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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

Large-Scale Cryogen Systems and Test Facilities

NASA has completed initial construction and verification testing of the Integrated Systems Test Facility (ISTF) Cryogenic Testbed. The ISTF is located at Complex 20 at Cape Canaveral Air Force Station, Florida. The remote and secure location is ideally suited for the following functions: (1) development testing of advanced cryogenic component technologies, (2) development testing of concepts and processes for entire ground support systems designed for servicing large launch vehicles, and (3) commercial sector testing of cryogenic- and energy-related products and systems. The ISTF Cryogenic Testbed consists of modular fluid distribution piping and storage tanks for liquid oxygen/nitrogen (56,000 gal) and liquid hydrogen (66,000 gal). Storage tanks for liquid methane (41,000 gal) and Rocket Propellant 1 (37,000 gal) are also specified for the facility. A state-of-the-art blast proof test command and control center provides capability for remote operation, video surveillance, and data recording for all test areas.

Johnson, R. G.↗
NASA NTRS2007

Aerogel Insulation Applications for Liquid Hydrogen Launch Vehicle Tanks

Aerogel based insulation systems for ambient pressure environments were developed for liquid hydrogen (LH2) tank applications. Solutions to thermal insulation problems were demonstrated for the Space Shuttle External Tank (ET) through extensive testing at the Cryogenics Test Laboratory. Demonstration testing was performed using a 1/10th scale ET LH2 intertank unit and liquid helium as the coolant to provide the 20 K cold boundary temperature. Cryopumping tests in the range of 20K were performed using both constant mass and constant pressure methods. Long-duration tests (up to 10 hours) showed that the nitrogen mass taken up inside the intertank is reduced by a factor of nearly three for the aerogel insulated case as compared to the un-insulated (bare metal flight configuration) case. Test results including thermal stabilization, heat transfer effectiveness, and cryopumping confirm that the aerogel system eliminates free liquid nitrogen within the intertank. Physisorption (or adsorption) of liquid nitrogen within the fine pore structure of aerogel materials was also investigated. Results of a mass uptake method show that the sorption ratio (liquid nitrogen to aerogel beads) is about 62 percent by volume. A novel liquid nitrogen production method of testing the liquid nitrogen physical adsorption capacity of aerogel beads was also performed to more closely approximate the actual launch vehicle cooldown and thermal stabilization effects within the aerogel material. The extraordinary insulating effectiveness of the aerogel material shows that cryopumping is not an open-cell mass transport issue but is strictly driven by thermal communication between warm and cold surfaces. The new aerogel insulation technology is useful to solve heat transfer problem areas and to augment existing thermal protection systems on launch vehicles. Examples are given and potential benefits for producing launch systems that are more reliable, robust, reusable, and efficient are outlined.

Fesmire, J. E.↗
NASA NTRS2007

Cost-Efficient Storage of Cryogens

NASA's cryogenic infrastructure that supports launch vehicle operations and propulsion testing is reaching an age where major refurbishment will soon be required. Key elements of this infrastructure are the large double-walled cryogenic storage tanks used for both space vehicle launch operations and rocket propulsion testing at the various NASA field centers. Perlite powder has historically been the insulation material of choice for these large storage tank applications. New bulk-fill insulation materials, including glass bubbles and aerogel beads, have been shown to provide improved thermal and mechanical performance. A research testing program was conducted to investigate the thermal performance benefits as well as to identify operational considerations and associated risks associated with the application of these new materials in large cryogenic storage tanks. The program was divided into three main areas: material testing (thermal conductivity and physical characterization), tank demonstration testing (liquid nitrogen and liquid hydrogen), and system studies (thermal modeling, economic analysis, and insulation changeout). The results of this research work show that more energy-efficient insulation solutions are possible for large-scale cryogenic storage tanks worldwide and summarize the operational requirements that should be considered for these applications.

Fesmire, J. E.↗
NASA NTRS2007

Numerical Modeling of Propellant Boil-Off in a Cryogenic Storage Tank

A numerical model to predict boil-off of stored propellant in large spherical cryogenic tanks has been developed. Accurate prediction of tank boil-off rates for different thermal insulation systems was the goal of this collaboration effort. The Generalized Fluid System Simulation Program, integrating flow analysis and conjugate heat transfer for solving complex fluid system problems, was used to create the model. Calculation of tank boil-off rate requires simultaneous simulation of heat transfer processes among liquid propellant, vapor ullage space, and tank structure. The reference tank for the boil-off model was the 850,000 gallon liquid hydrogen tank at Launch Complex 39B (LC- 39B) at Kennedy Space Center, which is under study for future infrastructure improvements to support the Constellation program. The methodology employed in the numerical model was validated using a sub-scale model and tank. Experimental test data from a 1/15th scale version of the LC-39B tank using both liquid hydrogen and liquid nitrogen were used to anchor the analytical predictions of the sub-scale model. Favorable correlations between sub-scale model and experimental test data have provided confidence in full-scale tank boil-off predictions. These methods are now being used in the preliminary design for other cases including future launch vehicles

Majumdar, A. K.↗
NASA NTRS2007

Large-Scale Cryogenic Testing of Launch Vehicle Ground Systems at the Kennedy Space Center

The development of a new launch vehicle to support NASA's future exploration plans requires significant redesign and upgrade of Kennedy Space Center's (KSC) launch pad and ground support equipment systems. In many cases, specialized test equipment and systems will be required to certify the function of the new system designs under simulated operational conditions, including propellant loading. This paper provides an overview of the cryogenic test infrastructure that is in place at KSC to conduct development and qualification testing that ranges from the component level to the integrated-system level. An overview of the major cryogenic test facilities will be provided, along with a detailed explanation of the technology focus area for each facility

Ernst, E. W.↗
NASA NTRS2007

AeroFoam

No abstract available

Smith, Trent M.↗
NASA NTRS2008

Cryogenic Moisture Uptake in Foam Insulation for Space Launch Vehicles

Rigid polyurethane foams and rigid polyisocyanurate foams (spray-on foam insulation), like those flown on Shuttle, Delta IV, and will be flown on Ares-I and Ares-V, can gain an extraordinary amount of water when under cryogenic conditions for several hours. These foams, when exposed for eight hours to launch pad environments on one side and cryogenic temperature on the other, increase their weight from 35 to 80 percent depending on the duration of weathering or aging. This effect translates into several thousand pounds of additional weight for space vehicles at lift-off. A new cryogenic moisture uptake apparatus was designed to determine the amount of water/ice taken into the specimen under actual-use propellant loading conditions. This experimental study included the measurement of the amount of moisture uptake within different foam materials. Results of testing using both aged specimens and weathered specimens are presented. To better understand cryogenic foam insulation performance, cryogenic moisture testing is shown to be essential. The implications for future launch vehicle thermal protection system design and flight performance are discussed.

Fesmire, James E.↗
NASA NTRS2010

Glass Bubbles Insulation for Liquid Hydrogen Storage Tanks

A full-scale field application of glass bubbles insulation has been demonstrated in a 218,000 L liquid hydrogen storage tank. This work is the evolution of extensive materials testing, laboratory scale testing, and system studies leading to the use of glass bubbles insulation as a cost efficient and high performance alternative in cryogenic storage tanks of any size. The tank utilized is part of a rocket propulsion test complex at the NASA Stennis Space Center and is a 1960's vintage spherical double wall tank with an evacuated annulus. The original perlite that was removed from the annulus was in pristine condition and showed no signs of deterioration or compaction. Test results show a significant reduction in liquid hydrogen boiloff when compared to recent baseline data prior to removal of the perlite insulation. The data also validates the previous laboratory scale testing (1000 L) and full-scale numerical modeling (3,200,000 L) of boiloff in spherical cryogenic storage tanks. The performance of the tank will continue to be monitored during operation of the tank over the coming years.

Glass bubble↗
NASA NTRS2007

Cryogenic Thermal Performance Testing of Bulk-Fill and Aerogel Insulation Materials

The research testing and demonstration of new bulk-fill materials for cryogenic thermal insulation systems was performed by the Cryogenics Test Laboratory at NASA Kennedy Space Center. Thermal conductivity testing under actual-use cryogenic conditions is a key to understanding the total system performance encompassing engineering, economics, and materials factors. A number of bulk fill insulation materials, including aerogel beads, glass bubbles, and perlite powder, were tested using a new cylindrical cryostat. Boundary temperatures for the liquid nitrogen boil-off method were 293 K and 78 K. Tests were performed as a function of cold vacuum pressure from high vacuum to no vacuum conditions. Results are compared with other complementary test methods in the range of 300 K to 20 K. Various testing techniques are shown to be required to obtain a complete understanding of the operating performance of a material and to provide data for answers to design engineering questions.

Scholtens, B. E.↗
NASA NTRS2014

Ground Operations Autonomous Control and Integrated Health Management

An intelligent autonomous control capability has been developed and is currently being validated in ground cryogenic fluid management operations. The capability embodies a physical architecture consistent with typical launch infrastructure and control systems, augmented by a higher level autonomous control (AC) system enabled to make knowledge-based decisions. The AC system is supported by an integrated system health management (ISHM) capability that detects anomalies, diagnoses causes, determines effects, and could predict future anomalies. AC is implemented using the concept of programmed sequences that could be considered to be building blocks of more generic mission plans. A sequence is a series of steps, and each executes actions once conditions for the step are met (e.g. desired temperatures or fluid state are achieved). For autonomous capability, conditions must consider also health management outcomes, as they will determine whether or not an action is executed, or how an action may be executed, or if an alternative action is executed instead. Aside from health, higher level objectives can also drive how a mission is carried out. The capability was developed using the G2 software environment (www.gensym.com) augmented by a NASA Toolkit that significantly shortens time to deployment. G2 is a commercial product to develop intelligent applications. It is fully object oriented. The core of the capability is a Domain Model of the system where all elements of the system are represented as objects (sensors, instruments, components, pipes, etc.). Reasoning and decision making can be done with all elements in the domain model. The toolkit also enables implementation of failure modes and effects analysis (FMEA), which are represented as root cause trees. FMEA's are programmed graphically, they are reusable, as they address generic FMEA referring to classes of subsystems or objects and their functional relationships. User interfaces for integrated awareness by operators have been created.

Figueroa, Fernando↗
NASA NTRS2013

Physics Based Model for Online Fault Detection in Autonomous Cryogenic Loading System

We report the progress in the development of the chilldown model for rapid cryogenic loading system developed at KSC. The nontrivial characteristic feature of the analyzed chilldown regime is its active control by dump valves. The two-phase flow model of the chilldown is approximated as one-dimensional homogeneous fluid flow with no slip condition for the interphase velocity. The model is built using commercial SINDAFLUINT software. The results of numerical predictions are in good agreement with the experimental time traces. The obtained results pave the way to the application of the SINDAFLUINT model as a verification tool for the design and algorithm development required for autonomous loading operation.

Cryogenics↗
NASA NTRS2015

The Safe Removal of Frozen Air from the Annulus of an LH2 Storage Tank

Large Liquid Hydrogen (LH2) storage tanks are vital infrastructure for NASA. Eventually, air may leak into the evacuated and perlite filled annular region of these tanks. Although the vacuum level is monitored in this region, the extremely cold temperature causes all but the helium and neon constituents of air to freeze. A small, often unnoticeable pressure rise is the result. As the leak persists, the quantity of frozen air increases, as does the thermal conductivity of the insulation system. Consequently, a notable increase in commodity boil-off is often the first indicator of an air leak. Severe damage can result from normal draining of the tank. The warming air will sublimate which will cause a pressure rise in the annulus. When the pressure increases above the triple point, the frozen air will begin to melt and migrate downward. Collection of liquid air on the carbon steel outer shell may chill it below its ductility range, resulting in fracture. In order to avoid a structural failure, as described above, a method for the safe removal of frozen air is needed. A thermal model of the storage tank has been created using SINDA/FLUINT modeling software. Experimental work is progressing in an attempt to characterize the thermal conductivity of a perlite/frozen nitrogen mixture. A statistical mechanics model is being developed in parallel for comparison to experimental work. The thermal model will be updated using the experimental/statistical mechanical data, and used to simulate potential removal scenarios. This paper will address methodologies and analysis techniques for evaluation of two proposed air removal methods.

cryogenic insulation↗
NASA NTRS2016

Total Hydrocarbon Content (THC) Testing in Liquid Oxygen (LOX)

The measured Total Hydrocarbon Content (THC) levels in liquid oxygen (LOX) systems at Stennis Space Center (SSC) have shown wide variations. Examples of these variations include the following: 1) differences between vendor-supplied THC values and those obtained using standard SSC analysis procedures; and 2) increasing THC values over time at an active SSC test stand in both storage and run vessels. A detailed analysis of LOX sampling techniques, analytical instrumentation, and sampling procedures will be presented. Additional data obtained on LOX system operations and LOX delivery trailer THC values during the past 12-24 months will also be discussed. Field test results showing THC levels and the distribution of the THC's in the test stand run tank, modified for THC analysis via dip tubes, will be presented.

Meneghelli, B. J.↗
NASA NTRS2017

Inferential Framework for Autonomous Cryogenic Loading Operations

We address problem of autonomous cryogenic management of loading operations on the ground and in space. As a step towards solution of this problem we develop a probabilistic framework for inferring correlations parameters of two-fluid cryogenic flow. The simulation of two-phase cryogenic flow is performed using nearly-implicit scheme. A concise set of cryogenic correlations is introduced. The proposed approach is applied to an analysis of the cryogenic flow in experimental Propellant Loading System built at NASA KSC. An efficient simultaneous optimization of a large number of model parameters is demonstrated and a good agreement with the experimental data is obtained.

Luchinsky, Dmitry G.↗
NASA NTRS2016

Physics Based Model for Cryogenic Chilldown and Loading. Part III: Correlations

In this report we discuss the details of the correlations used to recognize flow patterns and predict frictional losses, heat and mass transfer in the cryogenic two phase flow. The emphasis are put on the formulation of the correlation problem in terms of concise parametric and functional spaces allowing for efficient online search of the model parameters and accurate prediction of the phenomena observed during cryogenic loading. A special attention is paid to the discussion of the correlation dependence on the gravity. In this context the physics of stability, friction, and boiling in the two-phase flow that underlies the required correlations is discussed.

two-phase flow↗
NASA NTRS2018

MRI-based Quantification of Optic Nerve Tortuosity and Subarachnoid Space 3D Geometry: Reliability Assessment

In some astronauts, long-duration space flight results in ophthalmic structure changes such as optic nerve (ON) kinking, ON distention, and globe flattening. Assessment of the ON and ON sheath (ONS) may provide insight into the mechanisms responsible for ophthalmic structure changes seen in a subset of astronauts. Automated and manual methods were developed to quantify 3D ON/ONS geometry and ON tortuosity.

Rohr, Jesse J.↗