Successful cryogenic pressure testing of additively manufactured titanium tank for space applications
June 25, 2025
A team from South Korea is reported to have successfully fabricated a spherical Ti-6Al-4V high-pressure tank, with a capacity of 130 litres and a diameter of 640 mm, using laser-wire Directed Energy Deposition (DED) Additive Manufacturing. The tank has demonstrated its structural integrity through a pressure test under cryogenic conditions, reportedly making it the world’s first successful metal AM pressure vessel able to withstand such extreme space-like environments.
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The joint research team consists of the Korea Institute of Industrial Technology (KITECH), Korea Aerospace Research Institute (KARI), KP Aero Industries, AM Solutions, and Hanyang University. KITECH was responsible for developing and implementing the DED Additive Manufacturing technology.
“This achievement proves that Additive Manufacturing technology is capable of meeting the extreme performance requirements demanded by space missions, opening new possibilities for aerospace component manufacturing,” explained Dr Hyub Lee, principal researcher at KITECH who led the project.
To satisfy stringent aerospace dimensional and structural requirements, two titanium hemispheres were individually manufactured and then joined through a sequence of heat treatment, precision machining, and welding to form a complete pressure vessel. During manufacturing, real-time monitoring using sensor data and optimised deposition path planning ensured dimensional accuracy and structural integrity. Non-destructive evaluation (NDE) confirmed the absence of defects, enabling subsequent cryogenic pressure testing.
The cryogenic proof pressure test was conducted under the supervision of KARI. The tank was cooled to -196°C using liquid nitrogen and stepwise pressurised to a proof pressure of 330 bar, exceeding the tank’s operational pressure requirement of 220 bar by the standard aerospace safety margin. Strain gauges, temperature sensors, and visual monitoring systems verified performance in alignment with prior structural simulations.
By eliminating the need for forging dies and extensive machining, the DED-based AM method is able to significantly shorten manufacturing lead times and enables rapid customisation for diverse satellite and launch vehicle configurations.
The team aims to pursue additional qualification processes and collaborate with private space companies to accelerate commercialisation of the technology across broader aerospace sectors.
