Flightworthy, high performance insulation development. I
Multilayer insulation systems for cryogenics protection aboard spacecraft, considering mechanical properties, radiation shielding, component evacuation rate and outgassing
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Multilayer insulation systems for cryogenics protection aboard spacecraft, considering mechanical properties, radiation shielding, component evacuation rate and outgassing
Multilayer insulation systems development and selection for cryogenics thermal protection on space vehicles, considering mechanical properties, radiation shielding, components, evacuation rate and outgassing
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The In-Situ production of propellants for Martian and Lunar missions has been heavily discussed since the mid 1990's. One portion of the production of the propellants is the liquefaction, storage, and delivery of the propellants to the stage tanks. Two key technology development efforts are required: large refrigeration systems (cryocoolers) to perform the liquefaction and high performance insulation within a soft vacuum environment. Several different concepts of operation may be employed to liquefy the propellants based on how and where these two technologies are implemented. The concepts that were investigated include: using an accumulator tank to store the propellant until it is needed, liquefying in the flow stream going into the tank, and liquefying in the flight propellant tank itself. The different concept of operations were studied to assess the mass and power impacts of each concept. Additionally, the trade between insulation performance and cryocooler mass was performed to give performance targets for soft vacuum insulation development. It was found that liquefying within the flight propellant tank itself adds the least mass and power requirements to the mission.
High performance insulation design, and manufacturing plan of torus tank for Saturn 5 vehicle
Vacuum-insulated glazing (VIG) with a low-emittance coating has a great market potential as an effective transparent insulator. The thermal insulating performance of VIG is determined by its design, including material selection and configuration of different components. Thermal conductance of the vacuum gap as a transport bottleneck is one of the primary factors controlling the thermal transport across VIG. In particular, because support pillars provide the main thermal transport channels across the vacuum gap, increasing the pillar thermal resistance is a key strategy for creating effective thermal insulation while maintaining the vacuum space. Here, the effects of various pillar design parameters, such as thermal conductivity, geometry, and arrangement, on the VIG thermal performance were comprehensively investigated via the finite element method. In addition, analytical models for thermal transport were examined and thermal conductance across the VIG unit was experimentally measured for validation. The pillar design parameters, especially the height, shape, spacing, and arrangement of the pillars, showed significant effects on the thermal performance of VIG. This research also shows that the smaller contact area for horizontal pillars can effectively decrease the heat loss by more than 30%. Because current VIG analytical equations of thermal performance are only applicable to cylindrical pillars, an analytical equation that can better describe the thermal performance of rectangular parallelepiped pillars is presented, along with a discussion about the mechanism of thermal transfer for different pillar shapes. Thermo-mechanical analyses based on 3D FEM simulations can provide valuable insights into the effect of various design parameters on the overall performance the VIG, allowing for the development of an optimal VIG design.
An experimental investigation was conducted to determine the thermal effectiveness of an aluminized Mylar-silk net insulation system containing up to 160 layers. The experimentally measured heat flux was compared with results predicted by using (1) a previously developed semi-empirical equation and (2) an effective-thermal-conductivity value. All tests were conducted at a nominal hot-boundary temperature of 294 K (530 R) with liquid hydrogen as the heat sink. The experimental results show that the insulation performed as expected and that both the semi-empirical equation and effective thermal conductivity of a small number of layers were adequate in predicting the thermal performance of a large number of layers of insulation.
High performance multilayer insulation and micrometeoroid protection system for cryogenic tanks in outer space
A test campaign was performed to build an SRM-insulation-material thermal-performance database using MSFC’s Solid Fuel Torch that could be leveraged to enhance understanding of the relationship between ablation rates and internal-environment parameters and improve insulation performance predictions. Seven hot-fire tests were performed along with data analysis that revealed the thermal performance differences among the tested materials. Functional Data Analysis was employed to create a model of material ablation rate as a function of six covariates. The relative importance of several environmental parameters was indicated, and the gaps in the operational space covered by the database were identified.
Commonly encountered 'passive' insulation has been improved in recent years using 'dynamic'insulation based on closed cycle cryocoolers attached to photon shields. The paper presents a novel insulation performance measure based on ideal thermodynamic limits. Each floating insulation package has a unique value. In contrast real vessels with vent tube and supports are characterized by an 'effectiveness' less than unity.
Design problems of high-performance multilayer insulation systems using evacuated flexible-jacket scheme for cryogenic stages
Thermal degradation of high performance multilayer insulation on liquid hydrogen tank in vicinity of penetration
High performance insulation for spacecraft cryogenic-storage tanks
The conventional manufacturing processes for aerogel insulation materials mostly rely on the supercritical drying, which suffers from issues of massive energy consumption, high-cost equipment, and prolonged processing time. Considering the large market demand for the aerogel insulation material in the next decade, a cost-effective and scalable fabrication technique is highly desired. In this paper, a direct ink writing (DIW) method is used to three-dimensionally fabricate the silica aerogel insulation material, followed by room-temperature and ambient pressure drying. Compared with the supercritical drying and freeze-drying techniques, the reported method significantly reduces the fabrication time and costs. The cost-effective DIW technique offers the capability to print complex hollow internal structures, coupled with the porous aerogel structure, it is found to be beneficial for the thermal insulation property. In this work, the addition of fiber to the ink assures the durability of the fabricated product, without sacrificing the thermal insulation performance. The foam ink preparation methods and the printability are demonstrated in this paper, along with the printing of complex three-dimensional geometries. The thermal insulation performance of the printed objects is characterized, and the mechanical properties were also examined. The proposed approach is found to have a 56% reduction in the processing time. The printed silica aerogels exhibit a low thermal conductivity of 0.053 W m –1 K –1 .
Fabrication and demonstration of high performance multilayer cryogenic insulation applied to Torus tank mock-up
Multilayer insulation coverings with low conductivity foam spacers are interleaved with quarter mil aluminized polymer film radiation shields to cover flight type liquid hydrogen tankage of space vehicles with a removable, structurally compatible, lightweight, high performance cryogenic insulation capable of surviving extended space mission environments.
Atmospheric entry and need for thermal protection systems (TPS) is discussed. Ceramic insulations for use as passive TPS are described. Different modes of heat transfer in ceramic insulation are described, and a thermal model is presented. Figures of merit for insulation performance are described and various methods for improving insulation performance are presented.