Systems and methods for launch vehicle dome manufacturing

1 . A method for forming a dome used in a launch vehicle, comprising:

cutting a disk from a plate, the disk having a first disk diameter;

forming a bend in the disk, the bend applying a curvature to at least a portion of the disk using at least one bump forming process performed on a bump forming machine, the disk having a second disk diameter after the forming;

performing a first heat-treating process to the disk, the first heat-treating process reducing residual stresses within the disk;

performing a second heat-treating process to the disk, the second heat-treating process increasing a strength of the disk; and

machining the disk to remove at least a portion of a thickness of the disk.

2 . The method of claim 1 , further comprising:

performing a tempering process to the disk, the tempering process increasing a ductility of the disk.

3 . The method of claim 2 , wherein the tempering process applies a -O temper designation to the disk.

4 . The method of claim 1 , further comprising:

quenching the disk after at least one of the first heat-treating process or the second heat-treating process, wherein water used to quench the disk includes glycol to slow heat transfer from the disk.

5 . The method of claim 1 , further comprising:

forming a flange onto the disk, the flange positioned along an outer diameter of the disk.

6 . The method of claim 1 , wherein the first disk diameter is greater than the second disk diameter.

7 . The method of claim 1 , further comprising:

determining the bend is within a threshold tolerance, via a fit check tool.

8 . The method of claim 1 , wherein the plate is formed from 2219 aluminum alloy.

9 . The method of claim 1 , wherein the second heat-treating process applies a -T62 temper designation to the disk.

10 . A method for forming a dome used in a launch vehicle, comprising:

cutting a disk from a flat plate;

increasing a ductility of the disk, via an annealing process;

shaping the disk into an elliptical profile, via a bump forming process performed on a bump forming machine;

reducing a residual stress in the disk, via a first heat-treating process;

increasing a strength of the disk, via a second heat-treating process; and

reducing a thickness of the disk, via a machining operation.

11 . The method of claim 10 , wherein the annealing process applies a -O temper designation to the disk.

12 . The method of claim 10 , wherein the elliptical profile is 2:1 width to depth ratio.

13 . The method of claim 10 , wherein the plate is formed from 2219 aluminum alloy.

14 . The method of claim 10 , wherein the second heat-treating process applies a -T62 temper designation to the disk.

15 . The method of claim 10 , wherein the annealing process is performed before the shaping, the first heat-treating process is performed before the increasing of the strength, and the second heat-treating process is performed before the reducing of the thickness.

16 . The method of claim 10 , wherein the shaping further comprises applying at least one bend to a portion of the disk, further comprising:

determining the at least one bend is within a threshold tolerance, via a fit check tool.

17 . A method for forming a dome used in a launch vehicle, comprising:

cutting a circular disk from a 2219 aluminum alloy plate, the disk having a first diameter;

forming, using a bump forming process performed on a bump forming machine, the circular disk into a dome having a 2:1 width to depth ratio elliptical profile, the dome having a second diameter;

performing an annealing process to the dome to reduce residual stresses within the dome;

performing a tempering process to the dome to increase a strength of the dome, the tempering process applying a -T62 temper designation to the dome; and

removing, using a machining process, at least a portion of a thickness of the dome.

18 . The method of claim 17 , further comprising:

performing a tempering process to the disk, prior to forming the dome, the tempering process increasing a ductility of the disk and applying a -O temper designation to the disk.

19 . The method of claim 17 , further comprising:

coupling the dome to a barrel section of the launch vehicle.

20 . The method of claim 17 , further comprising:

forming a flange onto the dome.