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Two devices are necessary for abrasion and fracture testing of materials evaluated for storage of hydrogen at high pressure for long periods. The first device abrades tensile specimens. The second device tests for fracture toughness of metals. Both devices permit testing in both yield and failure modes in high pressure hydrogen.
The NASA Safety Standard, which establishes a uniform process for hydrogen system design, materials selection, operation, storage, and transportation, is presented. The guidelines include suggestions for safely storing, handling, and using hydrogen in gaseous (GH2), liquid (LH2), or slush (SLH2) form whether used as a propellant or non-propellant. The handbook contains 9 chapters detailing properties and hazards, facility design, design of components, materials compatibility, detection, and transportation. Chapter 10 serves as a reference and the appendices contained therein include: assessment examples; scaling laws, explosions, blast effects, and fragmentation; codes, standards, and NASA directives; and relief devices along with a list of tables and figures, abbreviations, a glossary and an index for ease of use. The intent of the handbook is to provide enough information that it can be used alone, but at the same time, reference data sources that can provide much more detail if required.
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A study was done of the feasibility of conducting liquid hydrogen orbital storage, acquisition, and transfer experiments aboard a spacecraft launched by a commercial Atlas launch vehicle. Three hydrogen tanks are mated to a spacecraft bus that is similar to that used for three-axis-controlled satellites. The bus provides power, communications, and attitude control along with acceleration levels ranging from 10 exp -6 to 10 exp -4 g. At launch, all the liquid hydrogen is contained in the largest tank, which has an insulation system designed for both space operation and the short-term launch pad and ascent environment. This tank is much lighter and lower in cost than a vacuum-jacketed design, and is made possible by the experiment tanking options available due to the hydrogen-fueled Centaur upper stage of the Atlas I.
A nickel-based superalloy that resists embrittlement by hydrogen more strongly than does nickel alloy 718 has been developed. Nickel alloy 718 is the most widely used superalloy. It has excellent strength and resistance to corrosion as well as acceptably high ductility, and is recognized as the best alloy for many high-temperature applications. However, nickel alloy 718 is susceptible to embrittlement by hydrogen and to delayed failure and reduced tensile properties in gaseous hydrogen. The greater resistance of the present nickel-based superalloy to adverse effects of hydrogen makes this alloy a superior alternative to nickel alloy 718 for applications that involve production, transfer, and storage of hydrogen, thereby potentially contributing to the commercial viability of hydrogen as a clean-burning fuel. The table shows the composition of the present improved nickel-based superalloy in comparison with that of nickel alloy 718. This composition was chosen to obtain high resistance to embrittlement by hydrogen while maintaining high strength and exceptional resistance to oxidation and corrosion. The most novel property of this alloy is that it resists embrittlement by hydrogen while retaining tensile strength greater than 175 kpsi (greater than 1.2 GPa). This alloy exhibits a tensile elongation of more than 20 percent in hydrogen at a pressure of 5 kpsi (approximately equal to 34 MPa) without loss of ductility. This amount of elongation corresponds to 50 percent more ductility than that exhibited by nickel alloy 718 under the same test conditions.
A subcritical liquid hydrogen orbital storage and transfer experiment was designed for flight in the Shuttle cargo bay. The Cryogenic Fluid Management Experiment (CFME) includes a liquid hydrogen tank supported in a vacuum jacket by two fiberglass epoxy trunnion mounts. This composite material was selected for the trunnions since it provides desirable strength, weight and thermal characteristics for supporting cryogenic tankage. An experimental program was conducted to provide material property and fatigue data for S-glass epoxy composite materials at ambient and liquid hydrogen temperatures and to verify structural integrity of the CFME trunnion supports.
A thermodynamic analysis is given of different regimes of storage of hydrogen, nitrogen, oxygen, and argon using the high vacuum of space. Optimal regimes are determined from the standpoint of minimizing weight characteristics. Several unique storage regimes are proposed.
A subcritical liquid hydrogen orbital storage and supply experiment is being designed for flight in the Space Shuttle cargo bay. The Cryogenic Fluid Management Experiment (CFME) includes a liquid hydrogen tank supported in a vacuum jacket by two fiberglass epoxy composite trunnion mounts. The ability of the CFME to last for the required seven missions depends primarily on the fatigue life of the composite trunnions at cryogenic temperatures. To verify the trunnion design and test the performance of the composite material, fatigue property data at 300 and 20 K were obtained for the specific E-glass fabric/S-glass unidirectional laminate that will be used for the CFME trunnions. The fatigue life of this laminate was greater at 20 K than at 300 K, and was satisfactory for the intended application.
NASA has completed a series of tests at the Kennedy Space Center to demonstrate the capability of using integrated refrigeration and storage (IRAS) to remove energy from a liquid hydrogen (LH2) tank and control the state of the propellant. A primary test objective was the keeping and storing of the liquid in a zero boil-off state, so that the total heat leak entering the tank is removed by a cryogenic refrigerator with an internal heat exchanger. The LH2 is therefore stored and kept with zero losses for an indefinite period of time. The LH2 tank is a horizontal cylindrical geometry with a vacuum-jacketed, multi-layer insulation system and a capacity of 125,000 liters. The closed-loop helium refrigeration system was a Linde LR1620 capable of 390W cooling at 20K (without any liquid nitrogen pre-cooling). Three different control methods were used to obtain zero boil-off: temperature control of the helium refrigerant, refrigerator control using the tank pressure sensor, and duty cycling (on/off) of the refrigerator as needed. Summarized are the IRAS design approach, zero boil-off control methods, and results of the series of zero boil-off tests.
Cryogenic gas storage systems were developed for the liquid storage of oxygen, hydrogen, nitrogen, and helium. Cryogenic storage is attractive because of the high liquid density and low storage pressure of cryogens. This situation results in smaller container sizes, reduced container-strength levels, and lower tankage weights. The Gemini and Apollo spacecraft used cryogenic gas storage systems as standard spacecraft equipment. In addition to the Gemini and Apollo cryogenic gas storage systems, other systems were developed and tested in the course of advancing the state of the art. All of the cryogenic storage systems used, developed, and tested to date for manned-spacecraft applications are described.
The NASA Advanced Exploration Systems (AES) program has a three year project to develop and demonstrate technologies to fundamentally change the way ground servicing activities support future access to space architectures. The AES Integrated Ground Operation Demonstration Units (IGODU) project has created two test beds for investigating and maturing two key elements of spaceport processing activities. The first is the GODU Integrated Refrigeration and Storage test bed that is demonstrating zero-loss storage of liquid hydrogen propellants and studying the storage and transfer of densified propellants. The second activity is the GODU Autonomous Control test bed that is implementing health management technologies and autonomous control capability of the propellant loading process to reduce the standing army of experts historically needed to ensure safe propellant loading operations. This presentation will give an overview of the activities at the Kennedy Space Center on these two test beds and its potential impact on future access to space programs.
Modern multi-layer insulation (MLI) allows to sharply reduce the heat leak into cryogenic propellant storage tanks through the tank surface and, as a consequence, significantly extend the storage duration. In this situation the MLI penetrations, such as support struts, feed lines, etc., become one of the most significant challenges of the tanks heat management. This problem is especially acute for liquid hydrogen (LH2) storage, since currently no efficient cryocoolers exist that operate at very low LH2 temperatures (20K). Even small heat leaks under microgravity conditions and over the period of many months give rise to a complex slowly-developing, large-scale spatiotemporal physical phenomena in a multi-phase liquid-vapor mixture. These phenomena are not well-understood nor can be easily controlled. They can be of a potentially hazardous nature for long-term on-orbital cryogenic torage, propellant loading, tank chilldown, engine restart, and other in-space cryogenic fluid management operations. To support the engineering design solutions that would mitigate these effects a detailed physics-based analysis of heat transfer, vapor bubble formation, growth, motion, coalescence and collapse is required in the presence of stirring jets of different configurations and passive cooling devices such as MLI, thermodynamic vent system, and vapor-cooled shield. To develop physics-based models and correlations reliable for microgravity conditions and long-time scales there is a need for new fundamental data to be collected from on-orbit cryogenic storage experiments. Our report discusses some of these physical phenomena and the design requirements and future studies necessary for their mitigation. Special attention is payed to the phenomena occurring near MLI penetrations.
Information is given in viewgraph form on nickel hydrogen battery design for the transporter energy storage subsystem (TESS). Information is given on use in the Space Station Freedom, the launch configuration, use in the Mobile Servicing Center, battery design requirements, TESS subassembley design, proof of principle testing of a 6-cell battery, possible downsizing of TESS to support the Mobile Rocket Servicer Base System (MBS) redesign, TESS output capacity, and cell testing.
An introduction to the closed cycle hydrogen-oxygen polymer electrolyte membrane (PEM) regenerative fuel cell (RFC), recently constructed at NASA Glenn Research Center, is presented. Illustrated with explanatory graphics and figures, this report outlines the engineering motivations for the RFC as a solar energy storage device, the system requirements, layout and hardware detail of the RFC unit at NASA Glenn, the construction history, and test experience accumulated to date with this unit.
Storing cryogenic propellants with zero boil off (ZBO) using a combination of active (cryocoolers) and passive technologies has recently received a great deal of attention for applications such as future long-term space missions. This paper will examine a variety of potential near-term terrestrial applications for ZBO and, where appropriate, provide a rough order of magnitude cost benefit of implementing ZBO technology. NASA's Space Shuttle power system uses supercritical propellant tanks, which are filled several days before launch. If the launch does not occur within 48-96 hours, the tanks must be drained and refilled, further delaying the launch. By implementing ZBO, boil off could be eliminated and pad hold time extended. At the launch site, vented liquid hydrogen (LH2) storage dewars lose 1200-1600 gal/day through boiloff. Implementing ZBO would eliminate this, saving $300,000-$400,000 per year. Similarly, overland trucking of LH2 from the supplier to the launch site via roadable dewars results in a cryogen loss of ten percent per tanker (1500 gal/tanker). Providing a cryocooler on board the rig would prevent this loss. Previous work investigating variable density insulation found that a 50% reduction in evaporation from a 6000 gallon dewar would save $5000 per year. For a 20 year dewar lifetime, the payback period would be less than two years. Similar benefits could be realized at other storage facilities across the nation. Within the superconductivity community, there is skepticism about using coolers, based upon reliability concerns. By providing a cooler on the dewar, lifetime could be extended while retaining fail-safe capability. If the cooler failed, it would merely lower the storage life of the dewar.
A multidimensional computational model of the pressurization process in a slush hydrogen propellant storage tank was developed and its accuracy evaluated by comparison to experimental data measured for a 5 ft diameter spherical tank. The fluid mechanic, thermodynamic, and heat transfer processes within the ullage are represented by a finite-volume model. The model was shown to be in reasonable agreement with the experiment data. A parameter study was undertaken to examine the dependence of the pressurization process on initial ullage temperature distribution and pressurant mass flow rate. It is shown that for a given heat flux rate at the ullage boundary, the pressurization process is nearly independent of initial temperature distribution. Significant differences were identified between the ullage temperature and velocity fields predicted for pressurization of slush and those predicted for pressurization of liquid hydrogen. A simplified model of the pressurization process was constructed in search of a dimensionless characterization of the pressurization process. It is shown that the relationship derived from this simplified model collapses all of the pressure history data generated during this study into a single curve.
A multidimensional computational model of the pressurization process in a slush hydrogen propellant storage tank was developed and its accuracy evaluated by comparison to experimental data measured for a 5 ft diameter spherical tank. The fluid mechanic, thermodynamic, and heat transfer processes within the ullage are represented by a finite-volume model. the heat and mass fluxes at the ullage boundary were computed in auxiliary analyses and specified as input to the finite-volume model. the model was shown to be in reasonable agreement with the experimental data. A parameter study was undertaken to examine the dependence of the pressurization process on initial ullage temperature distribution and pressurant mass flow rate. It is shown that for a given heat flux rate at the ullage boundary, the pressurization process is nearly independent of initial temperature distribution. The mass flow rate study revealed decreasing pressurant mass requirements with increasing pressurant mass flow rate. Further, significant differences were identified between the ullage temperature and velocity fields predicted for pressurization of slush and those predicted for pressurization of liquid hydrogen. A simplified model of the pressurization process was constructed in search of a dimensionless characterization of the pressurization process. It is shown that the relationship derived from this simplified model collapses all of the pressure history data generated during this study into a single curve.
The analysis on the feasibility for using metal hydrides in the thermal protection system of cryogenic tanks in space was based on the heat capacity of ice as the phase change material (PCM). It was found that with ice the thermal protection system weight could be reduced by, at most, about 20 percent over an all LI-900 insulation. For this concept to be viable, a metal hydride with considerably more capacity than water would be required. None were found. Special metal hydrides were developed for hydrogen fuel storage applications and it may be possible to do so for the current application. Until this appears promising further effort on this feasibility study does not seem warranted.