Responsible Engineer for the Aeon R test stand feedlines, designed for cryogenic environments, pressurized fluids, and thermal and dynamic loads.
Fuel and Oxidizer Feedlines
As the responsible engineer for the test stand fuel and oxidizer feedlines, I collaborated with manufacturing engineers, weld technicians, and test engineers to deliver the system within a 2 month timeline. The feedlines included multi-ply double-braided bellows, powder bed fusion 3D-printed components, machined flanges, spring-energized metal seals, and v-band clamps. I designed custom hydrostatic proof plates and Orbital Tube Welding (OTW) weld fixtures, and analyzed the feedlines for potential risks and failures. Following the analysis, I validated a backup set of feedlines to save $30,544 per set of feedlines while incorporating DFM and risk mitigation feedback.
Throughout the internship, I designed 39 unique parts, released 21 components and assemblies, and pushed the feedlines 2 weeks ahead of schedule.
In-House V-Band Design
On a tight 1-month timeline, I designed, analyzed, and manufactured in-house v-band clamps connecting the turbopump inlets to the feedlines based on gapping requirements and yield strength. I worked with manufacturing engineers and machinists to receive feedback on designing for manufacturing to deliver this component for engine testing as a backup option for the COTS v-band clamps. I also developed a more accurate method to analyze v-band joints on ANSYS to better model how the torque on the t-bolt translates into the sheet metal bands providing a uniform clamping force.