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A detailed review of ISO 15859 "Space Systems - Fluid Characteristics, Sampling and Test Methods" was performed An approach to revising Parts 1-9 and 11-13 was developed and concurred by the NASA Technical Standards Program Office. The approach was to align them with the highest level source documents, and not to program-specific requirements. The updated documents were prepared and presented.
This paper describes an application of a general purpose computer program, GFSSP (Generalized Fluid System Simulation Program) for calculating flow distribution in a network of micro-channels. GFSSP employs a finite volume formulation of mass and momentum conservation equations in a network consisting of nodes and branches. Mass conservation equation is solved for pressures at the nodes while the momentum conservation equation is solved at the branches to calculate flowrate. The system of equations describing the fluid network is solved by a numerical method that is a combination of the Newton-Raphson and successive substitution methods. The numerical results have been compared with test data and detailed CFD (computational Fluid Dynamics) calculations. The agreement between test data and predictions is satisfactory. The discrepancies between the predictions and test data can be attributed to the frictional correlation which does not include the effect of surface tension or electro-kinetic effect.
This paper presents a numerical model of a system-level test bed - the multipurpose hydrogen test bed (MHTB) using Generalized Fluid System Simulation Program (GFSSP). MHTB is representative in size and shape of a fully integrated space transportation vehicle liquid hydrogen (LH2) propellant tank and was tested at Marshall Space Flight Center (MSFC) to generate data for cryogenic storage. GFSSP is a finite volume based network flow analysis software developed at MSFC and used for thermo-fluid analysis of propulsion systems. GFSSP has been used to model the self-pressurization and ullage pressure control by Thermodynamic Vent System (TVS). A TVS typically includes a Joule-Thompson (J-T) expansion device, a two-phase heat exchanger, and a mixing pump and spray to extract thermal energy from the tank without significant loss of liquid propellant. Two GFSSP models (Self-Pressurization & TVS) were separately developed and tested and then integrated to simulate the entire system. Self-Pressurization model consists of multiple ullage nodes, propellant node and solid nodes; it computes the heat transfer through Multi-Layer Insulation blankets and calculates heat and mass transfer between ullage and liquid propellant and ullage and tank wall. TVS model calculates the flow through J-T valve, heat exchanger and spray and vent systems. Two models are integrated by exchanging data through User Subroutines of both models. The integrated models results have been compared with MHTB test data of 50% fill level. Satisfactory comparison was observed between test and numerical predictions.
Sublimators have been proposed and used in spacecraft for heat rejection. Sublimators are desirable heat rejection devices for short duration use because they can transfer large amounts of heat using little mass and are self-regulating devices. Sublimators reject heat into space by freezing water inside a porous substrate, allowing it to sublimate into vapor, and finally venting it into space. The state of the art thermal control system in orbiting spacecraft is a two loop, two fluid system. The external coolant loop typically uses a toxic single phase fluid that acquires heat from the spacecraft and rejects most of it via a radiator. The sublimator functions as a transient topper for orbiting spacecraft during day pass periods when radiator efficiency decreases. The sublimator interfaces with the internal loop through a built in heat exchanger. The internal loop fluid is non-toxic and is typically a propylene glycol and water solution with inhibitors to prevent corrosion with aluminum fins of the heat exchangers. Feedwater is supplied from a separate line to the sublimator to maintain temperature control of the cabin and vehicle hardware. Water membrane evaporators have been developed for spacecraft and spacesuits. They function similar to a sublimator but require a backpressure valve which could be actuated for this application with a simple fully open or fully closed modes. This technology would be applied to orbital thermal control (lunar or planetary). This paper details a trade study showing that evaporators would greatly reduce the consumable that is used, effectively wasted, by sublimators during start up and shut down during the topping phases of each orbit. State of the art for 9 kW sublimators reject about 870 W per kilogram of mass and 1150 W per liter of volume. If water with corrosion inhibitors is used the evaporators would be about 80% of the mass and volume of the equivalent system. The size and mass increases to about 110% if the internal fluid is 50% propylene glycol/50% water. The true benefit comes from the backpressure valve, that prevents the cyclical shutdown/startup loss of the sublimator and amounts to as much as 0.85 kg per orbit.
This paper presents a multi-node finite volume model of No Vent Filling (NVF) of a cryogenic tank with Thermo-dynamic Vent System (TVS) assisted injector, using the Generalized Fluid System Simulation Program (GFSSP), a general purpose flow network code. NVF tests were conducted in a CRYOgenic Orbital Testbed (CRYOTE) tank which was filled by liquid nitrogen using a TVS assisted injector with vent valve closed during the entire filling process. In TVS assisted injector, the liquid flow splits into two streams: one stream is routed to a Joule-Thomson (J-T) orifice where the flow immediately flashes from liquid to vapor or two phase mixture because the downstream to J-T leg is maintained at vacuum level.; the other stream is injected into the tank after being cooled by cold vapor of J-T leg in a heat exchanger. The flow through J-T leg is also used to cool the outer metal matrix of the injector which in turn cools the vapor in the tank ullage. The cooling of vapor in the ullage by cold injector surface reduces ullage pressure that allows liquid to enter and fill the tank. An integrated numerical model of the test set up was developed. The model included the dual lines of TVS assisted injector, tank and tank wall. The tank was discretized into multiple fluid nodes and branches to represent the ullage and liquid nitrogen and multiple solid nodes to represent the tank wall and structure. The heat transfer between solid to fluid was calculated from pool boiling correlations which include film, transition, and nucleate boiling, as well as natural convection during pre- and post-boiling. The model also accounts for the condensation of vapor at ullage-injector interface and when it comes in contact with the liquid spray. The predicted pressure, resident mass, wall temperature in the tank were compared with the test data.
Flow stability down inclined plane for stratified fluid system consisting of two layers of viscous fluids of different densities
We have worked with our collaborators at the University of Milan (Professor Marzio Giglio and his group-supported by ASI) to define the science required to measure gradient driven fluctuations in the microgravity environment. Such a study would provide an accurate test of the extent to which the theory of fluctuating hydrodynamics can be used to predict the properties of fluids maintained in a stressed, non-equilibrium state. As mentioned above, the results should also provide direct visual insight into the behavior of a variety of fluid systems containing gradients or interfaces, when placed in the microgravity environment. With support from the current grant, we have identified three key systems for detailed investigation. These three systems are: 1) A single-component fluid to be studied in the presence of a temperature gradient; 2) A mixture of two organic liquids to be studied both in the presence of a temperature gradient, which induces a steady-state concentration gradient, and with the temperature gradient removed, but while the concentration gradient is dying by means of diffusion; 3) Various pairs of liquids undergoing free diffusion, including a proteidbuffer solution and pairs of mixtures having different concentrations, to allow us to vary the differences in fluid properties in a controlled manner.
All space vehicles require ground umbilical systems for servicing. Servicing requirements can include, but are not limited to, electrical power and control, propellant loading and venting, pneumatic system supply, hazard gas detection and purging as well as systems checkout capabilities. Of the various types of umbilicals, all require several common subsystems. These typically include an alignment system, mating and locking system, fluid connectors, electrical connectors and control !checkout systems. These systems have been designed to various levels of detail based on the needs for manual and/or automation requirements. The Automated Ground Umbilical Systems (AGUS) project is a multi-phase initiative to develop design performance requirements and concepts for launch system umbilicals. The automation aspect minimizes operational time and labor in ground umbilical processing while maintaining reliability. This current phase of the project reviews the design, development, testing and operations of ground umbilicals built for the Saturn, Shuttle, X-33 and Atlas V programs. Based on the design and operations lessons learned from these systems, umbilicals can be optimized for specific applications. The product of this study is a document containing details of existing systems and requirements for future automated umbilical systems with emphasis on design-for-operations (DFO).
Our understanding of early solar system fluids took a dramatic turn a decade ago with the discovery of fluid inclusion-bearing halite (NaCl) crystals in the matrix of two freshly fallen brecciated H chondrite falls, Monahans and Zag. Both meteorites are regolith breccias, and contain xenolithic halite (and minor admixed sylvite -- KCl, crystals in their regolith lithologies. The halites are purple to dark blue, due to the presence of color centers (electrons in anion vacancies) which slowly accumulated as 40K (in sylvite) decayed over billions of years. The halites were dated by K-Ar, Rb-Sr and I-Xe systematics to be 4.5 billion years old. The "blue" halites were a fantastic discovery for the following reasons: (1) Halite+sylvite can be dated (K is in sylvite and will substitute for Na in halite, Rb substitutes in halite for Na, and I substitutes for Cl). (2) The blue color is lost if the halite dissolves on Earth and reprecipitates (because the newly-formed halite has no color centers), so the color serves as a "freshness" or pristinity indicator. (3) Halite frequently contains aqueous fluid inclusions. (4) Halite contains no structural oxygen, carbon or hydrogen, making them ideal materials to measure these isotopic systems in any fluid inclusions. (5) It is possible to directly measure fluid inclusion formation temperatures, and thus directly measure the temperature of the mineralizing aqueous fluid. In addition to these two ordinary chondrites halite grains have been reliably reported in several ureilites, an additional ordinary chondrite (Jilin), and in the carbonaceous chondrite (Murchison), although these reports were unfortunately not taken seriously. We have lately found additional fluid inclusions in carbonates in several additional carbonaceous chondrites. Meteoritic aqueous fluid inclusions are apparently relatively widespread in meteorites, though very small and thus difficult to analyze.
The IPD rocket engine is the product of a joint Air Force/NASA program to demonstrate the concept of a full-flow staged combustion power cycle. In this type of rocket engine cycle, both the entire fuel flow and the entire oxidizer flow are combusted in one of two pre-bumers and used to drive two turbopumps, thus utilizing the flow work of the total propellant flow. The basis of the IPD engine program relies on integrating newly developed and pre-existing hardware to demonstrate the component and material technologies to make this concept feasible, while simultaneously saving development time and costs. To provide insight to the project team and contractors during engine development and test phases, the engine system was modeled at MSFC using the Rocket Engine Transient Simulation (ROCETS) software to analyze system performance and determine component integration issues. The ROCETS software is used extensively a MSFC to perform steady-state power-balances and transient simulations of thermodynamic power and general fluid systems. The software is favored for its capability to solve large systems of non-linear equations, its librarie of fluid properties and flow devices, its flexibility to modify existing code to improve the physics-derived approximations of real fluid thermodynamic behavior, and the ability to add unique system constraints. The purpose of this paper is to present the methodology used to model the IPD engine system, detail the pitfalls encountered with the software, and explain the approximations made to more accurately represent engine component and fluid behavior. Engine system performance output from the model will be presented and explained in comparison with real fluid and component behavior.
The missions of the National Aeronautics and Space Administration (NASA) routinely produce unique requirements and challenges for development and application of Computational Fluid Dynamics (CFD) methods. NASA presently embodies four distinct Mission Directorates: Aeronautics Research, Exploration Systems, Science, and Space Operations. These missions generate requirements for systems that operate in a wide variety of environments. They range from the high-speed flight of aerodynamically optimized vehicles operating in the earth’s atmosphere to spacecraft designed for missions that don’t favor aerodynamic optimization, some operating in the atmosphere of planets and planetary moons such as Mars and Venus or Saturn’s moon Titan. Systems supporting these vehicles, such as rocket and jet propulsion, reaction control systems, fluid and thermal transfer systems, etc. can also generate their own unique set of flow phenomena that challenge today’s CFD methodology. Through the NASA Engineering and Safety Center (NESC), NASA annually conducts state-of-the-discipline assessments in fifteen distinct engineering disciplines. These assessments are performed by the NASA Technical Fellows that lead Technical Discipline Teams (TDT) of recognized experts in these fifteen areas. In the Aerosciences discipline, three topics have been identified as the top challenges for the discipline: aero-plume interaction prediction, unsteady separated flows, and aerothermodynamic prediction. These challenge areas are defined by the Agency’s high-risk projects and problems on which the NESC is requested to perform independent testing, analysis, and assessments. When viewed as a whole, these tests, analyses, and assessments provide a clear view of the recurring technical challenges facing Agency engineers and researchers and can be used to guide future research and technology development. The present state-of-the-art in the application of CFD at NASA is the use of Reynolds-Averaged Navier- Stokes (RANS) solvers, primarily executed in a steady-state mode of operation. In isolated cases, Unsteady RANS (URANS) solvers have been employed when steady RANS solutions produce poorly converging or oscillating results or in cases, such as aeroelastic analysis, which require unsteady aerodynamic simulation. For most traditional external and internal aerodynamic flows, structured overset grids or unstructured grids are employed to minimize geometric modeling and grid generation times. Grid adaptation, primarily as a series of coarse-grain intermediate processing steps is also seeing use on particularly complex flow problems and configurations. In the case of aerothermodynamic flows, engineers have been forced to continue to employ structured grid techniques as the present unstructured grid methodology has proven inadequate in the prediction of surface heating. In the area of aero-plume interaction modeling, two-gas, frozen chemistry simulation is generally the state-of-the- art, with some production solvers capable of predicting flows with only a single gas component. Prediction of flows falling into the afore-mentioned top Aerosciences technical challenges have severely stressed the present state-of-the-art in CFD prediction and for some problems, such as unsteady separated flows and aero-plume interaction cases, engineers have begun employing Large Eddy Simulation (LES) and Hybrid RANS/LES techniques. In some isolated aero-propulsion interaction cases, chemically reacting flow simulations have been applied. These methods are highly evolutionary and engineers have little experience in their application, so they cannot be heavily relied upon in today’s application environment. Therefore, this leads one to muse over which numerical technologies will be included in the CFD tools that will be employed 30 years in the future. This presentation will describe specific technical problems that have stressed NASA’s traditional CFD methods to their breaking point and will link these issues to the Agency’s top Aerosciences technical challenges. The discussion will then shift to the characteristics of future CFD solvers that will be required to attack these challenges and how these characteristics differ from the present state-of-the- art. High-order methods certainly appear to have a place in the development of future CFD tools and some of the physical characteristics of our most challenging problems suggest that high-order methods are the only way to effectively solve them. But there are some relatively severe implementation issues that face these methods, particularly in the area of general applicability and robust operation as an engineering tool. Desired characteristics of next-generation CFD solvers will be discussed and the author’s view of which emerging numerical technologies might be employed to address these attributes will also be presented
The Flow Boiling and Condensation Experiment (FBCE) to be manifested on the International Space Station (ISS) consists of a fluid system and the associated electronics to provide for conditioning the test fluid (normal-PerFluorohexane or nPFH-C6F14) to the proper thermodynamic state prior to entering a test module, which can be interchangeable based on the science objectives. Two separate test modules have been manufactured for the FBCE, the Flow Boiling Module (FBM), which investigates flow boiling for a subcooled liquid, saturated liquid, or two phase mixture, and the Condensation Module Heat Transfer (CM-HT), which investigates condensation of a flowing saturated or superheated vapor. The test fluid heating is accomplished using the Bulk Heater Module (BHM), which heats the fluid to various states based on the demands of the currently installed test module. ISS Internal Thermal Control System (ITCS) water is utilized to cool the test fluid prior to entering the circulation pump, and is also utilized for cooling for condensation in CM-HT, for cooling of a camera in FBM. An adjustable pressure bellows-type accumulator is used to set the pressure at the inlet of the test section, but does not provide active pressure control during testing. The flow of the test fluid is achieved using a gear pump controlled by a coriolis flow meter, which also provides the flow rate measurement. Flow rates for the ITCS water loops are measured and controlled using coriolis flow meters with directly controlled proportional valves. During execution of FBCE operations, the FBM is scheduled to collect data for three months before being exchanged with CM-HT for another three month data collection run. In this work, we present the development of the flight hardware, the associated challenges experienced during the development such as packaging flight system hardware, and the lessons learned in overcoming the encountered challenges.
An unstructured finite volume procedure has been developed for steady and transient thermo-fluid dynamic analysis of fluid systems and components. The procedure is applicable for a flow network consisting of pipes and various fittings where flow is assumed to be one dimensional. It can also be used to simulate flow in a component by modeling a multi-dimensional flow using the same numerical scheme. The flow domain is discretized into a number of interconnected control volumes located arbitrarily in space. The conservation equations for each control volume account for the transport of mass, momentum and entropy from the neighboring control volumes. In addition, they also include the sources of each conserved variable and time dependent terms. The source term of entropy equation contains entropy generation due to heat transfer and fluid friction. Thermodynamic properties are computed from the equation of state of a real fluid. The system of equations is solved by a hybrid numerical method which is a combination of simultaneous Newton-Raphson and successive substitution schemes. The paper also describes the application and verification of the procedure by comparing its predictions with the analytical and numerical solution of several benchmark problems.
We introduce the anti-symmetric representation of the extended magnetohydrodynamic (MHD) equations. In this representation, the use of the anti-symmetric flux operator (∇·ν+ν·∇) results in conservation theorems with discrete analogs. Inherently robust numerical applications are achieved with little effort, and conservation to machine precision is possible with simple numerical schemes. Starting from the two-fluid equations, we construct a single-fluid MHD model based on generalized center-of-mass variables for the mass (√ρ), momentum (√ρν), and pressure (√ p ). This model is shown to possess identical conservation properties to the two-fluid system, with the only restriction being the use of a single temperature. Common approximations to the Braginskii heat fluxes and to the gyroviscous stress tensor are cast into our representation for convenience. The discrete conservation properties are verified using the classic Orszag–Tang vortex problem. In addition to the favorable mass, momentum, and energy conservation properties, the time reversibility of the simulations is demonstrated.
An coarse-grained approach to thermocapillarity effects in binary fluid systems is discussed along with example numerical results.
We present a new finite element framework for modeling compressible, turbulent multiphase flows with heat transfer. For two-fluid systems with a free surface, the Volume of Fluid (VOF) method is implemented without the need for interface reconstruction, while turbulence is resolved using a dynamic Vreman large eddy simulation (LES) model. Unlike most two-phase VOF studies, which neglect heat transfer, the present approach incorporates energy transport equations within the VOF formulation to account for heat exchange, an effect particularly important in turbulent flows. Conjugate heat transfer is often challenging in finite volume methods, which require explicit specification of heat fluxes at the solid–fluid interface, limiting accuracy and predictive capability. By contrast, the finite element formulation does not require heat flux inputs, allowing more accurate and robust simulation of heat transfer between solids and fluids. The method is demonstrated through three representative cases. First, a two-fluid instability with a single-mode perturbation is simulated and validated against analytical growth rates. Second, conjugate heat transfer is examined in a high-temperature flow over a cold metal cylinder, with validation performed both quantitatively—via pressure coefficient comparisons with experimental data—and qualitatively using vector field topology. Finally, compressible spray injection and breakup are modeled, demonstrating the ability of the framework to capture interfacial dynamics and atomization under turbulent, high-speed conditions. In the compressible spray injection and breakup case, the results indicate that the finite element formulation achieved higher predictive accuracy and robustness than the finite-volume method. With the same mesh resolution, the FEM reduced the root mean square error (RMSE) and mean absolute percentage error (MAPE) from 6.96 mm and 26.0% (for the FVM) to 4.85 mm and 12.7%, respectively, demonstrating improved accuracy and robustness in capturing interfacial dynamics and heat transfer. The study also introduced vector field topology to visualize and interpret coherent flow structures and instabilities, offering insights beyond conventional scalar-field analyses.
A finite volume-based network flow modeling tool, Generalized Fluid System Simulation Program (GFSSP), was used to simulate the no-vent filling of a cryogenic tank with a thermodynamic vent system assisted injector. The tank was discretized into nodes in the radial and axial directions to calculate two-dimensional axisymmetric flow with heat transfer between the solid wall and fluid. The nodes are connected by branches where momentum equations are solved to calculate the flowrates. The mass and energy conservation equations and the equation of state are solved to calculate pressure, temperature, and resident mass at the nodes. The energy conservation equations at the solid nodes were solved to calculate the temperature of the solid wall. The system of equations was solved by a combination of successive substitution and simultaneous Newton-Raphson method. The numerical model accounts for a) different regimes of pool boiling heat transfer, b) condensation of vapor around the spray droplets, c) condensation of vapor at the interface of the cooled injector and ullage, and d) condensation at the liquid-vapor interphase. The numerical predictions of tank pressure, filling rate, and wall temperatures were compared with the test data. The paper also presents the effect of nodal discretization by comparing the results of the 1D and 2D models and examines the effect of the droplet diameter on tank filling.
A finite volume-based network flow modeling tool, Generalized Fluid System Simulation Program (GFSSP), was used to simulate the no-vent filling of a cryogenic tank with a thermodynamic vent system assisted injector. The tank was discretized into nodes in the radial and axial directions to calculate two-dimensional axisymmetric flow with heat transfer between the solid wall and fluid. The nodes are connected by branches where momentum equations are solved to calculate the flowrates. The mass and energy conservation equations and the equation of state are solved to calculate pressure, temperature, and resident mass at the nodes. The energy conservation equations at the solid nodes were solved to calculate the temperature of the solid wall. The system of equations was solved by a combination of successive substitution and simultaneous Newton-Raphson method. The numerical model accounts for a) different regimes of pool boiling heat transfer, b) condensation of vapor around the spray droplets, c) condensation of vapor at the interface of the cooled injector and ullage, and d) condensation at the liquid-vapor interphase. The numerical predictions of tank pressure, filling rate, and wall temperatures were compared with the test data. The paper also presents the effect of nodal discretization by comparing the results of the 1D and 2D models and examines the effect of the droplet diameter on tank filling.