Materials Challenges for Sustainability in Reusable Space Launch Systems

The Apollo and Space Shuttle programs are two examples where technical barriers were broken and significant materials and processing advances were made in a relatively short period of time. Today we undergo another boost in materials and processing technology with the private sector becoming very involved in launch vehicles, space transport, space stations, and lunar landers. In order to drive the cost of space travel down significantly, the launch systems must be reusable and efficient. They must also be as lightweight as practical, and withstand the mechanical rigors of multiple launches, the thermal stresses of re-entry, and corrosion issues related to oceanic recovery. Corrosion protection is an area where significant progress is being made in replacing hexavalent chromium surface treatments with more environmentally-friendly conversion coatings. This talk will focus on these challenges, and some of the steps being taken to overcome them.