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NASA NTRS2000

Flammability: A Review and Analysis

With its founding in 1975, Committee G-4 of the American Society for Testing and Materials (ASTM) embarked on the process of defining the flammability of metallic materials in oxygen-enriched atmospheres. In this process, they are joined by the National Aeronautics and Space Administration (NASA), the National Fire Protection Association (NFPA), and the Compressed Gas Association (CGA). Although none of these organizations has explicitly defined flammability, the following definitions and statements provide a composite understanding of the concept: 1. "This Standard Guide (ASTM G94-92) is concerned primarily with the properties of a material associated with its relative susceptibility to ignition and propagation of combustion." 2. "A material is considered flammable at the maximum use pressure if at least one sample burns more than 6 in. (15.2 cm). At least, five samples must be tested." NASA 3. "Flammable: Capable, when ignited of maintaining combustion under the specified environmental conditions." NFPA 53. 4. "Combustion: A complex sequence of chemical reactions between a fuel and an oxidant accompanied by the evolution of heat, and usually, the emission of light." NFPA 53. and 5. "A safe oxygen-piping transmission or distribution system is one that is designed and installed in accordance with all applicable codes and regulations for the service conditions and locations involved and further meets the special requirements for oxygen services." CGA-G4 Flammability thus equates, after ignition, to propagation of combustion, synonymous with steady state burning, under specified environmental conditions. Properties for which quantitative values are given in ASTM G94-92 and which are used to describe metals flammability consistent with the concept of steady state burning are either system independent properties, such as, enthalpies of reaction, burn ratios, flame temperatures, thermal conductivity, and heat release; or system dependent properties, such as, oxygen index, promoted combustion, threshold pressure and burn rates. Each property is reviewed and analyzed as to whether it provides an absolute or relative measure for flammability. It is shown that burn ratio, as applied to the actual steady state combustion condition, approaches the desired absolute measure of flammability.

Wilson, D. Bruce↗

NASA NTRS2002

Direct-Drive Gas-Cooled Reactor Power System: Concept and Preliminary Testing

This paper describes the concept and preliminary component testing of a gas-cooled, UN-fueled, pin-type reactor which uses He/Xe gas that goes directly into a recuperated Brayton system to produce electricity for nuclear electric propulsion. This Direct-Drive Gas-Cooled Reactor (DDG) is designed to be subcritical under water or wet- sand immersion in case of a launch accident. Because the gas-cooled reactor can directly drive the Brayton turbomachinery, it is possible to configure the system such that there are no external surfaces or pressure boundaries that are refractory metal, even though the gas delivered to the turbine is 1144 K. The He/Xe gas mixture is a good heat transport medium when flowing, and a good insulator when stagnant. Judicious use of stagnant cavities as insulating regions allows transport of the 1144-K gas while keeping all external surfaces below 900 K. At this temperature super-alloys (Hastelloy or Inconel) can be used instead of refractory metals. Super-alloys reduce the technology risk because they are easier to fabricate than refractory metals, we have a much more extensive knowledge base on their characteristics, and, because they have a greater resistance to oxidation, system testing is eased. The system is also relatively simple in its design: no additional coolant pumps, heat exchanger, or freeze-thaw systems are required. Key to success of this concept is a good knowledge of the heat transfer between the fuel pins and the gas, as well as the pressure drop through the system. This paper describes preliminary testing to obtain this key information, as well as experience in demonstrating electrically heated testing of simulated reactor components.

Wright, S. A.↗

NASA NTRS2003

Thermally Simulated Testing of a Direct-Drive Gas-Cooled Nuclear Reactor

This paper describes the concept and preliminary component testing of a gas-cooled, UN-fueled, pin-type reactor which uses He/Xe gas that goes directly into a recuperated Brayton system to produce electricity for nuclear electric propulsion. This Direct-Drive Gas-Cooled Reactor (DDG) is designed to be subcritical under water or wet-sand immersion in case of a launch accident. Because the gas-cooled reactor can directly drive the Brayton turbomachinery, it is possible to configure the system such that there are no external surfaces or pressure boundaries that are refractory metal, even though the gas delivered to the turbine is 1144 K. The He/Xe gas mixture is a good heat transport medium when flowing, and a good insulator when stagnant. Judicious use of stagnant cavities as insulating regions allows transport of the 1144-K gas while keeping all external surfaces below 900 K. At this temperature super-alloys (Hastelloy or Inconel) can be used instead of refractory metals. Super-alloys reduce the technology risk because they are easier to fabricate than refractory metals, we have a much more extensive knowledge base on their characteristics, and, because they have a greater resistance to oxidation, system testing is eased. The system is also relatively simple in its design: no additional coolant pumps, heat exchanger, or freeze-thaw systems are required. Key to success of this concept is a good knowledge of the heat transfer between the fuel pins and the gas, as well as the pressure drop through the system. This paper describes preliminary testing to obtain this key information, as well as experience in demonstrating electrical thermal simulation of reactor components and concepts.

Godfroy, Thomas↗

NASA NTRS2009

Regenerative Performance of the NASA Symmetrical Solid Oxide Fuel Cell Design

The NASA Glenn Research Center is developing both a novel cell design (BSC) and a novel ceramic fabrication technique to produce fuel cells predicted to exceed a specific power density of 1.0 kW/kg. The NASA Glenn cell design has taken a completely different approach among planar designs by removing the metal interconnect and returning to the use of a thin, doped LaCrO3 interconnect. The cell is structurally symmetrical. Both electrodes support the thin electrolyte and contain micro-channels for gas flow-- a geometry referred to as a bi-electrode supported cell or BSC. The cell characteristics have been demonstrated under both SOFC and SOE conditions. Electrolysis tests verify that this cell design operates at very high electrochemical voltage efficiencies (EVE) and high H2O conversion percentages, even at the low flow rates predicted for closed loop systems encountered in unmanned aerial vehicle (UAV) applications. For UAVs the volume, weight and the efficiency are critical as they determine the size of the water tank, the solar panel size, and other system requirements. For UAVs, regenerative solid oxide fuel cell stacks (RSOFC) use solar panels during daylight to generate power for electrolysis and then operate in fuel cell mode during the night to power the UAV and electronics. Recent studies, performed by NASA for a more electric commercial aircraft, evaluated SOFCs for auxiliary power units (APUs). System studies were also conducted for regenerative RSOFC systems. One common requirement for aerospace SOFCs and RSOFCs, determined independently in each application study, was the need for high specific power density and volume density, on the order of 1.0 kW/kg and greater than 1.0 kW/L. Until recently the best reported performance for SOFCs was 0.2 kW/kg or less for stacks. NASA Glenn is working to prototype the light weight, low volume BSC design for such high specific power aerospace applications.

Cable, Thomas L.↗

NASA NTRS1976

Performance and emission characteristics of swirl-can combustors to near-stoichiometric fuel-air ratio

Emissions and performance characteristics were determined for two full annular swirl-can combustors operated to near stoichiometric fuel-air ratio. Test condition variations were as follows: combustor inlet-air temperatures, 589, 756, 839, and 894 K; reference velocities, 24 to 37 meters per second; inlet pressure, 62 newtons per square centimeter; and fuel-air ratios, 0.015 to 0.065. The combustor average exit temperature and combustor efficiency were calculated from the combustor exhaust gas composition. For fuel-air ratios greater than 0.04, the combustion efficiency decreased with increasing fuel-air ratios in a near-linear manner. Increasing the combustor inlet air temperature tended to offset this decrease. Maximum oxides of nitrogen emission indices occurred at intermediate fuel-air ratios and were dependent on combustor design. Carbon monoxide levels were extremely high and were the primary cause of poor combustion efficiency at the higher fuel-air ratios. Unburned hydrocarbons were low for all test conditions. For high fuel-air ratios SAE smoke numbers greater than 25 were produced, except at the highest inlet-air temperatures.

Diehl, L. A.↗

NASA NTRS2005

Proton-Exchange-Membrane Fuel Cell Powerplants Developed and Tested for Exploration Missions

Proton-exchange-membrane fuel cell (PEMFC) technology has received major attention for terrestrial applications, such as the automotive and residential markets, for the past 20 years. This attention has significantly advanced the maturity of the technology, resulting in ever more compact, efficient, reliable, and inexpensive PEMFC designs. In comparison to the terrestrial operating environment, the space operating environment is much more demanding. Microgravity to high-gravity loads and the need to use pure oxygen (rather than air) as the fuel cell oxidizer place more stringent demands on PEMFC technology. NASA and its partners from industry are leveraging terrestrial PEMFC advancements by conducting parallel space technology development for future exploration missions. A team from the NASA Glenn Research Center, NASA Johnson Space Center, and NASA Kennedy Space Center recently completed the first phase of a PEMFC powerplant development effort for exploration missions. The industry partners for this phase of the development effort were ElectroChem, Inc., and Teledyne Energy Systems, Inc. Under contract to Glenn, both of these industry partners successfully designed, fabricated, and tested a breadboard PEMFC powerplant in the 1- to 5-kW power range. These powerplants were based on existing company-proprietary fuel cell stack designs, combined with off-the-shelf components, which formed the balance of the powerplant design. Subsequent to the contractor development efforts, both powerplants were independently tested at Johnson to verify operational and performance characteristics, and to determine suitability for further technology development in the second phase of the NASA-led effort. Following the independent NASA testing, Teledyne Energy Systems, Inc., was selected to develop an engineering model PEMFC powerplant. This effort was initiated by the 2nd Generation Reusable Launch Vehicle (RLV) Program Office in 2001; it transitioned to the Next Generation Launch Technologies (NGLT) Program Office in 2003. The effort is now being funded by the Exploration Program Office. We plan to summarize the results from the ongoing engineering model PEMFC powerplant development in a future Research & Technology article.

Hoberecht, Mark A.↗

NASA NTRS1973

Design and evaluation of combustors for reducing aircraft engine pollution

Efforts in reducing exhaust emissions from turbine engines are reported. Various techniques employed and the results of testing are briefly described and referenced for detail. The experimental approaches taken to reduce oxides of nitrogen emissions include the use of: (1) multizone combustors incorporating reduced dwell times, (2) fuel-air premixing, (3) air atomization, (4) fuel prevaporization, and (5) gaseous fuel. Since emissions of unburned hydrocarbons and carbon monoxide are caused by poor combustion efficiency at engine idle, the studies of fuel staging in multizone combustors and air assist fuel nozzles have indicated that large reductions in these emissions can be achieved. Also, the effect of inlet-air humidity on oxides of nitrogen was studied as well as the very effective technique of direct water injection. The emission characteristics of natural gas and propane fuels were measured and compared with those of ASTM-Al kerosene fuel.

Jones, R. E.↗

NASA NTRS1997

Sample Delivery and Computer Control Systems for Detecting Leaks in the Main Engines of the Space Shuttle

The main engines of the Space Shuttle use hydrogen and oxygen as the fuel and oxidant. The explosive and fire hazards associated with these two components pose a serious danger to personnel and equipment. Therefore prior to use the main engines undergo extensive leak tests. Instead of using hazardous gases there tests utilize helium as the tracer element. This results in a need to monitor helium in the ppm level continuously for hours. The major challenge in developing such a low level gas monitor is the sample delivery system. This paper discuss a system developed to meet the requirements while also being mobile. Also shown is the calibration technique, stability, and accuracy results for the system.

Griffin, Timothy P.↗

NASA NTRS1997

Qualitative Flow Visualization of a 110-N Hydrogen/Oxygen Laboratory Model Thruster

The flow field inside a 110 N gaseous hydrogen/oxygen thruster was investigated using an optically accessible, two-dimensional laboratory test model installed in a high altitude chamber. The injector for this study produced an oxidizer-rich core flow, which was designed to fully mix and react inside a fuel-film sleeve insert before emerging into the main chamber section, where a substantial fuel film cooling layer was added to protect the chamber wall. Techniques used to investigate the flow consisted of spontaneous Raman spectra measurements, visible emission imaging, ultraviolet hydroxyl spectroscopy, and high speed schlieren imaging. Experimental results indicate that the oxygen rich core flow continued to react while emerging from the fuel-film sleeve, suggesting incomplete mixing of the hydrogen in the oxygen rich core flow. Experiments also showed that the fuel film cooling protective layer retained its integrity throughout the straight section of the combustion chamber. In the converging portion of the chamber, however, a turbulent reaction zone near the wall destroyed the integrity of the film layer, a result which implies that a lower contraction angle may improve the fuel film cooling in the converging section and extend the hardware lifetime.

deGroot, Wim A.↗

NASA NTRS1995

Hypergolic oxidizer and fuel scrubber emissions

Hypergolic fuels and oxidizer are emitted to the environment during fueling and deservicing shuttle and other spacecraft. Such emissions are difficult to measure due to the intermittent purge flow and to the presence of suspended scrubber liquor. A new method for emissions monitoring was introduced in a previous paper. This paper is a summary of the results of a one-year study of shuttle launch pads and orbiter processing facilities (OPF's) which proved that emissions can be determined from field scrubbers without direct measurement of vent flow rate and hypergol concentration. This new approach is based on the scrubber efficiency, which was measured during normal operations, and on the accumulated weight of hypergol captured in the scrubber liquor, which is part of the routine monitoring data of scrubber liquors. To validate this concept, three qualification tests were performed, logs were prepared for each of 16 hypergol scrubbers at KSC, the efficiencies of KSC scrubbers were measured during normal operations, and an estimate of the annual emissions was made based on the efficiencies and the propellant buildup data. The results have confirmed that the emissions from the KSC scrubbers can be monitored by measuring the buildup of hypergol propellant in the liquor, and then using the appropriate efficiency to calculate the emissions. There was good agreement between the calculated emissions based on outlet concentration and flow rate, and the emissions calculated from the propellant buildup and efficiency. The efficiencies of 12 KSC scrubbers, measured under actual servicing operations and special test conditions, were assumed to be valid for all subsequent operations until a significant change in hardware occurred. An estimate of the total emissions from 16 scrubbers for three years showed that 0.3 kg/yr of fuel and 234 kg/yr of oxidizer were emitted.

Parrish, Clyde F.↗

NASA NTRS1975

PPO foam - Liquid hydrogen insulation

An extensive fabrication and test program is described which has demonstrated the integrity of PPO (polyphenylene oxide) foam as an internal insulation. PPO is shown to be capable of withstanding multiple reuses on such cryogenic-fueled launch vehicles as the Space Shuttle. The major advantages of this internal insulation is the absence of a pressure load on the insulation, reduced handling damage, and minimization of cyclic thermal stresses by a 'warm' bond line.

Yates, G. B.↗

NASA NTRS2007

Radiative Extinction of Gaseous Spherical Diffusion Flames in Microgravity

Radiative extinction of spherical diffusion flames was investigated experimentally and numerically. The experiments involved microgravity spherical diffusion flames burning ethylene and propane at 0.98 bar. Both normal (fuel flowing into oxidizer) and inverse (oxidizer flowing into fuel) flames were studied, with nitrogen supplied to either the fuel or the oxygen. Flame conditions were chosen to ensure that the flames extinguished within the 2.2 s of available test time; thus extinction occurred during unsteady flame conditions. Diagnostics included color video and thin-filament pyrometry. The computations, which simulated flow from a porous sphere into a quiescent environment, included detailed chemistry, transport and radiation, and yielded transient results. Radiative extinction was observed experimentally and simulated numerically. Extinction time, peak temperature, and radiative loss fraction were found to be independent of flow rate except at very low flow rates. Radiative heat loss was dominated by the combustion products downstream of the flame and was found to scale with flame surface area, not volume. For large transient flames the heat release rate also scaled with surface area and thus the radiative loss fraction was largely independent of flow rate. Peak temperatures at extinction onset were about 1100 K, which is significantly lower than for kinetic extinction. One observation of this work is that while radiative heat losses can drive transient extinction, this is not because radiative losses are increasing with time (flame size) but rather because the heat release rate is falling off as the temperature drops.

Santa, K. J.↗

NASA NTRS2012

Peregrine 100-km Sounding Rocket Project

The Peregrine Sounding Rocket Program is a joint basic research program of NASA Ames Research Center, NASA Wallops, Stanford University, and the Space Propulsion Group, Inc. (SPG). The goal is to determine the applicability of this technology to a small launch system. The approach is to design, build, and fly a stable, efficient liquefying fuel hybrid rocket vehicle to an altitude of 100 km. The program was kicked off in October of 2006 and has seen considerable progress in the subsequent 18 months. This research group began studying liquifying hybrid rocket fuel technology more than a decade ago. The overall goal of the research was to gain a better understanding of the fundamental physics of the liquid layer entrainment process responsible for the large increase in regression rate observed in these fuels, and to demonstrate the effect of increased regression rate on hybrid rocket motor performance. At the time of this reporting, more than 400 motor tests were conducted with a variety of oxidizers (N2O, GOx, LOx) at ever increasing scales with thrust levels from 5 to over 15,000 pounds (22 N to over 66 kN) in order to move this technology from the laboratory to practical applications. The Peregrine program is the natural next step in this development. A number of small sounding rockets with diameters of 3, 4, and 6 in. (7.6, 10.2, and 15.2 cm) have been flown, but Peregrine at a diameter of 15 in. (38.1 cm) and 14,000-lb (62.3-kN) thrust is by far the largest system ever attempted and will be one of the largest hybrids ever flown. Successful Peregrine flights will set the stage for a wide range of applications of this technology.

Zilliac, Gregory↗

NASA NTRS2019

Mars Ascent Vehicle Hybrid Propulsion Development

Hybrid propulsion is being investigated as a propulsion method for a possible Mars Ascent Vehicle (MAV) application. MAV is part of a proposed larger Mars Sample Return (MSR) campaign plan to bring samples from Mars to earth for examination. The Mars Ascent Vehicle would launch Mars surface samples found and packaged by the Mars 2020 mission to orbit around Mars. This version of hybrid propulsion is based on a wax based solid fuel, called SP7A, and a Mixed Oxides of Nitrogen oxidizer, MON-25. SP7 is a new fuel formulation developed by Space Propulsion Group and was modified for this application to be resistant to Mars temperature extremes and modified again to lower the regression rate to become SP7A. MON-25 was chosen for its low freezing temperature. Due to cost constraints, MON-3 was the oxidizer used during testing through 2018. In 2019, full scale hybrid testing with MON-25 commenced in Mojave, CA by Whittinghill Aerospace. One flight motor will be subjected to thermal cycling in a vacuum and later fired in a vacuum to demonstrate the proposed Liquid Injection Thrust Vector Control system performance at White Sands Test Facility (WSTF). In addition, there will be MON-25 characterization work done at Purdue University and WSTF. Additional testing of subscale and full scale motors will be conducted with MON-3 with fuel grain stress, fuel grain support and case design test objectives by Space Propulsion Group Inc. of Butte, MT. This paper documents some of the testing, issues and accomplishments with the MAV hybrid propulsion option that is being considered (along with a two-stage solid propulsion option).

Story, G. T.↗

NASA NTRS1989

A fuel cell energy storage system concept for the Space Station Freedom Extravehicular Mobility Unit

An update is given on work to design and build a Fuel Cell Energy Storage System (FCESS) bench-tested unit for the Space Station Freedom Extravehicular Mobility Unit (EMU). Fueled by oxygen and hydride-stored hydrogen, the FCESS is being considered as an alternative to the EMU zinc-silver oxide battery. Superior cycle life and quick recharge are the main attributes of FCESS. The design and performance of a nonventing, 28 V, 34 Ahr system with 7 amp rating are discussed.

Adlhart, Otto J.↗

NASA NTRS2008

NASA's PEM Fuel Cell Power Plant Development Program for Space Applications

A three-center NASA team led by the Glenn Research Center in Cleveland, Ohio is completing a five-year PEM fuel cell power plant development program for future space applications. The focus of the program has been to adapt commercial PEM fuel cell technology for space applications by addressing the key mission requirements of using pure oxygen as an oxidant and operating in a multi-gravity environment. Competing vendors developed breadboard units in the 1 to 5 kW power range during the first phase of the program, and a single vendor developed a nominal 10-kW engineering model power pant during the second phase of the program. Successful performance and environmental tests conducted by NASA established confidence that PEM fuel cell technology will be ready to meet the electrical power needs of future space missions.

Hoberecht, Mark A.↗

NASA NTRS1977

Syntheses and Degradations of Fluorinated Heterocyclics: Perfluoroalkyl and Perfluroalkylether-1,2,4-Oxadiazoles - 2

3-Perfluoroalkylether-5-perfluoro-n-heptyl-1,2,4-oxadiazole and 3,S-bis(perfluoroalkylether)-1,2,4-oxadiazole were synthesized and characterized. The 3, 5-bis(perfluoroalkylether)-l, 2,4-oxadiazole was subjected to thermal, thermal oxidative, and hydrolytic degradations at 235 and 325 C and was found to be stable under these conditions as evidenced by practically quantitative recovery of the test samples. In the presence of Jet-A fuel at 235 C a low degree of degradation, approximately 4%, was observed. 3,5-Bis(perfluoro-n-heptyl)-1,2,4-oxadiazole was found to be stable to attack by water at 325 C; however in air in the presence of jet-A at 235 C the extent of degradation was in excess of 10%.

Paciorek, K. J. L.↗

NASA NTRS1957

Results of turbojet engine operation tests using a 50-50 mixture of JP-4 and tributyl borate as the fuel

An experimental investigation was conducted on a centrifugal-type turbojet engine using a 50-50 mixture of tributyl borate and JP-4 as the fuel to determine the magnitude and the location of the boric oxide deposits in the engine as well as the effect of these deposits on the engine performance. Large deposits of boric acid formed in the combustor walls and on the turbine rotor and stator blades. The deposits had no effect on the engine thrust.

Schafer, Louis J , Jr↗