Engineering topics
Johnson, Wesley
Publications and source records attributed to Johnson, Wesley.
Cryogenic Selective Surfaces: A Phase 2 NIAC Project: Mid-Term Continuation Review
The NASA Innovative Advanced Concepts (NIAC) program has been funding work at KSC (Kennedy Space Center) on a new coating that should allow cryogenic commodities to be stored in deep space. Recently a mid-term review of this work was given. I am requesting that this presentation be cleared for release so that the material can be presented publicly at an upcoming FISO (Future in Space) telecom.
Cryogenic Selective Surfaces
The NASA Innovative Advanced Concept (NIAC) program has been funding work at KSC on a novel coating that should allow cryogenic materials to be stored in deep space. The NIAC Symposium will be the last week of September and it is a requirement that the funded material be presented both orally and at a poster session. This DAA submission is requesting approval to go public with both the presentation and the poster.
Large Scale Production of Densified Hydrogen to the Triple Point and Below
Recent demonstration of advanced liquid hydrogen storage techniques using Integrated Refrigeration and Storage technology at NASA Kennedy Space Center led to the production of large quantities of densified liquid and slush hydrogen in a 125,000 L tank. Production of densified hydrogen was performed at three different liquid levels and LH2 temperatures were measured by twenty silicon diode temperature sensors. Overall densification performance of the system is explored, and solid mass fractions are calculated. Experimental data reveal hydrogen temperatures dropped well below the triple point during testing, and were continuing to trend downward prior to system shutdown. Sub-triple point temperatures were seen to evolve in a time dependent manner along the length of the horizontal, cylindrical vessel. The phenomenon, observed at two fill levels, is detailed herein. The implications of using IRAS for energy storage, propellant densification, and future cryofuel systems are discussed.
Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER)
Abstract: NASA is currently investigating methods to reduce the boil-off rate on large cryogenic upper stages. Two such methods to reduce the total heat load on existing upper stages are vapor cooling of the cryogenic tank support structure and integration of thick multilayer insulation systems to the upper stage of a launch vehicle. Previous efforts have flown a 2-layer MLI blanket and shown an improved thermal performance, and other efforts have ground-tested blankets up to 70 layers thick on tanks with diameters between 2 3 meters. However, thick multilayer insulation installation and testing in both thermal and structural modes has not been completed on a large scale tank. Similarly, multiple vapor cooled shields are common place on science payload helium dewars; however, minimal effort has gone into using boil-off to intercept heat on large structural surfaces associated with rocket stages. A majority of the vapor cooling effort focuses on metallic cylinders called skirts, which are the most common structural components for launch vehicles. In order to provide test data for comparison with analytical models, a 4 meter diameter test tank and assembly is currently being designed to include skirt structural systems with integral vapor cooling. In order to give a more representative result for actual applications, the technologies will be designed for an 8.4 m and scaled down to a 4 meter tank. In order to prove that the insulation system and vapor cooling attachment methods are structurally sound, acoustic testing will also be performed on the system. The test tank with insulation and vapor cooled shield installed will be tested thermally in the B2 test facility at NASAs Plum Brook Station both before and after being vibration tested at Plum Brooks Space Power Facility.
Development Path for Cryogenic Insulation Systems Supporting NASA Exploration
The currently stated exploration plan for NASA includes the possibilities ranging from short (several hour duration) upper stage missions sending astronauts towards the vicinity of the moon to multiyear missions to Mars and even making and liquefying propellant on the surface of Mars. As such, NASA has developed a plan to develop multilayer insulation (MLI) at a level it can be engineered for large space craft and upper stage mission durations between several hours to several days. The Evolvable Cryogenics project has been investigating design details related to the design of large MLI blankets for in-space application. Basic MLI performance for large upper stages is scheduled to be demonstrated in 2018 on the Evolvable Cryogenics projects Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER). Different paths are being pursued for Mars Surface applications and these concepts are much less defined and still being traded.
KEA-144: Final Results of the Ground Operations Demonstration Unit for Liquid Hydrogen (GODU-LH2) Project
GODU-LH2 system has successfully met all test objectives at the 33%, 67%, and 100% tank fill level. Complete control over the state of the fluid has been demonstrated using Integrated Refrigeration and Storage (IRAS). Almost any desired point along the H2saturation curve can essentially be "dialed in" and maintained indefinitely. System can also be used to produce densified hydrogen in large quantities to the triple point. Exploring multiple technology infusion paths. Studying implementation of IRAS technology into new LH2sphere for EM-2 at LC39B. Technical interchange also occurring with STMD, LSP, ULA, DoE, KIST, Kawasaki, Shell Oil, SpaceX, US Coast Guard, and Virgin Galactic.
Liquid Nitrogen Zero Boiloff Testing
Cryogenic propellants such as liquid hydrogen (LH2) and liquid oxygen (LO2) are a part of NASAs future space exploration due to their high specific impulse for rocket motors of upper stages suitable for transporting 10s to 100s of metric tons of payload mass to destinations outside of low earth orbit and for their return. However, the low storage temperatures of LH2 and LO2 cause substantial boil-off losses for missions with durations greater than several months. These losses can be eliminated by incorporating high performance cryocooler technology to intercept heat load to the propellant tanks and modulating the cryocooler to control tank pressure. The active thermal control technology being developed by NASA is the reverse turbo-Brayton cycle cryocooler and its integration to the propellant tank through a distributed cooling tubing network coupled to the tank wall. This configuration was recently tested at NASA Glenn Research Center, in a vacuum chamber and cryo-shroud that simulated the essential thermal aspects of low Earth orbit, its vacuum and temperature. Testing consisted of three passive tests with the active cryo-cooler system off, and 7 active tests, with the cryocooler powered up. The test matrix included zero boil-off tests performed at 90 full and 25 full, and several demonstrations at excess cooling capacity and reduced cooling capacity. From this, the tank pressure response with varied cryocooler power inputs was determined. This test series established that the active cooling system integrated with the propellant tank eliminated boil-off and robustly controlled tank pressure.
International Space Exploration Coordination Group Assessment of Technology Gaps for LOx/Methane Propulsion Systems for the Global Exploration Roadmap
As part of the Global Exploration Roadmap (GER), the International Space Exploration Coordination Group (ISECG) formed two technology gap assessment teams to evaluate topic discipline areas that had not been worked at an international level to date. The participating agencies were ASI, CNES, DLR, ESA, JAXA, and NASA. Accordingly, the ISECG Technology Working Group (TWG) recommended two discipline areas based on Critical Technology Needs reflected within the GER Technology Development Map (GTDM): Dust Mitigation and LOX/Methane Propulsion. LOx/Methane propulsion systems are enabling for future human missions Mars by significantly reducing the landed mass of the Mars ascent stage through the use of in-situ propellant production, for improving common fluids for life support, power and propulion thus allowing for diverse redundancy, for eliminating the corrosive and toxic propellants thereby improving surface operations and resusabilty, and for inceasing the performance of propulsion systems. The goals and objectives of the international team are to determine the gaps in technology that must be closed for LOx/Methane to be used in human exploration missions in cis-lunar, lunar, and Mars mission applications. An emphasis is placed on near term lunar lander applications with extensibility to Mars. Each agency provided a status of the substantial amount of Lox/Methane propulsion system development to date and their inputs on the gaps in the technology that are remaining. The gaps, which are now opportunities for collaboration, are then discussed.
Design and Operation of a Calorimeter for Advanced Multilayer Insulation Testing
A calorimeter has been constructed to accurately measure insulation performance with a nominal 90K cold outer boundary and a 20K inner boundary. Unique features of this design include use of mechanical cryocoolers instead cryogens and measurement of the heat load with a calibrated rod to serve as a conduction path. The calorimeter is operational and has completed its first test series. The initial test series was designed to look for differences in performance between a single layer of aluminum foil and a sheet of double aluminized mylar (DAM). Although it has been speculated that the aluminum foil would perform better, since the mylar coating might not thick enough to stop the transmission of long wave length infrared radiation, our testing showed a higher heat load for the aluminum foil than the DAM. The aluminum foil showed a heat load of 132 mW at an 87 K outer temperature and 152 mW at a 107K outer temperature. Whereas the DAM showed a heat load of 66 mW at an 88 K outer temperature and 81 mW at 108 K.
Demonstration of Hybrid Multilayer Insulation for Fixed Thickness Applications
Once on orbit, high performing insulation systems for cryogenic systems need just as good radiation (optical) properties as conduction properties. This requires the use of radiation shields with low conductivity spacers in between. By varying the height and cross-sectional area of the spacers between the radiation shields, the relative radiation and conduction heat transfers can be manipulated. However, in most systems, there is a fixed thickness or volume allocated to the insulation. In order to understand how various combinations of different multilayer insulation (MLI) systems work together and further validate thermal models of such a hybrid MLI set up, test data is needed. The MLI systems include combinations of Load Bearing MLI (LB-MLI) and traditional MLI. To further simulate the space launch vehicle case wherein both ambient pressure and vacuum environments are addressed, different cold-side thermal insulation substrates were included for select tests.
Fundamentals of Cryogenics
Analysis of the extreme conditions that are encountered in cryogenic systems requires the most effort out of analysts and engineers. Due to the costs and complexity associated with the extremely cold temperatures involved, testing is sometimes minimized and extra analysis is often relied upon. This short course is designed as an introduction to cryogenic engineering and analysis, and it is intended to introduce the basic concepts related to cryogenic analysis and testing as well as help the analyst understand the impacts of various requests on a test facility. Discussion will revolve around operational functions often found in cryogenic systems, hardware for both tests and facilities, and what design or modelling tools are available for performing the analysis. Emphasis will be placed on what scenarios to use what hardware or the analysis tools to get the desired results. The class will provide a review of first principles, engineering practices, and those relations directly applicable to this subject including such topics as cryogenic fluids, thermodynamics and heat transfer, material properties at low temperature, insulation, cryogenic equipment, instrumentation, refrigeration, testing of cryogenic systems, cryogenics safety and typical thermal and fluid analysis used by the engineer. The class will provide references for further learning on various topics in cryogenics for those who want to dive deeper into the subject or have encountered specific problems.
In-Space Propellant Production Using Water
A new era of space exploration is being planned. Manned exploration architectures under consideration require the long term storage of cryogenic propellants in space, and larger science mission directorate payloads can be delivered using cryogenic propulsion stages. Several architecture studies have shown that in-space cryogenic propulsion depots offer benefits including lower launch costs, smaller launch vehicles, and enhanced mission flexibility. NASA is currently planning a Cryogenic Propellant Storage and Transfer (CPST) technology demonstration mission that will use existing technology to demonstrate long duration storage, acquisition, mass gauging, and transfer of liquid hydrogen in low Earth orbit. This mission will demonstrate key technologies, but the CPST architecture is not designed for optimal mission operations for a true propellant depot. This paper will consider cryogenic propellant depots that are designed for operability. The operability principles considered are reusability, commonality, designing for the unique environment of space, and use of active control systems, both thermal and fluid. After considering these operability principles, a proposed depot architecture will be presented that uses water launch and on orbit electrolysis and liquefaction. This could serve as the first true space factory. Critical technologies needed for this depot architecture, including on orbit electrolysis, zero-g liquefaction and storage, rendezvous and docking, and propellant transfer, will be discussed and a developmental path forward will be presented. Finally, use of the depot to support the NASA Science Mission Directorate exploration goals will be presented.
Instrument for Measuring Thermal Conductivity of Materials at Low Temperatures
With the advance of polymer and other non-metallic material sciences, whole new series of polymeric materials and composites are being created. These materials are being optimized for many different applications including cryogenic and low-temperature industrial processes. Engineers need these data to perform detailed system designs and enable new design possibilities for improved control, reliability, and efficiency in specific applications. One main area of interest is cryogenic structural elements and fluid handling components and other parts, films, and coatings for low-temperature application. An important thermal property of these new materials is the apparent thermal conductivity (k-value).
Subcooling for Long Duration In-Space Cryogenic Propellant Storage
Cryogenic propellants such as hydrogen and oxygen are crucial for exploration of the solar system because of their superior specific impulse capability. Future missions may require vehicles to remain in space for months, necessitating long-term storage of these cryogens. A Thermodynamic Cryogen Subcooler (TCS) can ease the challenge of cryogenic fluid storage by removing energy from the cryogenic propellant through isobaric subcooling of the cryogen below its normal boiling point prior to launch. The isobaric subcooling of the cryogenic propellant will be performed by using a cold pressurant to maintain the tank pressure while the cryogen's temperature is simultaneously reduced using the TCS. The TCS hardware will be integrated into the launch infrastructure and there will be no significant addition to the launched dry mass. Heat leaks into all cryogenic propellant tanks, despite the use of the best insulation systems. However, the large heat capacity available in the subcooled cryogenic propellants allows the energy that leaks into the tank to be absorbed until the cryogen reaches its operational thermodynamic condition. During this period of heating of the subcooled cryogen there will be minimal loss of the propellant due to venting for pressure control. This simple technique can extend the operational life of a spacecraft or an orbital cryogenic depot for months with minimal mass penalty. In fact isobaric subcooling can more than double the in-space hold time of liquid hydrogen compared to normal boiling point hydrogen. A TCS for cryogenic propellants would thus provide an enhanced level of mission flexibility. Advances in the important components of the TCS will be discussed in this paper.