1

Manufacturing and Testing of Propellant

Tank

A
Project report Submitted in partial fulfillment of the
requirement for the award of the Degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

By

K. LINGAMURTHY
O1063-A3158

SCHOOL OF CONTINUING AND DISTANCE EDUCATION

JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY
HYDERABAD-28
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ACKNOWLEDGEMENTS

With deep sense of gratitude, I acknowledge the guidance, help and active cooperation rendered
by the following people whose guidance has sustained the effort, which led to the successful
completion of this project.

My sincere thanks to Shri Y sreenivas Rao, Project Director, PGAD / RCI, DRDO for
providing me an opportunity to complete this project work.

I am extremely grateful to Shri P Srihari, Scientist ‘ G ’ , PGAD / RCI, DRDO, Kanchanbagh,

Hyderabad for his valuable guidance in carrying out the project work.

I take this opportunity to express my sincere thanks to Shri T Vikram Sc C, Shri K.

Ramprasad Rao, Shri M.P. Sagar for their co-operation in the completion of the project work.

I express my sincere thanks to Management of PGAD/RCI, Kanchanbagh, Hyderabad for

providing me an opportunity to carryout this project in PGAD/RCI. I also express my gratitude
to one and all for instant support and help rendered in completing the project.

I express the gratitude to my parents who made me what I am today. And last but not the least I
thank God for giving me an opportunity to carry out this work in such a great and prestigious
organization.
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ABOUT RCI / PGAD ORGANISATION

(Research Centre Imarat/ PROGRAMME ‘AD”)

Bharat Ratna Dr. A.P.J. Abdul Kalam, Hon’ble President of India was the Founder
Director of Research Centre Imarat (RCI), Ex-SA to Rakshamantri and Director General,
DRDO. As the name designates, the organization plays a key role over the rapid development of
various missile – PRITHVI, AGNI, TRISHUL, AKASH, DHANUSH and NAG under
Integrated Guided Missile Development Programme (a Programme of great National
Importance). Padmashree Dr. VK Saraswat, Distinguished Scientist is the present Director of
RCI and Chairman of Aeronautical Society of India, Hyderabad which in turn brings together
Scientists, Engineers, Academia and Industry too a common platform for dissemination of
knowledge and research information.
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Abstract

This project work addresses the design and manufacturing of elliptical propellant tank (80 lit) for
divert & attitude control system (DACS) of a flight main emphasis is made on the fabrication of
the propellant tank.

The Propellant tank are elliptical shape and are made of Aluminum alloy (ELI grade) in annealed
condition this report covers the quality of assurance requirements for fabrication of Propellant
tank. The Kill vehicle consist of first stage solid propulsion system & divert and altitude control
system (DACS). DACS thrusters (for vehicle translation) and reaction control system thrusters
(P/Y/R for altitude correction).

Rocket Thruster is used for attitude control of Missile, for which the DACS system is used, and
the propellant tank is used for storing the propellant .The Present Project deals with Fabrication
and testing of the propellant tank and it will be carried out as per ASME pressure vessel code,
the design part has been validated well before and our project work mainly emphasis on the
manufacturing process viz forging, welding and machining of the component level and sub-
component level. The testing part is also addressed in our project viz mechanical testing,
metallurgical test etc.
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CONTENTS

1.0 Project work ……………………………………………………………… 6

2.0 Introduction ………………………………………………………………. 6

2.1 Technical specifications of propellant tank……………………………………….. 6

2.2 Raw materials chosen for Propellant tank………………………………………….. 7

2.3 Material Properties…………………………………………………………………….. 7

2.3.1 Tensile properties………………………………………………………………….. 8

2.3.2 Fracture toughness…………………………………………………………………. 8

2.3.3 Microstructure……………………………………………………………………… 8

2.3.4 Surface contamination…………………………………………………………….. 8

2.4 Inspection of raw materials ………………………………………………………… 8

2.5 Components…………………………………………………………………………. 8

2.5.1 Hemispheres ……………………………………………………………………… 8

2.5.2 Other machined components …………………………………………………….. 9

2.5.3 Identification………………………………………………………………………. 9

2.5.3.1 Various Types of forging processes ………………………………………........ 9-12

2.5.3.2 Various Types of machining processes……………………………………... 12-16

3. Description ……………………………………………………………… 16

4. Design procedure……………………………………………………… 16-20

4.1 Estimation of inlet port diameter of the propellant tank (pneumatic side)………16

4.2 Estimation of outlet port diameter of the propellant tank (propellant side)……... 17

4.3 Estimation of inner dimensions of the propellant tank………………………….. 18

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4.4 Estimation of thickness of the propellant tank at crown and knuckle………….. 19

4.5 Estimation of lug dimensions…………………………………………………….. 19

4.5.1 Force due to direct load………………………………………………………… 19
4.5.2 Force due to moment…………………………………………………………… 19
4.6 Estimation of bolt strength torque required and factor of safety………………. 20
4.6.1 Initial stress due to screwing up forces ……………………………………….. 20
4.6.2 Stress due to external load…………………………………………………….. 20
5.0 Welding………………………………………………………………………………. 25-28

5.1 Materials for welding trails………………………………………………………... 25

5.2 Welding procedure specification ………………………………………………... 25

5.3 Procedure qualification record …………………………………………………. 25

5.3.1 Macro examination…………………………………………………………….. 25

5.3.2 Weld examination …………………………………………………………….. 25

5.3.3 Visual inspection ……………………………………………………………… 26

5.3.4 Penetration …………………………………………………………………….. 26

5.3.5 Incomplete fusion …………………………………………………………….. 26

5.3.6 Cracks………………………………………………………………………….. 26

5.3.7 Voids and Pores………………………………………………………………… 26

5.3.8 Undercut and root notches ……………………………………………………. 26

5.3.9 Mismatch……………………………………………………………………….. 26

5.3.10 Overlaps ……………………………………………………………………… 26

5.3.11 Radiographic inspection …………………………………………………….. 26

5.3.12 Cracks, undercuts, lack of fusion, lack of penetration …………………….. 26

5.3.13 Porosity, voids and inclusions………………………………………………... 27

5.3.14 Dye penetrate inspection …………………………………………………….. 27

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5.4 Welder qualification …………………………………………………………….. 27

5.4.1 Manufacturer shall identify trained welders…………………………………. 27

5.4.2 Qualification plan……………………………………………………………… 27

5.4.3 Test set-up…………………………………………………………………….. 28

5.4.4 Welding of propellant tank……………………………………………………. 28

5.5 Weld test coupons for batch qualification……………………………………… 28

5.6 Quality control requirement- weld pair ………………………………………… 28

6. Testing………………………………………………………………………………… 29-32

6.1 Inward goods inspection ……………………………………………………….. 29

6.2 Tensile test ………………………………………………………………………. 29

6.3 Impact test ………………………………………………………………………. 30

6.4 Hydraulic pressure tests…………………………………………………………. 30

6.4.1 Hydraulic proof test procedure……………………………………………….. 30

6.5 Strain gauging……………………………………………………………………. 31

6.6 NDT test

6.7 Hydraulic burst pressure test……………………………………………………... 31

6.8 Pneumatic leak test……………………………………………………………….. 32

7.0 Weight………………………………………………………………………………….. 32

8.0 Identification…………………………………………………………………………... 33

9.0 Packaging……………………………………………………………………………… 33

10.0 Certificates…………………………………………………………………………… 33

11. Conclusions…………………………………………………………………………….. 33

12. References……………………………………………………………………………… 33
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1.0 Project work

This project work addresses the design and manufacturing of elliptical propellant tank
(80 lit) for divert & attitude control system (DACS) of a flight main emphasis is made on the
fabrication of the propellant tank.

The fabrication of Propellant tank involves the following activities

1. Inspection of raw materials

2. Hot press forming of hemispheres
3. Testing and inspection of hemispheres
4. Machining of hemispheres
5. Qualification of welding schedule and operation (WPS & PQR)
6. TIG Welding
7. Inspection of welding
8. Machining of adapters and other components

The Propellant tank are elliptical shape and are made of Aluminum alloy (ELI grade) in annealed
condition this report covers the quality of assurance requirements for fabrication of Propellant
tank. The Kill vehicle consist of first stage solid propulsion system & divert and altitude control
system (DACS). DACS thrusters (for vehicle translation) and reaction control system thrusters
(P/Y/R for altitude correction).

2.1 Technical specifications

Material : Aluminum (ELI grade)

Design pressure : 60 KSC

Proof pressure : 66 KSC

Burst pressure : 190 KSC

Shape : Elliptical

Outer dia : Major axis 652 mm, Minor axis 424 mm

Thickness : 16 mm (at knuckle) 64mm (at crown)

Volume : 80 liters

Weight : 17 or 16 kg

Propellant : MON-10 and UH-25

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2.2 Raw materials:-

The hemispheres shall be manufactured by hot press forming from plates. The adapters shall be
manufactured from forged bars. The plates and forgings shall be in annealed condition and shall
confirm to aerospace standards respectively. The alloys shall be multiple melted and final
melting shall be vacuum consumable electrode melted and the chemical composition shall be
checked on one sample for every melt no of plates and forgings, and shall confirm to the
following specifications.

Element Minimum Maximum

Aluminum 5.50 6.50

Vanadium 3.50 4.50

Iron - 0.25

Oxygen - 0.13

Carbon - 0.08

Nitrogen - 0.05 (500ppm)

Hydrogen - 0.0125 (125ppm)

Yttrium - 0.005 (50ppm)

Others (each) - 0.10

Others (total) - 0.40

Titanium - Remainder

All the plates and forgings shall be supplied in annealed condition meeting their requirements
given in furnace temperature uniformity surveys and calibration of temperature controllers and
recorders shall be done in accordance with SAE AMS2750C

2.3 Material Properties:-

The plates and forged bars shall be checked for the following properties.

A batch for plates/forgings is defined as the plates or forgings produced from the same melt and
subjected to heat treatment in the same heat.
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2.3.1 Tensile properties: Three specimens in each of longitudinal and transverse direction
for each batch of plates and three specimens in longitudinal direction for each batch of forged
bars shall be tested for tensile properties and the results shall confirm to the following
requirements

UTS = 896 Mpa Min

0.2% ps = 827 Mpa Min

Elongation = 10% Min

(In 50.0 mm Gauge length)

2.3.2 Fracture toughness: - Three specimens for each batch of plates and forged bars shall
be tested for fracture toughness 3 and K1C value shall not be less than 55 Mpa √m . If a valid
K1C value is not obtained, the KQ (invalid K1C) shall not be less than 70 Mpa √m

2.3.3 Microstructure: - one specimen for each batch of plates and forged bars should be
subjected to metallurgical examination the microstructure shall be that structure resulting from
alpha - beta processing the microstructure shall confirm (I) or (ii) or (iii)

(I) Equiaxed alpha in a transformed beta matrix

(ii) Equiaxed alpha and elongated alpha in a transformed beta matrix

(iii) Partially broken and distorted grain boundary alpha with plate like alpha

A microstructure showing a continuous network of alpha in prior beta grain boundaries is not
acceptable

2.3.4 Surface contamination: - one specimen shall be checked by microscopic

examination at not lower than 100X magnification. It shall be free of any oxygen rich layer such
as alpha case or other surface contamination

2.4 Inspection clearance for raw materials:-

Inspection clearance for the plates and forgings mentioned above shall be provided by

2.5 Components:-

2.5.1 Hemispheres: The hemispheres shall be formed by hot press forming from the plates by
keeping allowance on both inner and outer diameter the forming shall be carried out in
accordance to the procedure. The time – temperature recorded for heating the blanks for hot
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pressing shall be maintained the press formed dish shall be machined on both sides the finished
hemisphere shall be subjected to dimensional inspection as per the respective drawing and dye
penetrant check on inside and outside surface and no surface crack and indications is permitted.
For each hemisphere thickness mapping shall be done at 8 equispaced locations at every 45
degree totaling to 32 locations and it shall meet the requirements specified in the drawing.

2.5.2 Other machined components:-

All the machined components shall be subjected to dimensional inspection as per the respective
drawings. All the threads shall be checked with GO/NOGO thread gauges duly calibrated. All
the components shall be dye penetrate check and no surface crack and indications are permitted.
The hardness shall be checked on three numbers of randomly chosen copper washers in
accordance with IS 1501 (part 2) and should not be more than 70 HV. For each batch of machine
setting for making V grove one component shall be randomly selected and a satellite impression
shall be taken from the groove and the same shall be inspected for the groove dimensions on
profile projector.

2.5.3 Identification:

Each component shall be given a unique identification number maintaining the traceability to the
raw material batch identification engraving etc.., which is detrimental to the function of pressure
vessel, shall not be marked on the shell.

2.5.3.1 Types of forging processes

There are basically three methods to make forged part

Impressions die forging

Impression die forging pounds or presses metal between two dies that contain a precut profile of
the desired part. Parts from a few ounces to 60,000lbs.can are made using this process. Some of
the smaller parts are actually forged well.

Process capabilities

Commonly referred to as closed die forging, impression-die forging of steel, aluminium, titanium
and other alloys can also produce an almost limitless variety of 3-D shapes that range in weight
from mere ounces up to more than 25 tons. Impression-die forgings are routinely produced on
hydraulic presses, mechanical presses and hammers, with capacities up to 50,000 tons, 20,000
tons and 50,000 lbs respectively.
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As the name implies, two or more dies containing impressions of the part shape are brought
together as forging stock undergoes plastic deformation. Because metal flow is restricted by the
die counters, this process can yield more complex shapes and closer tolerances than open-die
forging processes.

Part geometry's range from some of the easiest to forge simple spherical shapes, block- like
rectangular solids ,and disc like configurations to the most intricate components with thin and
long sections that incorporate thin webs and relatively high vertical projections like ribs and
bosses. Although many parts are generally symmetrical, others incorporate all sorts of design
elements that combine to make the forging very non-symmetrical.

Most engineering metals and alloys can be forged via conventional impression-die processes,
among them carbon and alloy steels, tool steels and stainless, aluminum and copper alloys, and
certain titanium alloys. Strain rate and temperature - sensitive materials ( magnesium, highly
alloyed nickel based super alloys ,refractory alloys and some titanium alloys )may require more
sophisticated forging processes and/or special equipment for forging in impression dies.

Cold forging

Most forging is done as hot work, at temperatures up to 2300 degrees F, however ,a variation of
Impression die forging is cold forging. Cold forging encompasses many processes -- bending,
cold drawing, cold heading, coining, extrusions and more, to yield a diverse range of part shapes.
The temperature of metals being cold forged may range from room temperature to several
hundred degrees.

Process capabilities
Cold forging encompasses many process bending, cold drawing, cold heating, coining, extrusion,
punching, thread rolling and more to yield a diverse range of part shapes. These include various
shaft-like components, cup- shaped geometry's hollow parts with stems and shafts, all kinds of
upset and bent configurations, as well as combinations.

Parts with radial flow like round configurations with center flanges, rectangular pets, and non- ax
symmetric parts with 3-and6-fold symmetry have been produced by warm extrusion .with cold
forging of steel rod, wire, bar, shaft-like parts with 3-planebends and headed design features are
not uncommon.

Typical parts are most effective in the range of 10lbs. or less; symmetrical parts up to 7lbs
readily lead themselves to automated processing. material options range from lower-alloy and
carbon steels to 300 and 400 series stainless, selected aluminum alloys, brass and bronze.

In the process a chemically lubricated bar slug is forced in to closed under extreme pressure. The
unheated metal thus flows into the desired shape. Forward extrusion involves steel flow in the
direction of ram force .it is used when diameter of the bar is to be decreased and the length
increased. Backward Extrusion, where the metal flows opposite to the ram force, generates
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hollow parts. In upsetting, the metal flows at right angles to the ram force, increasing diameter
and reducing length.

Open die forging

Open die forging is performed between flat dies with no precut profiles is the dies. movement of
the work piece is key to this method.

Larger parts over 20,000 lbs. and 80feet in length can be hammered or pressed in to shape this
way.

Process capabilities
Open- die forging can produce forgings from few pounds up to more than 150 tons. Called open-
die because the metal is not confined laterally by impression does during forging this process
progressively works the starting stock in to the desired shape, most commonly between flat-
faced dies .In practice, open- die forging comprises many process variations ,permitting an
extremely board range of shapes and sizes to be produced.

Practically all forgeable ferrous and non- ferrous alloys can be open- forged, including some
exotic materials like age- hardening super alloys and corrosion- resistant refractory alloys.

Open-die shape capability is indeed wide in latitude In addition to round, square, rectangular,
hexagonal bars and other basic shapes, open- process can produce:

* Step shafts- solid shafts whose diameter increase or decrease at multiple

Location along the longitudinal axes.

* Hollow cylinders in shape, usually with length much greater than the diameter of the part.
Length, wall thickness, ID and OD can be varied as needed.

* Ring-like parts can resemble washers or approach hollow cylinders in shape, depending on the
height/wall thickness ratio.

* Counter-formed metal shells like pressure vessels, which mat incorporate extruded nozzle and
other design features

Seamless rolled ring forging

Seamless rolled ring forging is typically performed by punching a hole, round piece of metal and
then rolling and squeezing the donut hole and to a thin ring. Ring diameters can be anywhere
from few inches to 30feet.

Process capabilities
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Ring forged by seamless ring rolling process can weigh less than 1 lb up to 350,000lbs., while
O.D's range from just a few inches up to 30- ft in diameter. Performance- wise, there is no equal
for forged, circular- cross section rings used in energy generation,mining,aerospace,off- highway
equipment and other critical applications .

Seamless ring configurations can be flat, or feature higher vertical walls. Heights of rolled rings
range from less than an inch up to more than 9ft.

Depending on the equipment utilized ,wall thickness / height ratios of rings typically range from
1:16 up to 16:1 , although greater proportions have been achieved with specially processing .In,
fact seamless tubes up to 48- in. diameter and over 20-ft long are extruded on 20 to 30,000-ton
forging presses.

High tangential strength and ductility make forged rings well suited for torque- and pressure -
resistant components, such as gears, engine bearings for aircraft, wheel bearings, couplings, rotar
spacers, sealed discs and cases, flanges, pressure vessels and valve bodies. Material includes not
only carbon and alloy steels, but also non- ferrous alloys of aluminum, copper and titanium, as
well as nickel-base alloys.

Machining

Machining is any of various processes in which a piece of raw material is cut in to a desired
final shape and size by a controlled material removal machining is a part of manufacturing many
material products

The machining is classified in to

 Turning
 Drilling
 Milling
 Shaping
 Grinding

Turning:-

Turning operations are operations that rotate the work piece as the primary method of moving
metal against cutting tool lathes are principal machining tool used in machining
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Fig-1: Schematic picture of turning machine

Milling:-

Milling operations are operations in which cutting tool rotates to bring cutting edges against
work piece milling machines are principal machining tools used in milling.

Generally there are two types of milling. They are

 Up milling
 Down milling
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Fig-2: Schematic diagram of Milling machine

Drilling:-

Drilling operations are operations in which holes are produced are refined by bringing a rotating
cutter with cutting edges at lower extremity in to contact with work piece. It is used in drill press

Fg-3 Schematic diagram of drilling

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Shaping:-

Shaping is a manufacturing process used for material removal in which work piece reciprocates.
It is the stationary cutting tool producing a plane surface the main difference between shaping
and planning is that in shaping tool reciprocates across stationary work piece while in case of
planning is opposite of shaping

Fig-4 Schematic diagram of Shaping

Grinding:-

It is a type of machining using an abrasive wheel as cutting tool each grain of abrasive on the
wheels surface cuts a small chip from the work piece via shape deformation grinding is used to
finish work pieces that must show high surface quality high accuracy of shape and dimension
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3. Description

DACS is a pressure fed bi-propellant liquid hot gas reaction system in which propellant
combination is MON-10 as oxidizer and UH-25 as fuel. The propellants which are stored in the
propellant tank are pressure fed to the thrusters by the high pressure gas stored in the air bottles.
The gas enters the propellant tank and pressurized the propellant by a deformable metallic
bladder. The bladder in the propellant tank shall ensure positive separation of the propellant and
pressurized gas.

The propellant tank is a positive expulsion type of tank, which ensures the propellant flow
through the outlet in any orientation of the missile. The capacity of the tank is approximately 80
liters, which gives a total impulse requirement of 372.78 KN-sec.the propellant tank consist of a
top dish assembly with an aluminum bladder and bottom dish assembly which are welded
together to form an elliptical propellant tank.

4. Design procedure

4.1 Estimation of inlet port diameter of the propellant tank (pneumatic side):

At any given time the maximum thrusters demand from the system is two divert
thrusters + one pitch +one yaw + one roll pair of thrusters. The estimated total propellant flow
for this demand is given
Max. Oxidizer flow rate : 11.0 kg/s
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Max. Fuel flow rate : 6.25 kg/s

Total propellant flow rate : 17.52 kg/s
Volumetric flow rate (V prop) : 15.27 kg/s

Taking an air bottles initial pressure of 36Mpa, final air bottles pressure of 7.4Mpa, regulator
outlet pressure (equal to propellant tank pressure) as 4.6 Mpa,

The final temperature is given by, Tf =Ti (pf/pi)(ᵞ-1)/ᵞ

Tf =188.83K

Initial pressure (pi) = 36.29 Mpa

Final pressure (pf) = 4.6 Mpa
Initial temperature (Ti ) = 298 K
Index of expansion of air γ=1.4
Flow velocity through inlet port (V): assuming flow Mach number is: 0.2,
V = 0.2*√ (P*R*Tf) = 55.08 m/s
Where,
R is characteristic gas constant of air (287 j/ kg-k)
Flow cross section area (Ac/s): of port is given by the following relationship,
Ac/s= (Vprop/2)/V = 1.10X10-4m2
Where, Vprop is volumetric flow rate of air flow through pipe lines=15027 liters/s
Hence, the inlet port diameter (d) is given by,
d = √ (4*acs/π) =0.0132m = 13.2mm = 14mm
The port diameter (d) is chosen as 16mm.

4.2 Estimation of outlet port diameter of the propellant tank:(propellant side)

The outlet port diameter (di in mm) is evaluated from the following relationship

di = 4.61 * √ (volume flow rate (Lpm)/flow velocity)

di = 36.2mm

Where,

Volume flow rate = 470.15 Lpm

Flow velocity = 7.62 m/s for pressure lines (Assumed for minimum pressure drop)

The port diameter (di) is chosen as 38mm

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4.3 Estimation of inner dimensions of the propellant tank:

This design philosophy has been taken from Ref (1). Elliptical shape of the propellant tank has
been considered due to space constraint along the axis of motor. In this configuration, tank has to
be mounted in the flight section with eight integrated webs of top dish assembly, which are to be
fixed to the bulk heads of the section using strings.

Major axis dimension has been fixed to 720mm against to flight section diameter is 980mm,
which is to be placed along radial direction. So that remaining space is required to accommodate
the strings, cable harness routing and feed lines.

Major elliptical half-diameter of the tank (a) = 310 mm

Volume of the propellant tank (v) = 80 liters
Minor elliptical half diameter of the tank (b) = [(3-v)/ (4*π*a2)] = 206mm
Ellipse ratio (k) = a/b =1.5

For calculated value of ‘k’, stress factor value has been selected for combined stress from the
plot of Ref (1), k=0.85ondition

4.4 Estimation of thickness of the propellant tank at crown and knuckle:

Aluminum alloy AA6502 in WP condition has been chosen for the propellant tank

Mechanical properties of material are given below on yield

Ultimate tensile stress (SU) = 280 Mpa

0.2% Proof stress (SY) = 240 Mpa
In the Weld Zone (From welded test specimen)
Ultimate Tensile stress (SUW) =175 Mpa
0.2% Proof stress (SYW) = 125 Mpa

Factor of safety:
Factor of safety on yield (FSY) = 1.25
Factor of safety on UTS (FSU) = 1.5
Design or allowable stress on yield (SDY) = ((SYW)/FSY) = 100Mpa
Design or allowable stress on UTS (SDU) = ((SUW)/FSU) = 116.66 Mpa

Working Pressure of the propellant tank (P) = 5.88Mpa

Thickness at the knuckle (tk) = (k*p*a/SDY) = 0.0158m =15.8mm =16mm
Thickness at the crowns (tcr) = (P*R*FSᵞ/2*Sᵞ) = 0.0048m = 4.84mm = 5mm
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Thickness variation is 6mm at crown and 16mm at knuckle with uniform variation.

4.5 Estimation of lug dimensions:-

In this configuration tank has to be mounted in the flight section with eight integrated webs of
the top dish assembly, which is to be fixed to the bulk heads of the section using strings.

As per EN test specification mentioned in Ref (2) propellant tank to be experienced to

acceleration of 10g in 3 axis so that lug has to be designed to withstand the acceleration of 10g

Weight of the propellant tank (WT) = 40kg

Weight of the propellant (WP) =115.2kg
Total weight of the propellant tank (m) = (WT) + (WP) = 155.2kg = 160kg

In this case, total two types of loads will be acted in the propellant tank assembly
 Direct load
 Moment load

4.5.1 Force due to direct load:

Force due to direct load is acting on the propellant tank due to longitudinal acceleration
of (a10)
F = m x a = 160 x 9.81 = 15696N
The total force is shared by total no’s of integrated lugs to top dish assembly during
longitudinal acceleration of the missile. But in worst condition, during missile
maneuvering, 4 no’s of lugs will have minimum stress. So that lugs will be designed in
such way that to withstand this force
Force is shared by each lug FD= F/4 =3924N

4.5.2 Force due to moment load:

Distance between C.G location of tank of lug (D) =0.335m

Forces acting due to moment on lug at minimum cross section is also shared by 4 no’s
lugs as shown in figure.
FM = FD x D = 1314.54 N
Total force is acting on propellant tank (due to direct and moment loads):
F = FD + FM = 5238054 N.
Dimension of lug: width = 35mm, thickness = 10mm
In this calculation minimum cross section of lug has been considered at the center of the
bolt (as shown in figure)
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Alug = 0.025 x 0.01m = 2.5x10-4m2

Allowable shear stress due to total load (τ) = F/Alug = 20.96 Mpa
Maximum shear stress 0.5 x Su = 12705 Mpa

Factor of safety = (maximum shear stress) / (allowable shear stress) = 6.08 = 6

4.6 Estimation of bolt strength torque required and factor of safety:

The following stresses are induced in a bolt due to static loading

 Initial stresses due to screwing up forces
 Tensile stresses due to stretching of bolt.
 Torsional shear stress caused by the frictional resistance of the
threads during its tightening.
 Stress due to external load.

4.6.1 Initial stress due to screwing up forces: (these stresses are due to when it
is screwed up tightly)

(Tensile stress due to stretching)

Nominal diameter of bolt = 0.01m
Load due to initial tightening Fi =1420 d = 14.2 N (for structural joints)
Stress due to tightening Si = (4 x Fi)/ (π x dc) = 0.25Mpa
Torsional shear stress caused by the frictional resistance of the threads during its tightening.
For EN – 24, 10.9 class properties:
Ultimate tensile stress = 1040-1220 Mpa
0.2% proof stress = 940Mpa
Torsional shear stress = (ultimate tensile stress) / 2 = 520Mpa.
Core dia of the bolt (dc) = 8.5 mm = 0.0085m
Torque required (T) = (πxdc3 x τin)/16 = 62.7Nm

4.6.2 Stress due to external load

Direct load FDB = F/4 = 3924N

Load due to moment = FMB = FDB * D = 1314.54N
Total load due to combined load:
F = FDB + FMB = 5238.54 N
Stress due to external load SEB = (4*F/π*dc) = 92.31 Mpa
Total stresses due to pre tightening and external load due to tensile loading
St = Si + SEB = 92.56Mpa
Factor of safety = (0.2% proof stress /Allowable shear stress) =10.15 Mpa
 24

5.0 Welding

The hemisphere shall be welded by TIG Welding the filler wire will be selected by manufacturer
so as to achieve the specified mechanical properties of the weldment.

Welding
A joining process of two materials coalesced at their contacting surface by applying heat and
pressure.

Types of welding
1. Arc Welding.

2. Resistance Welding.

3. Oxy-Fuel Welding.

4. Fusion Welding

Arc Welding Electric

Arc welding is one of the fusion welding processes in which coalescence of the metal is achieved
by the heat from an electric arc between an electrode and work piece .Electric arc is generated
when electrode is brought into contact with the work and is then quickly separated by a short
distance approximately 2 mm. the circuit operates at low voltage and high current so arc is
established in the gap due to thermionic emission from electrode (cathode) to work piece
(anode). the arc is sustained due to continuous presence of a thermally ionized column of gas.
this arc produces at temperature of the order of 5500oc or higher. In this way a pool of molten
metal consisting of work piece metal and filler metal is formed in the welding zone. the electrode
is moved along the joint with perpendicular zigzag motion. the solidified molten weld pool
makes the strong welded joint. movement of the electrode relative to work piece is accomplished
by either manually or by mechanical means in case of automatic welding machines. better
uniformity and good quality weldment are possible in case of automatic welding process.

Oxy-Acetylene Welding
Oxy-acetylene welding can be used for welding of wide range of metals and alloys. Acetylene
mixed with oxygen when burnt under a controlled environment produces large amount of heat
giving higher temperature rise. This burning also produces carbon dioxide which helps in
preventing oxidation of metals being welded. Highest temperature that can be produced by this
welding is 3200oC. The chemical reaction involved in burning of acetylene is
2C2H2 + 5O2 = 4CO2 + 2H2O+ Heat
 25

on the basis of supply pressure of gases oxy-acetylene welding is categorized as high pressure
welding in this system both gases oxygen and acetylene supplied to welding zone are high
pressure from their respective high pressure cylinders. The other one is low pressure welding in
which oxygen is supplied from high pressure cylinder but acetylene is generated by the action of
water on calcium carbide and supplied at low pressure. In this case high pressure supply of
oxygen pulls acetylene at the welding zone. A comparison can be drawn between low pressure
and high pressure welding. High pressure welding equipment is handy, supplies pure acetylene at
constant pressure, with better control and low expenses as compared to low pressure welding.

TIG Welding
This is similar to arc welding. Additionally it requires a cylinder of inert gas, valve, pressure
regulator and hose pipe with sprayer to spray inert gas in the welding pool. A non-consumable
tungsten electrode is used to establish arc. Sometimes inert gas sprayer is also mounted in the
electrode holder. As per the requirement additional filler metal can be provided from the outside
to make up the joint. This is suitable for welding of most of the metal and alloys except lead and
zinc due to their very low melting point. It is also observed as IG welding.

MIG Welding
This is similar to TIG welding. At the place of non-consumable tungsten electrode, a consumable
metal electrode is used in the form of continuously fed metal wire. The electrode wire and inert
gas are fed through welding gun. Only DC is recommended for this type of welding giving
positive polarity to electrode wire. Feeding speed of electrode wire is adjusted according to the
welding speed. This is used for the welding of carbon steel, low alloys steel, stainless steel and
alloys of the metal exhibiting resistance to heat.

Power Source
Both AC (Alternative Current) and DC (Direct Current) can be used for welding. AC machines
are recommended for ferrous metal and DC machines are recommended for other metals for
better result. Main constituent of welding machine is transformers which convert the supply to
low voltage and high current. For AC welding power is required at 80 to 110 volt and 50 to 80
ampere. For sustaining the established are power factor is kept low. In case of DC welding power
is required at 8 to 25 volts and 50 ampere. Polarity is also are significant factor. Two types of
polarities are possible in case of DC welding.

Straight Polarity
Electrode is made negative pole and work piece is made positive pole. It is also called as
electrode negative.
 26

Reversed Polarity
Electrode is made positive pole and work piece is made negative pole. It is called electrode
positive too. As we know that two third of the total heat is generated at positive pole and only
one third at negative pole. Polarity is decided according to the requirement of heat at either pole.

Welding Electrodes
These are also called welding rods. Two types of welding electrodes are generally used.
Consumable electrodes and non-consumable electrodes. Consumable electrodes are the source of
filler metal in case of is welding. Consumable electrodes can further be classified into two
categories coated and bare electrodes. Bare electrodes are simple rods mode of filler metal with
no coating over them. In case of bare electrode flux is required additionally. These electrodes are
rarely used. Bare non-consumable electrodes are used in case of gas shielded welding processes
(MIG and UIG).

Non-consumable Electrodes
They are made of tungsten or carbon. These do not melt in the process of welding and so called
non-consumable electrodes. Their depletion rate is very low. In case of non-consumable
electrodes metal and flux is supplied additionally. Generally non-consumable electrodes are used
in MIG and TIG welding processes.

Coated Consumable Electrodes

These are the most popular arc welding electrodes. No additional filler metal and flux are
required with them. In general these electrodes have core of mild steel and coating over them of
flux material. Coating on the electrode performs many functions. It develops a reducing
atmosphere and prevents oxidation, forms separable slag from metal impurities, establishes ac
providing necessary alloying elements to the weld pool. The common ingredients act as flux
which help in slag formation are asbestos, mica, silica, fluorspar, steatite, titanium dioxide, iron
oxide, metal carbonates, etc. Ingredients used to produce reducing atmosphere are cellulose
dolomite, wood flour, starch. Iron powder provides higher deposition rate. Manganese oxide
and potassium silicate and titanate are the alloying elements and

Filler metal
In case of use of non-consumable electrode separate filler metal is used to improve properties of
weldment. Selection of a filler metal depends on the metal to be welded.

Coated Filler Metal

Rods of this type of filler metal consists the coating of flux material.
 27

Bare Filler Metal

No coating of flux is there, it is supplied additionally as per the requirement. For stainless steel
and alloy steel filler metal should be alloy of chromium and vanadium. For the welding of
copper filler metal should be phosphorous mixed copper. Filler metal composition should be
same as that of the material to be welded. Sometimes additional alloying elements are added to
them to improve mechanical properties of weldment.

Flux Material
Like gas welding flux is also used in arc welding to prevent oxidation of hot element. As
oxidation of hot metal imparts poor mechanical properties of joint. Some flux material as
discussed in gas welding are used in arc welding. Flux can be supplied through coating of
electrode or coating on filler metal or separately. Sometimes spray of inert gas is used to prevent
oxidation and no flux is required.

Fillet welding

Fillet welded joints such as tee, lap and corner joints are the most common connection in welded
fabrication. In total they probably account for around 70 to 80% of all joints made by arc
welding. No edge preparation is needed and assemblies in piping systems are simpler. Therefore,
fillet welds are usually cheaper than butt welds.

Butt welding

A Butt Weld is a circumferential butt welded joint, and the most common type of joint employed
in the fabrication of welded pipe systems. A butt joint is the most universally used method of
joining pipe to itself, fittings, flanges, Valves, and other equipment. This welding technique is
widely applied in situations where a quality weld desired, and the weld by X-ray technically
should be investigated.

Residual Stresses and Warpage

Rapid heating and then uncontrolled cooling result in uneven expansion and contraction in the
work piece and weldment. This causes development of residual stresses in the weldment.
Distortion and Warpage may also be there. Sometimes wrong selection of filler metal and
welding technique may also be the cause of residual stress and Warpage.

Cracks

This is a serious welding defect appears as fracture type interruptions in the weld. Crack works
as a point of stress concentration so reduce the strength of the joint.
 28

Cavities or Porosity
Porosity consists of small voids in weld metal formed by gases entrapped during solidification.
Shape of the voids may be spherical holes or elongated holes. There can be another type of voids
and immediately after welding shrinkage voids formed due to shrinkage of metal during
solidification.

Weld purging.

The act of removing, from the vicinity of the joint, oxygen, water vapors and any other gases or
vapors that might be harmful to a welding joint as it is being welded and immediately after
welding.

5.1 Materials for welding trails

Test coupon plates prepared from the same plates which are to be used for fabrication of
hemisphere shall use for generating welding procedure specification (WPS) And procedure
qualification record (PQR) and also for Welder and batch qualification the thickness of the plates
shall be machined to 8.5 mm thick the welded test coupon size shall be 300*250 mm.A distance
of a 25 mm shall be discarded on either ends of the welded test coupon

5.2 Welding procedure specification (wps)

A detailed welding procedure specification (WPS) indicating all the world parameters shall be
generated for each joint and shall be submitted to DRDL for approval

5.3 Procedure qualification record (pqr)

PQR shall be generated for adaptor joint and cirseam joint with approved wps welding shall be
carried out on one set of plates given at Para 7 to generate test coupon the plates shall machined
down to 8.5 mm thick and the edge preparation and joint configuration shall be simulated to that
of actual propellant tank joint and the approved WPS shall be conducted on the specimen made
from weld joint

5.3.1 Macro examination

One section shall be taken transverse to the weld direction and shall be examined at 3 to 10x
magnification minimum world bead width will be established and recorded the macro
examination shall confirm to the acceptance criteria given for visual inspection at Para 8.3.1

5.3.2 Weld examination

All the weld joints shall be subjected to following examination

 29

5.3.3 Visual inspection

All weldment examined at 3x magnification or greater shall meet the following

5.3.4 Penetration

Joints shall have complete penetration

5.3.5 Incomplete fusion

Incomplete fusion is not acceptable

5.3.6 Cracks

Surface cracks not acceptable in the weld surface and heat affected zone

5.3.7 Voids and Pores

Voids and pores open to the surface are not acceptable

5.3.8 Undercut and root notches

Not permissible

5.3.9 Mismatch

Mismatch shall not exceed 5% of thickness

5.3.10 Overlaps

Not acceptable

5.3.11 Radiographic inspection

All welds shall be subjected to 100% radiographic inspection in accordance with ASME Boiler
& pressure vessel code section V sensitivity of radiographs shall be less than 2% following is the
acceptance criteria

5.3.12 Cracks, undercuts, lack of fusion, lack of penetration:

Not acceptable
 30

5.3.13 Porosity, voids and inclusions

Weld discontinuities such as porosity, voids & inclusions and aligned indication shall confirm to
the acceptance standards in ASME Boiler and pressure vessel code section viii Division 2 Article
I-5 However the max pore size shall not exceed 1.5vm. In size radiography shall be conducted
and certified from a qualified ASNT/ISNT level II inspector

5.3.14 Dye penetrate inspection

All welds shall be dye penetrate inspected in accordance with SAE AMS 264to locate
imperfections open to the surface no defects are permitted. 8 microns wide and 50 microns deep
cracking shall be detected by the method adapted

5.4 Welder qualification

5.4.1 Manufacturer shall identify trained welders capable of understanding the following items

(a) Welding parameters

(b) Reading of drawings

(c) Operation and control of welding equipment

(d) Electrode details

(E) Process of inspection and acceptance welding

It is preferable if the welders have previous experience on welding of Titanium alloy components

5.4.2 Qualification plan

5.4.2.1 Welder qualification tests shall be carried out after WPS and PQR are duly approved by
DRDL Welder qualification tests will be carried out in presence of designated inspection agency
representatives

5.4.2.2 The qualification test set up and test procedure are enlisted as follows

5.4.2.3 If the results are satisfactory according to the requirements mentioned in above referred
paragraphs, the Welder shall be qualified for a period of 6 months, provided the Welder is
continuously on the job.

5.4.2.4 If there is a break of more than three months the welder shall be re-qualified
 31

5.4.2.6 If any change is introduced in the welding process, materials, welding parameters, etc.re
qualification shall be done.

5.4.3 Test set-up

Welder qualification test shall be conducted for a welder on the same welding
machine, which will be used for regular fabrication activities of the propellant tank .The machine
shall have suitable meters to record the voltage and current during the welding process .Similar
arrangements shall be made to correct flow rates of shielding and purging gas.

5.4.4 Welding of propellant tank

The propellant tank shall be welded as per the qualified WPS and with qualified welder
.while welding each joint of the propellant tank the weld parameters shall be recorded .The
welding shall be subjected to examination.

5.5 Weld test coupons for batch qualification

For every batch of propellant tank three test coupons shall be tested ,one in the beginning ,one in
the middle and one at the end as per approved WPS and with qualified welder ,each coupon
representing a batch of 7 No's of bottle minimum .All test coupons shall be subjected to weld
examination .Three tensile test specimens shall be made from each test coupon and tested and the
results shall meet the requirements given for the qualification of the total batch of propellant
tank.

5.6 Quality control requirement- weld pair

5.6.1 Repair of weld shall be permitted only once, at any particular spot .For each weld joint,
the nature of defect, its location and its repair in detail shall be recorded.

Note1: The minimum distance between two repairable weld defects shall be 10 times the
thickness (in the weld zone).

Note2: Maximum length of repair weld shall be less than 10% of the length of the weldment for
each weld joint.
 32

5.6.2 For line defects grinding shall be done in the specified area with flood cooling

5.6.3 Localized defects like tungsten inclusion, oxide inclusion, cluster of porosities etc. , shall
be removed by countersunk bit drilling with adequate cooling.

5.6.4 Manual TIG welding shall be used for weld repairs.

5.6.5 Repair welding shall be done as per the approved welding procedure Specification (WPS)
generated for repair welds.

5.6.6 The repair weld should pass through the normal inspection procedure mentioned.

6. Ultrasonic testing:- All the plates and forgings in discalced or proof machined condition
shall be subjected to ultrasonic testing in accordance with SAE AMS 2631B and acceptance
level shall be Class A (2.0 mm FBH for single discontinuity) ultrasonic inspection shall be
carried out by qualified ASNT/ISNT level 2 personnel calibration of ultrasonic testing equipment
will be carried out in accordance with are 3.2.5 of SAE AMS 2631 B

6.1 Inward goods inspection (igi) :- All the test certificates countersigned and cleared by
the designated inspection agency shall be verified by the Propellant tank manufacturer 100%
visual inspection shall be verified with those mentioned interested test certificates
recommendation made by the inspection agency in the test certificates if any shall be
implemented

6.2 Tensile test

The three transverse weld tensile test specimen shall he made as per QW 462.1 (a) of ASME
BPVC section IX with a Gauge length of 50 mm and tested and properties shall meet the
following requirements the weld bead and penetration shall be flush machined on the samples

UTS. : 834 Mpa Min

0.2% PS. : 785 Mpa Min

Elongation : 5% Min
 33

6.3 Impact test

6 no's each of charpy impact test specimen shall be made in accordance with ASTME23 from (I)
parent metal (ii) welded portion from the welded test material the welded samples shall be made
such that the notch shall be located on the weld in longitudinal direction three specimen shall be
tested at room temperature and three specimen at -40 c for both parent material and welded
specimen shall be mine Nm the average value of energy absorption at -40 c shall be not less than
90% of corresponding average values absorbed at room temperature and - 40c shall not exceed
20% separately

6.4 Hydraulic pressure tests

Each propellant tank shall be subjected to proof pressure test. one tank is selected by the
designated inspection Agency, at random from batch after the completion of proof pressure test
to qualify the batch. Data regarding weight, dimensions and internal volume of each propellant
tank shall be recorded in the proof pressure test report. Data regarding weight, dimensions and
internal volume of each tank shall be recorded in the proof pressure test report.

The water used for these tests shall be reagent grade water as per IS:1070-1992.it is essential that
the water is free from particles that would damage threaded portions while tightening the mating
parts. The propellant tank after the test shall be cleaned and drier to closing their ports all
necessary safety precautions shall be observed by the manufacturer while carrying out the tests.
it is essential to keep tank in pit and protected by sand bags at a safe distance during Pressure test
.The least count of pressure measuring device shall be better than 1KSC.

6.4.1 Hydraulic proof test procedure

The propellant tank is to be pressurized in steps of 100KSC at uniform rate of 1KFC per second
and held for about 10sec in each step to record volumetric stretch. At the pressure of 400KSC it
should be held for 5.0 minutes before recording volumetric stretch.

From 40KSC to 60 KSC the bottle shall be pressurized in one minute .the pressure at 60KSC
shall be held for 60sec and the volumetric stretch should be recorded after the duration. No leak
is permissible during the proof pressure test.
This should be followed by depressurization to ambient pressure in the shortest
time duration by opening the valve fully.Net volumetric permanent stretch shall then
be recorded. This shall not exceed 10% of total increase in volume recorded at proof
pressure ofv600KSC.Format for proof pressure test is shown in appendix 2.The
volumetric stretch shall be calculated as follows,
 34

The volumetric permanent stretch ( V3-V1) / (V2-V1)*100

Where V1= initial volume of propellant tank

V2= volume at proof pressure

V3= volume after depressurization

6.5 Strain gauging:-

During proof pressure test strains shall be monitored at 5 locations as per sketch
shown at appendix 3 with rosette strain gauges .After depressurization the residual
strain shall be recorded .The residual strain at each location shall not exceed 10% of
strain of strain at proof pressure at the same location.

6.6 NDT test

After p ro of pressure test the w e l d j o i n t s of t h e p r o p e l l a n t tank shall be

inspected and shall be compared with the pre -proof test details. No change in details
is permissible.

6.7 Hydraulic burst pressure test:-

One bottle selected by the designated inspection agency out of batch 22no's shall
be subjected to burst pressure test after proof pressure test .pressurization
process for this test should start from the beginning after complete depressurization
after proof pressure test and noting of permanent stretch. The propellant tank shall be
pressurized continuously up to 60 KSC and held there f o r two minutes .Then the
pressure shall be increased to 110 KSC
 35

KSC gradually and held here for one minute. As it is unsafe to visually check the tank
for leakage or burst, this will be ensured by holding the propellant tank at this
pressure for the specified time by monitoring the pressure gauge ,which shall not
show any drop in pressure during holding time. That shall be increased steadily and
the valve at which leakage or bursting occurs shall be recorded after the lapse 60 sec
hold.

The burst pressure shall not be less than 110 KSC.

If the propellant tank fails before the hold time or at/before this pressure in the
burst test, two more propellant tank shall be randomly chosen from the same lot and
subjected to burst pressure test. Only if both these propellant tank pass this test
with burnt pressure above 110 KSC the lot shall be accepted. The burnt tested
propellant tank with relevant records shall be supplied to the purchaser along with the batch.
The burst propellant tank with relevant records shall be supplied along with the batch it was
chosen from.

6.8 Pneumatic leak test:

Soap bubble technique shall be adopted for carrying out leak test. every propellant tank which
has already been cleared for further use by inspecting agency, after proof test, shall be subjected
to pneumatic pressurization up to 60KSC.and held at this pressure for one minute. Then the
pressure shall be reduced to 50KSC.The inlet port tightened with 185N-m torque. A soap
solution shall be spread over this port to detect any bubble deformation. A solution of
commercial leak testing fluid may be used .Use of household detergents is not allowed as they do
not get satisfactory results.

If no sign of bubble is even. The propellant tank shall be allowed to lie undisturbed for more than
24 hours and again subjected to application of soap solution. On noticing no sign of bubble
formation, the propellant tank can be considered leak proof. The leak- profess of the air bottle is
the responsibility of manufacturer. In case the leak rates does not meet the specifications,
rectification of the propellant tank shall be carried out the manufacturer of his cost .Snoop
solution may be used for detecting leak.

7.0 Weight

Weight of the propellant tank (with components assembled) shall be recorded and reported .it
shall meet the requirement mentioned.
 36

8.0 Identification

Each propellant tank shall have the following information electro etched on the flat surface of the
socket, on either side.

(i) Manufacturer name

(ii) Serial No. of propellant tank.

(iii) Supply order no.

Apart from above proof pressure test date and value of proof pressure shall be stenciled or
written with paint/indelible ink.

Height : 3.50mm

Width. : 0.20m

Depth. : 0.05mm

9.0 Packaging

Each propellant tank shall be packed in separate wooden box with proper cushioning on all the
six sides with thermocole and any free movement- rolling of propellant tank shall be resisted by
copper dimensioning of the box. On each package manufacturer's name, supply order No's and
propellant tank serial number shall be written.

10.0 Certificates

For each propellant tank, the following certificates shall be submitted by the manufacturer.

(a) Raw materials (plates and forged bars)

Batch number

Annealing cycle certificate

Ultrasonic test certificate

Chemical composition

Mechanical properties

Fracture toughness test certificate

 37

Microstructure certificate

Surface contamination check certificate

(b) Components

Dimensional inspection report

DP test report

Thickness mapping

Inspection report for cap mesh

(c) WPS, PQR & Operator qualification

Visual inspection report

Radiology report

DP report

Macro test report

Micro test report

Tensile test report

Impact test report at room temperature and -40 C, for parent material

(d) Welding inspection of propellant tank: The following need to be covered for
each and every job for ensuring the quality of the product.

Welding records

Visual inspection report

Radiographic inspection report

DP report

Details of weld repairs

 38

(e) Batch qualification reports

Welding schedule and welding records

Visual inspection report

DP test report

Radiographic inspection report

Tensile test report

(f) Proof pressure test report and weld inspection

(g) Burst test report

11. Conclusions:-

As per above design calculations elliptical tank dimensions are finalized as follows:
 Elliptical tank:
Inner dimensions : Major axis = 620mm Minor axis = 412mm
 Outer dimensions : Major axis = 652mm Minor axis = 424mm
Thickness variation is 16mm (knuckle) and 6mm (crown)
 Port diameters:
Pneumatic side : d = 16mm
Propellant side : di = 38mm
 Lug dimensions:
Width = 35mm
Thickness = 10mm
 Bolt dimensions: M10 x 1.5mm

12. References:-

I. NASA SP-125, Design of Rocket engine

II. Environmental test specification for AD interceptor missiles
III. Preliminary design report of Divert and Altitude control system for PAD Deliverable
version (PDV) Missile.
IV. 2007 ASME Boiler and Pressure vessel code volume-1
V. Machine design R.S Kurmi and J.K Gupta