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Vibration of pump shaft is damped at impeller--where vibration-induced deflections are greatest--by shroud and seal. Damping reduces vibrational motion of shaft at bearings and load shaft places on them. Flow through clearance channel absorbs vibration energy.
The high pressure turbomachinery of the Space Shuttle Main Engine has the highest power-to-weight ratio of any operational machine known. Subsynchronous rotor whirl of the high pressure oxygen turbopump occurred in development testing at full-power level (109 percent thrust). The means by which the turbopump was successfully uprated is presented herein. The subsynchronous motion was determined to be driven by impeller destabilizing forces in combination with low net damping and bearing degradation. The degradation resulted from ball wear due primarily to an excessive loading condition of operating too near the lightly damped rotor second critical speed while under a large static load and, secondarily, from reverse bearing loading or loss of internal clearance and coolant during simulated flight conditions. The rotor response was reduced by stiffening the shaft and supports, optimizing the stiffness and damping of annular seals, and increasing the bearing deadband. The uprated oxygen turbopump configuration was verified by converting the pump and bearing support into a load cell for the purpose of systematically quantifying the load reduction benefits relative to baseline turbopumps. The damped second critical speed margin and the load sharing have been substantially improved which has resulted in reduced bearing loads for improved service life of the machine at full-power level.
A brief overview is presented of the development and technological activities of the free-piston Stirling engine. The engine started as a small scale fractional horsepower engine which demonstrated basic engine operating principles and the advantages of being hermetically sealed, highly efficient, and simple. It eventually developed into the free piston Stirling engine driven heat pump, and then into the SP-100 Space Reactor Power Program from which came the Space Power Demonstrator Engine (SPDE). The SPDE successfully operated for over 300 hr and delivered 20 kW of PV power to an alternator plunger. The SPDE demonstrated that a dynamic power conversion system can, with proper design, be balanced; and the engine performed well with externally pumped hydrostatic gas bearings.
The objective, to complete the development of an engineering model of a spaceborne hydrogen maser, was successfully achieved. A layout of the maser and detail drawings of the physics package was completed during the first 7 months of the contract. A computer model was made for the maser's thermal design. Using numerical computations, heater resistances were established for 7 temperature controlled zones. The physics package includes: a vacuum manifold that houses four sorption pumps capable of scavenging hydrogen for 4 years, a titanium vacuum tank housing the cavity, metallic seals for all vacuum joints, an RF dissociator within the vacuum envelope, a two-layer printed circuit solenoid and four layers of moly-permalloy magnetic shields. Problems were encountered and overcome in the procurements of the PC solenoid and the magnetic shields. After completion of the fabrication of the maser's components, the maser was assembled using these parts and other components made available by SAO, NRL, and NASA from earlier development work. In March, 1990, the vacuum system was assembled, and by May the maser assembly was completed. The magnetic shielding was poor and the shields were removed, reannealed by a local vendor, and the maser was reassembled. The maser began tests in early June and has been oscillating since that time. The test results of the maser are very good and a life test of the maser is being conducted. It is anticipated that the development and construction of a maser to be tested in space under a new contract from NASA's Marshall Space Flight Center will continue.
A pump system of the reciprocating piston type is described, which facilitates direct motor drive and cylinder sealing. A threaded middle potion of the piston is engaged by a nut connected to rotate with the rotor of an electric motor, in a manner that minimizes loading on the rotor by the use of a coupling that transmits torque to the nut but permits it to shift axially and radially with respect to the rotor. The nut has a threaded hydrostatic bearing for engaging the threaded piston portion, with an oil-carrying groove in the nut being interrupted. A fluid emitting seal located at the entrance to each cylinder, can serve to center the piston within the cylinder, wash the piston, and to aid in sealing. The piston can have a long stroke to diameter ratio to minimize reciprocations and wear on valves at high pressures. The voltage applied to the motor can be reversed prior to the piston reaching the end of its stroke, to permit pressure on the piston to aid in reversing the motor.
Since November 2008, the ISS Urine Processor Assembly (UPA) has successfully generated distillate from crew urine. Several rounds of modifications and upgrades have also been implemented to improve overall system performance throughout the years. The Distillation Assembly (DA) is the latest upgraded unit available, installed in September 2020. This unit has shown immediate performance improvements and redesign success. Most significant upgrades have been a redesigned drive train to eliminate belt slips, improved sealing to reduce leak paths and improve wear, and a redesigned liquid level sensor. The Purge Pump and Separator Assembly (PPSA) technology demonstration is the next available upgraded unit and has finished ground assembly and testing and is targeted for ISS delivery within the coming year. Most recent ground studies have identified areas to focus future UPA upgrade considerations with exploration missions in mind, specifically for better fault detection and isolations approaches as well as potential hardware redesigns to facilitate successful dormancy operations.
Several medical conditions require the administration of intravenous (IV) fluids,but limitations of mass, volume, shelf-life, transportation, and local resources can restrict the availability of these important fluids. Such limitations are expected in long-duration space exploration missions and in remote or austere places on Earth. This design uses regular drinking water that is pumped through two filters to produce, in minutes, sterile, ultrapure water that meets the stringent quality standards of the United States Pharmacopeia for Water for Injection (Total Bacteria, Conductivity, Endo - toxins, Total Organic Carbon). The device weighs 2.2 lb (1 kg) and is 10 in. long, 5 in. wide, and 3 in. high (≈25, 13, and 7.5 cm, respectively) in its storage configuration. This handheld device produces one liter of medical-grade water in 21 minutes. Total production capacity for this innovation is expected to be in the hundreds of liters. The device contains one battery powered electric mini-pump. Alternatively, a manually powered pump can be attached and used. Drinking water enters the device from a source water bag, flows through two filters, and final sterile production water exits into a sealed, medical-grade collection bag. The collection bag contains pre-placed crystalline salts to mix with product water to form isotonic intravenous medical solutions. Alternatively, a hypertonic salt solution can be injected into a filled bag. The filled collection bag is detached from the device and is ready for use or storage. This device currently contains one collection bag, but a manifold of several pre-attached bags or replacement of single collection bags under sterile needle technique is possible for the production of multiple liters. The entire system will be flushed, sealed, and radiation-sterilized. Operation of the device is easy and requires minimal training. Drinking water is placed into the collection bag. Inline stopcock flow valves at the source and collection bags are opened, and the mini-pump is turned on by a switch to begin fluid flow. When the collection bag is completely filled with the medical- grade water, the pump can be turned off. The pump is designed so it cannot pump air, and overfilling of the collection bag with fluid is avoided by placing an equal amount of water in the source bag. Backflow is avoided by inline check valves. The filled collection bag is disconnected from its tubing and is ready for use. The source bag can be refilled for production of multiple liters, or the source bag can be replaced with an input tube that can be placed in a larger potable water source if the device is attended. The device functions in all orientations independent of any gravity fields. In addition to creating IV fluids, the device produces medical-grade water, which can be used for mixing with medications for injection, reconstituting freeze-dried blood products for injection, or for wound hydration or irrigation. Potential worldwide use is expected with medical activities in environments that have limited resources, storage, or resupply such as in military field operations, humanitarian relief efforts, submarines, commercial cruise ships, etc.
The effect of coning on radial forces in face seals having angular misalignment is analyzed. Both the hydrostatic and hydrodynamic components of the resultant radial force are presented. It is shown that the displacement of the primary seal ring due to the action of radial forces is always in a direction which may cause inward pumping. However, in most cases the radial force is very small.
Experimental results are summarized, and it is pointed out that gravity-driven convection can alter the diffusive-advective mass transport behavior in the growth of crystals by physical vapor transport. Specially designed and constructed transparent furnaces are described which are being used to study the effects of gravity in the crystal growth of the compound semiconductors PbTe and CdTe. The theory underlying vapor transport behavior is reviewed, with attention given to the vapor-solid behavior of compound materials, to one-dimensional mass transport, and to gravity-induced (natural) convection. In the transparent furnaces, the quartz capillary tube mounted along the axis of the main quartz ampoule is used to measure the temperature at the growth surface (vapor-solid crystal interface) and the source, as well as the complete temperature profile along the axis of the tube. The light-pipe works to remove heat from the growth end of the ampoule by radiative heat transfer. The ampoules are sealed after being evacuated to the low 10 to the -8th torr range with a cryogenic vacuum pump.
New technologies for space-based, reusable, throttleable, cryogenic, orbit transfer propulsion are being evaluated. A variable-thrust (200 to 3000 lbF), 2000 psi chamber pressure, LO2/LH2 engine has been selected to demonstrate the 20-hour, 500-restart life goal, and a specific impulse of 480 lbF-sec/lbM. The advanced design uses warm oxygen to power a fully integrated turbopump that delivers 4500 psi LO2. The selected engine cycle provides the following advantages over conventional expander cycle designs which use H2 to drive the LH2 and LO2 pumps; higher engine operating pressures and performance in a smaller envelope, lower turbine operating temperatures, elimination of interpropellant seals and purges, and an extended throttling range. The design approach and results of testing to characterize materials for use in high-pressure gaseous oxygen are discussed. Test methods include particle impact testing in a sonic-flow, hot GO2 streams and forced, high-speed friction rubbing testing. Materials are exposed to oxygen and nitrogen atmospheres at pressures of 100, 1000, and 3000 psi to identify separately the gas cooling effects from the metal oxidation effects at the rubbing surface. The selection of candidate design materials is based on an analytical parameter defined as the burn factor. Typical materials tested include carbon steel, stainless steel, nickel, copper, and monel alloys.
The Turbomachinery Laboratory at Texas A&M has been providing experimental data and computational codes for the design seals for many years. The program began with the development of a Halon based seal test rig. This facility provided information about the effective stiffness and damping in whirling seals. The Halon effectively simulated cryogenic fluids. Another test facility was developed (using air as the working fluid) where the stiffness and damping matrices can be determined. This data was used to develop bulk flow models of the seal's effect upon rotating machinery; in conjunction with this research, a bulk flow model for calculation of performance and rotordynamic coefficients of annular pressure seals of arbitrary non-uniform clearance for barotropic fluids such as LH2, LOX, LN2, and CH4 was developed. This program is very efficient (fast) and converges for very large eccentricities. Currently, work is being performed on a bulk flow analysis of the effects of the impeller-shroud interaction upon the stability of pumps. The data was used along with data from other researchers to develop an empirical leakage prediction code for MSFC. Presently, the flow field inside labyrinth and annular seals are being studied in detail. An advanced 3-D Doppler anemometer system is being used to measure the mean velocity and entire Reynolds stress tensor distribution throughout the seals. Concentric and statically eccentric seals were studied; presently, whirling seals are being studied. The data obtained are providing valuable information about the flow phenomena occurring inside the seals, as well as a data base for comparison with numerical predictions and for turbulence model development. A finite difference computer code was developed for solving the Reynolds averaged Navier Stokes equation inside labyrinth seals. A multi-scale k-epsilon turbulence model is currently being evaluated. A new seal geometry was designed and patented using a computer code. A large scale, 2-D seal flow visualization facility is also being developed.
A novel dry coal feeding concept was developed for injecting ground coal into high-pressure gasifiers. Significant power savings are projected because the coal is injected directly with a ram and there is no requirement for pumping large volumes of gas or fluid against pressure. A novel feature of the concept is that a new seal zone is formed between the ram and injection tube each cycle. The seal zone comprises a mixture of a small quantity of finely ground coal and a fluid. To demonstrate the feasibility of the concept, coal was injected into a 1000-psi chamber with an experimental device having a 7-1/2-inch-diameter ram and a 28-inch-long stroke.
A means of eliminating the subsynchronous rotor whirl encountered during the development testing of the high-pressure oxygen turbopump of the Space Shuttle Main Engine is proposed. The rotor response is improved by reducing the pump end bearing loads and adding damping between the rotor and housing. In the present method, the impeller annular seals are converted into damping seals and the second rotor critical speed is increased due to the added stiffness of the seal conversion and the stiffening of the rotor shaft.
Protective plug resists slowly built-up pressure or automatically releases itself if pressure rises suddenly. Seals out moisture at pressures ranging from 50 micrometers of mercury to 200 pounds per square inch. Designed to seal throat of 38 Reaction Control Thrusters on Space Shuttle protecting internal components from corrosion. Plug conforms to contour of nozzle throat, where O-ring forms pressure seal. After plug inserted, cover attached by use of cover-fitting assembly. Modified versions useful in protecting engines, pumps, reaction vessels, and other industrial equipment during shipment and maintenance.
Operation of Hall thrusters with bismuth propellant has been shown to be a promising path toward high-power, high-performance, long-lifetime electric propulsion for spaceflight missions. For example, the VHITAL project aims td accurately, experimentally assess the performance characteristics of 10 kW-class bismuth-fed Hall thrusters - in order to validate earlier results and resuscitate a promising technology that has been relatively dormant for about two decades. A critical element of these tests will be the precise metering of propellant to the thruster, since performance cannot be accurately assessed without an accurate accounting of mass flow rate. Earlier work used a pre/post-test propellant weighing scheme that did not provide any real-time measurement of mass flow rate while the thruster was firing, and makes subsequent performance calculations difficult. The motivation of the present work was to develop a precision liquid bismuth Propellant Management System (PMS) that provides real-time propellant mass flow rate measurement and control, enabling accurate thruster performance measurements. Additionally, our approach emphasizes the development of new liquid metal flow control components and, hence, will establish a basis for the future development of components for application in spaceflight. The design of various critical components in a bismuth PMS are described - reservoir, electromagnetic pump, hotspot flow sensor, and automated control system. Particular emphasis is given to material selection and high-temperature sealing techniques. Open loop calibration test results are reported, which validate the systems capability to deliver bismuth at mass flow rates ranging from 10 to 100 mg/sec with an uncertainty of less than +/- 5%. Results of integrated vaporizer/liquid PMS tests demonstrate all of the necessary elements of a complete bismuth feed system for electric propulsion.
A modified approach to Childs' previous work on fluid-structure interaction forces in the leakage path between an impeller shroud and its housing is presented in this paper. Three governing equations consisting of continuity, path-momentum, and circumferential-momentum equations were developed to describe the leakage path inside a pump impeller. Radial displacement perturbations were used to solve for radial and circumferential force coefficients. In addition, impeller-discharge pressure disturbances were used to obtain pressure oscillation responses due to precessing impeller pressure wave pattern. Childs' model was modified from an incompressible model to a compressible barotropic-fluid model (the density of the working fluid is a function of the pressure and a constant temperature only). Results obtained from this model yielded interaction forces for radial and circumferential force coefficients. Radial and circumferential forces define reaction forces within the impeller leakage path. An acoustic model for the same leakage path was also developed. The convective, Coriolis, and centrifugal acceleration terms are removed from the compressible model to obtain the acoustics model. A solution due to impeller discharge pressure disturbances model was also developed for the compressible and acoustics models. The results from these modifications are used to determine what effects additional perturbation terms in the compressible model have on the acoustic model. The results show that the additional fluid mechanics terms in the compressible model cause resonances (peaks) in the force coefficient response curves. However, these peaks only occurred at high values of inlet circumferential velocity ratios greater than 0.7. The peak pressure oscillation was shown to occur at the wearing ring seal. Introduction of impeller discharge disturbances with n = 11 diametral nodes showed that maximum peak pressure oscillations occurred at nondimensional precession frequencies of f = 6.4 and f = 7.8 for this particular pump. Bolleter's results suggest that for peak pressure oscillations to occur at the wearing ring seal, the nondimensional excitation frequency should be on the order of f = 2.182 for n = 11. The resonances found in this research do not match the excitation frequencies predicted by Bolleter. At the predicted peak excitation frequencies given by Bolleter, the compressible model shows an attenuation of the pressure oscillations at the seal exit. The compressibility of the fluid does not have a significant influence on the model at low values of nondimensional excitation frequency. At high values of nondimensional frequency, the effects of compressibility become more significant. For the acoustic analysis, the convective, Coriolis, and centrifugal acceleration terms do affect the results to a limited extent for precession excitation and to a large extent for a pressure excitation when the fluid operates at relatively high Mach numbers.
No abstract available
A balloon-borne photoionization mass spectrometer used to measure stratospheric trace gases is described. Ions are created with photons from high-intensity krypton discharge lamps and a quadrupole mass analyzer is employed for ion identification. Differential pumping is achieved with liquid helium cryopumping. To insure measurement of unperturbed stratospheric air, the entire system is contained in a sealed gondola and the atmospheric sample is taken some distance away during descent. The photoionization technique allows the detection of a low ionization potential constituent, such as nitric oxide, at less than a part in one billion in the presence of the major atmospheric gases and their isotopes. Operation of the mass spectrometer system was demonstrated during a daytime flight from Palestine, Texas on 26 April 1977. The sensitivity achieved and the unique selectivity afforded by this technique offer a capability for trace constituent measurement not possible with the more conventional electron impact ionization approach.