such as a laser. The fuel tank was printed in two halves and was then welded together. The diameter of the fuel tank was 640 mm. The 3D printing of the fuel tank was just completed in three days. The whole fabrication process was done in three weeks, which is faster in comparison to the traditional manufacturing.
3D printed fuel tank (Source: KAMIC)
Success in the durability test
The fuel tank was subjected to a critical durability test to see if it could survive the extreme pressure and lower temperatures in the space. The test involved placing the fuel tank in a closed chamber with liquid nitrogen at -196 ℃, and the pressure as high as 330 bar was applied. Result? The fuel tank remained intact and didn't even crack. The principal researcher, Dr. Lee Hyub, said that this test showed that large-scale 3D-printed structures can reliably withstand cryogenic and high-pressure conditions that simulate actual operating environments.
DED 3d printing of fuel tank (Source: KAMIC)
How will 3D printing change the space industry?
The team thinks they have paved the way for quicker, more individualized, and less expensive manufacture by demonstrating that a 3D-printed titanium tank can satisfy rigorous spaceflight requirements. Space industries may eventually be able to print parts to order and launch them much sooner than previously if those upcoming tests are successful.