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Design of aerospace reusable launch vehicle (RLV) structures offers diverse challenges due to stringent specifications in geometry, structural mass, integrity for thermal protection system and interfaces with propulsion, avionics and power systems. Airframe structures for RLVs should cater to the specified strength, stiffness and stability, and meet the functional and integration requirements of aerospace vehicles. To address these challenges, an integrated design cycle comprising load estimation, layout design, torsion box analysis and sizing of structural components is devised and presented. Verification of structural design is done by structural and thermo-structural analyses of the integrated airframe. Qualification of the airframe by integrated airframe test, thermo-structural test and acoustic test is also discussed.

Keywords

Airframe Structure, Integrated Design Cycle, Reusable Launch Vehicle, Thermal Protection System.
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