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United States Marine Corps

Modular Aerial Refueling System (MARS) Low-Profile Cargo Fuel Tank (LCT) for the C-130 Hercules

Next-Generation Multi-Mission Fuselage Tank System with Ballistic Resistance and Rapid Roll-on, Roll-off Capabilities
ASD's experience in manufacturing and maintaining fuselage fuel tanks spans three decades. Through this experience and in response to the requirements set forth in U.S. Air Force Special Operations Command, Lockheed Martin, and Boeing Company specifications and requirements documents, ASD has designed the next generation roll-on / roll-off fuselage fuel tank for tactical transports.

Traditional fuselage fuel tanks are single walled cylindrical welded aluminum structures. Aero Union's AS-60 MARS LCT (Modular Aerial Refueling System Low-Profile Cargo Carrying Tank) utilizes advanced materials and manufacturing techniques to create this next generation fuel tanking system.

The primary operational benefit of this low-profile box tank versus the older cylindrical tanks is its cargo carrying capability. The top of the tank has tie-downs, like the C-130 fuselage deck, and can support up to 10,000 pounds of cargo on each tank of a multi-tank configuration. The tank is low enough for an average sized person to stand on top comfortably inside the aircraft or to transport a vehicle. The electrical connections and fuel interface are similar to older tank systems to ensure aircraft compatibility, but the tank system's transfer pumps are a new design, which permit fuel transfer rates up to 600gpm.

The AS-60 MARS LCT also has some increased safety benefits. Each side panel is made of dual walled composite material containing self-sealing gel (activated when it comes in contact with fuel vapors). The dual walls provide an extra layer of vapor containment and the gel provides puncture protection of up to .30-caliber ballistic intrusion. The fuel transfer pumps are enclosed in their own vapor proof compartment.

The first prototype system is currently in manufacture and will be used to provide auxiliary fuel capacity for a C-130 Hercules transport that will be converted to a KC-130 configuration. First flight of this aircraft is scheduled for early 2005. This first system consists of two 1800-gallon tanks. Up to .50-caliber protection can be achieved with a thicker panel design if an associated weight penalty is acceptable. Scaled versions can be made to adapt this system to many different platforms for aerial refueling, range extension or bulk fuel transport.

The following diagrams illustrate some of the components of the MARS LCT.

Schematic details.

Exterior tank view.

Transparent tank view.