Abstract: A composite tank for a reusable launch vehicle comprises a composite wall, having a first coefficient of thermal expansion. The composite wall comprises a first end, a second end, a central axis, which passes through the first end and through the second end, and a cylindrical interior surface. The composite tank also comprises slosh baffles, formed from a second material, having a second coefficient of thermal expansion that is different from the first coefficient of thermal expansion. Each of the slosh baffles is attached to the cylindrical interior surface of the composite wall. Each of the slosh baffles is annular and is separated from the cylindrical interior surface of the composite wall by a radial gap, selected, in part, based on a difference between the first coefficient of thermal expansion and the second coefficient of thermal expansion. The radial gap is configured to change responsive to changes in temperature of the composite tank.

Abstract: Methods and systems for restricting movement in a flow mixer of an exhaust duct, the flow mixer having a first row of flutes and a second row of flutes generally opposite to the first row of flutes, each flute being elongated and defining an elongated axis. At least two flute ties connect, or couple, together at least two flutes from the first row of flutes and at least two flutes from the second row of flutes. A retainer is coupled to the flute ties and extends generally perpendicularly to the elongated axis of each of the flutes from the first and second rows of flutes. The combination of the retainer and flute ties is configured to generally restrain relative movement between the flutes from the first row and the flutes from the second row.

Abstract: Methods and systems for restricting movement in a flow mixer of an exhaust duct, the flow mixer having a first row of flutes and a second row of flutes generally opposite to the first row of flutes, each flute being elongated and defining an elongated axis. At least two flute ties connect, or couple, together at least two flutes from the first row of flutes and at least two flutes from the second row of flutes. A retainer is coupled to the flute ties and extends generally perpendicularly to the elongated axis of each of the flutes from the first and second rows of flutes. The combination of the retainer and flute ties is configured to generally restrain relative movement between the flutes from the first row and the flutes from the second row.

Abstract: A method for reworking a ceramic structure. A portion of a first facesheet is removed from the ceramic structure to form a first aperture. The first facesheet comprises a number of layers of a first ceramic material. A portion of an inner section of the ceramic structure is removed to form a second aperture. The second aperture extends from the first aperture into the inner section. The inner section comprises a second ceramic material bonded to the first facesheet and has a lower density than the first facesheet. A ceramic replacement material is placed in the second aperture. A number of replacement ceramic layers are placed in the first aperture. Ceramic particles are placed between the first facesheet and the number of replacement ceramic layers. The ceramic particles are sintered to bond the number of replacement ceramic layers to the first facesheet.

Abstract: An engine exhaust nozzle comprises a plurality of CMC staves attached to one or more support rings arranged axially. The support rings provide a circumferential load path between the staves and for attaching the exhaust nozzle to the metallic engine components. The staves are fixed to the support rings with a spacing intended to accommodate for relative movement due to the difference in CTE for the CMC and metallic components and due to thermal gradients through the wall thickness. The resulting apparatus is lightweight, relieves the nozzle of thermal stresses, and is easier to manufacture and repair.

Abstract: An engine exhaust nozzle comprises a plurality of CMC staves attached to one or more support rings arranged axially. The support rings provide a circumferential load path between the staves and for attaching the exhaust nozzle to the metallic engine components. The staves are fixed to the support rings with a spacing intended to accommodate for relative movement due to the difference in CTE for the CMC and metallic components and due to thermal gradients through the wall thickness. The resulting apparatus is lightweight, relieves the nozzle of thermal stresses, and is easier to manufacture and repair.

Abstract: The present invention is directed toward a laminate composite structure and a method for fabricating a laminate composite structure, wherein the laminate composite structure comprises a solid laminate and a composite sandwich structure. The solid laminate includes a bend having composite pins inserted there through. The composite sandwich structure is comprised of a core material sandwiched between top and bottom composite face sheets.

Abstract: The present invention is directed toward a laminate composite structure and a method for fabricating a laminate composite structure, wherein the laminate composite structure comprises a solid laminate and a composite sandwich structure. The solid laminate includes a bend having composite pins inserted there through. The composite sandwich structure is comprised of a core material sandwiched between top and bottom composite face sheets.