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NASA NTRS1991

The cryogenic on-orbit liquid analytical tool (COOLANT) - A computer program for evaluating the thermodynamic performance of orbital cryogen storage facilities

The United States plans to establish a permanent manned presence at the Space Station Freedom in low earth orbit (LEO) and then carry out exploration of the solar system from this base. These plans may require orbital cryogenic propellant storage depots. The COOLANT program has been developed to analyze the thermodynamic performance of these depots to support design tradeoff studies. It was developed as part of the Long Term Cryogenic Storage Facility Systems Study for NASA/MSFC. This paper discusses the program structure and capabilities of the COOLANT program. In addition, the results of an analysis of a 200,000 lbm hydrogen/oxygen storage depot tankset using COOLANT are presented.

Taylor, W. J.↗

NASA NTRS1991

Thermal performance of a liquid hydrogen tank multilayer insulation system at warm boundary temperatures of 630, 530, and 152 R

The results are presented of a study conducted to obtain experimental heat transfer data on a liquid hydrogen tank insulated with 34 layers of MLI (multilayer insulation) for warm side boundary temperatures of 630, 530, and 150 R. The MLI system consisted of two blankets, each blanket made up of alternate layers of double silk net (16 layers) and double aluminized Mylar radiation shields (15 layers) contained between two cover sheets of Dacron scrim reinforced Mylar. The insulation system was designed for and installed on an 87.6 in. diameter liquid hydrogen tank. Nominal layer density of the insulation blankets is 45 layers/in. The insulation system contained penetrations for structural support, plumbing, and electrical wiring that would be representative of a cryogenic spacecraft. The total steady state heat transfer rates into the test tank for shroud temperatures of 630, 530, 152 R were 164.4, 95.8, and 15.9 BTU/hr, respectively. The noninsulation heat leaks into the tank (12 fiberglass support struts, tank plumbing, and instrumentation lines) represent between 13 to 17 pct. of the total heat input. The heat input values would translate to liquid H2 losses of 2.3, 1.3, and 0.2 pct/day, with the tank held at atmospheric pressure.

Stochl, Robert J.↗

NASA NTRS2000

Manufacturing and NDE of Large Composite Aerospace Structures at MSFC

NASA's vision for transportation to orbit calls for new vehicles built with new materials technology. The goals of this new launch system development are to improve safety, dramatically reduce cost to orbit, and improve vehicle turn around time. Planned Space Shuttle upgrades include new reusable liquid propellant boosters to replace the solid propellant boosters. These boosters are to have wings and return to the launch site for a horizontal landing on an airport runway. New single and two stages to orbit concepts are being investigated. To reduce weight and improve performance composite materials are proposed for fuel and oxidizer tanks, fuel feedlines, valve bodies, aerostructures, turbomachinery components. For large composite structures new methods of fabrication are being proposed and developed. Containment of cryogenic fuel or oxidizer requires emphases on composite material densification and chemical compatibility. Ceramic matrix and fiber composites for hot rotating turbomachinery have been developed with new fabrication processes. The new requirements on the materials for launcher components are requiring development of new manufacturing and inspection methods. This talk will examine new and proposed manufacturing methods to fabricate the revolutionary components. New NDE methods under consideration include alternative X-ray methods, X-ray laminagraphy, advanced CT, Thermography, new ultrasonic methods, and imbedded sensors. The sizes, complexity, use environment, and contamination restrictions will challenge the inspection process. In flight self-diagnosis and rapid depot inspection are also goals of the NDE development.

Whitaker, Ann↗

NASA NTRS2004

Taming Liquid Hydrogen: The Centaur Upper Stage Rocket, 1958-2002

During its maiden voyage in May 1962, a Centaur upper stage rocket, mated to an Atlas booster, exploded 54 seconds after launch, engulfing the rocket in a huge fireball. Investigation revealed that Centaur's light, stainless-steel tank had split open, spilling its liquid-hydrogen fuel down its sides, where the flame of the rocket exhaust immediately ignited it. Coming less than a year after President Kennedy had made landing human beings on the Moon a national priority, the loss of Centaur was regarded as a serious setback for the National Aeronautics and Space Administration (NASA). During the failure investigation, Homer Newell, Director of Space Sciences, ruefully declared: "Taming liquid hydrogen to the point where expensive operational space missions can be committed to it has turned out to be more difficult than anyone supposed at the outset." After this failure, Centaur critics, led by Wernher von Braun, mounted a campaign to cancel the program. In addition to the unknowns associated with liquid hydrogen, he objected to the unusual design of Centaur. Like the Atlas rocket, Centaur depended on pressure to keep its paper-thin, stainless-steel shell from collapsing. It was literally inflated with its propellants like a football or balloon and needed no internal structure to give it added strength and stability. The so-called "pressure-stabilized structure" of Centaur, coupled with the light weight of its high- energy cryogenic propellants, made Centaur lighter and more powerful than upper stages that used conventional fuel. But, the critics argued, it would never become the reliable rocket that the United States needed.

Dawson, Virginia P.↗

NASA NTRS2013

Acoustic and Thermal Testing of an Integrated Multilayer Insulation and Broad Area Cooling Shield System

A Multilayer Insulation (MLI) and Broad Area Cooling (BAC) shield thermal control system shows promise for long-duration storage of cryogenic propellant. The NASA Cryogenic Propellant Storage and Transfer (CPST) project is investigating the thermal and structural performance of this tank-applied integrated system. The MLI/BAC Shield Acoustic and Thermal Test was performed to evaluate the MLI/BAC shield's structural performance by subjecting it to worst-case launch acoustic loads. Identical thermal tests using Liquid Nitrogen (LN2) were performed before and after the acoustic test. The data from these tests was compared to determine if any degradation occurred in the thermal performance of the system as a result of exposure to the acoustic loads. The thermal test series consisted of two primary components: a passive boil-off test to evaluate the MLI performance and an active cooling test to evaluate the integrated MLI/BAC shield system with chilled vapor circulating through the BAC shield tubes. The acoustic test used loads closely matching the worst-case envelope of all launch vehicles currently under consideration for CPST. Acoustic test results yielded reasonable responses for the given load. The thermal test matrix was completed prior to the acoustic test and successfully repeated after the acoustic test. Data was compared and yielded near identical results, indicating that the MLI/BAC shield configuration tested in this series is an option for structurally implementing this thermal control system concept.

Wood, J. J.↗

NASA NTRS2013

Acoustic and Thermal Testing of an Integrated Multilayer Insulation and Broad Area Cooling Shield System

Wood, Jessica J.↗

NASA NTRS2005

Integration Of Launch Vehicle Simulation/Analysis Tools And Lunar Cargo Lander Design

Part 2, which will be discussed in this report, will discuss the development of a Lunar Cargo Lander (unmanned launch vehicle) that will transport usable payload from Trans- Lunar Injection to the moon. The Delta IV-Heavy was originally used to transport the Lunar Cargo Lander to TLI, but other launch vehicles have been studied. In order to uncover how much payload is possible to land on the moon, research was needed in order to design the sub-systems of the spacecraft. The report will discuss and compare the use of a hypergolic and cryogenic system for its main propulsion system. The guidance, navigation, control, telecommunications, thermal, propulsion, structure, mechanisms, landing gear, command, data handling, and electrical power sub-systems were designed by scaling off other flown orbiters and moon landers. Once all data was collected, an excel spreadsheet was created to accurately calculate the usable payload that will land on the moon along with detailed mass and volume estimating relations. As designed, The Lunar Cargo Lander can plant 5,400 lbm of usable payload on the moon using a hypergolic system and 7,400 lbm of usable payload on the moon using a cryogenic system.

DeJean, George Brian↗

NASA NTRS2009

Development and Airborne Operation of a Compact Water Isotope Ratio Infrared Spectrometer

A sensitive laser spectrometer, named IRIS (water isotope ratio infrared spectrometer), was developed for the in situ detection of the isotopic composition of water vapour in the upper troposphere and the lower stratosphere. Isotope ratio measurements can be used to quantify troposphere stratosphere exchange, and to study the water chemistry in the stratosphere. IRIS is based on the technique of optical feedback cavity-enhanced absorption spectroscopy. It uses a room temperature near-infrared laser, and does not require cryogenic cooling of laser or detectors. The instrument weighs 51 kg including its support structure. Airborne operation was demonstrated during three flights aboard the European M55-Geophysica stratospheric research aircraft, as part of the AMMA/SCOUT-03 (African Monsoon Multidisciplinary Analysis/Stratospheric Climate links with emphasis on the Upper Troposphere and lower stratosphere) campaign in Burkina Faso in August 2006. The data are discussed with reference to a Rayleigh distillation model. As expected, there is no indication of non-mass-dependent fractionation (also known as mass-independent fractionation) in the troposphere. Furthermore, improvements to the thermal management system and a move to a (cryogen-free) longer-wavelength laser source are discussed, which together should result in approximately two orders of magnitude improvement of the sensitivity

Iannone, Rosario Q.↗

NASA NTRS1999

Time Temperature-Precipitation Behavior in An Al-Cu-Li Alloy 2195

Al-Cu-Li alloy 2195, with its combination of good cryogenic properties, low density, and high modulus, has been selected by NASA to be the main structural alloy of the Super Light Weight Tank (SLWT) for the Space Shuttle. Alloy 2195 is strengthened by an aging treatment that precipitates a particular precipitate, labeled as T1(Al2CuLi). Other phases, such as GP zone, (theta)', (theta)", theta, (delta)', S' are also present in this alloy when artificially aged. Cryogenic strength and fracture toughness are critical to the -SLWT application, since the SLWT will house liquid oxygen and hydrogen. Motivation for the Time-Temperature-Precipitation (TTP) study at lower temperature (lower than 350 F) comes in part from a recent study by Chen, The study found that the cryogenic fracture toughness of alloy 2195 is greatly influenced by the phases present in the matrix and subgrain boundaries. Therefore, the understanding of TTP behavior can help develop a guideline to select appropriate heat treatment conditions for the desirable applications. The study of TTP behavior at higher temperature (400 to 1000 F) was prompted by the fact that the SLWT requires a welded construction. Heat conduction from the weld pool affects the microstructure in the heat-affected zone (HAZ), which leads to changes in the mechanical properties. Furthermore, the SLWT may need repair welding for more than one time and any additional thermal cycles will increase precipitate instability and promote phase transformation. As a result considerable changes in HAZ microstructure and mechanical properties are expected during the construction of the SLWT. Therefore, the TTP diagrams can serve to understand the thermal history of the alloy by analyzing the welded microstructure. In the case welding, the effects of thermal cycles on the microstructure and mechanical properties can be predicted with the aid of the TTP diagrams. The 2195 alloy (nominally Al + 4 pct Cu + 1 pct Li + 0.3 pct Ag + 0.3 pct Mg + 0.1 pct Zr) used in this study was received in the form of 1.7 inch thick rolled plates. In brief goal of this study is to develop TTR diagram for the solutiontreated and stretched alloy 2195 from which the precipitation sequence at any service or aging conditions can be preducted.A subgrain boundary TTR diagram is also presented since precipitations at subgrain boundary can control and/or modify a wide veriety of material properties, such as cryogenic fracture toughness.

Chen, P. S.↗

NASA NTRS1985

Insulating Cryogenic Pipes With Frost

Crystallized water vapor fills voids in pipe insulation. Small, carefully controlled amount of water vapor introduced into dry nitrogen gas before it enters aft fuselage. Vapor freezes on pipes, filling cracks in insulation. Ice prevents gaseous nitrogen from condensing on pipes and dripping on structure, in addition to helping to insulate all parts. Industrial applications include large refrigeration plants or facilities that use cryogenic liquids.

Stephenson, J. G.↗

NASA NTRS2006

NASA Tech Briefs, November 2006

Topics include: Simulator for Testing Spacecraft Separation Devices; Apparatus for Hot Impact Testing of Material Specimens; Instrument for Aircraft-Icing and Cloud-Physics Measurements; Advances in Measurement of Skin Friction in Airflow; Improved Apparatus for Testing Monoball Bearings; High-Speed Laser Scanner Maps a Surface in Three Dimensions; Electro-Optical Imaging Fourier-Transform Spectrometer; Infrared Instrument for Detecting Hydrogen Fires; Modified Coaxial Probe Feeds for Layered Antennas; Detecting Negative Obstacles by Use of Radar; Cryogenic Pound Circuits for Cryogenic Sapphire Oscillators; PixelLearn; New Software for Predicting Charging of Spacecraft; Conversion Between Osculating and Mean Orbital Elements; Generating a 2D Representation of a Complex Data Structure; Making Activated Carbon by Wet Pressurized Pyrolysis; Composite Solid Electrolyte Containing Li+- Conducting Fibers; Electrically Conductive Anodized Aluminum Surfaces; Rapid-Chill Cryogenic Coaxial Direct-Acting Solenoid Valve; Variable-Tension-Cord Suspension/Vibration- Isolation System; Techniques for Connecting Superconducting Thin Films; Versatile Friction Stir Welding/Friction Plug Welding System; Thermal Spore Exposure Vessels; Enumerating Spore-Forming Bacteria Airborne with Particles; Miniature Oxidizer Ionizer for a Fuel Cell; Miniature Ion-Array Spectrometer; Promoted-Combustion Chamber with Induction Heating Coil; Miniature Ion-Mobility Spectrometer; Mixed-Salt/Ester Electrolytes for Low-Temperature Li+ Cells; Miniature Free-Space Electrostatic Ion Thrusters; Miniature Bipolar Electrostatic Ion Thruster; Holographic Plossl Retroreflectors; Miniature Electrostatic Ion Thruster With Magnet; Using Apex To Construct CPM-GOMS Models; Sequence Detection for PPM Optical Communication With ISI; Algorithm for Rapid Searching Among Star-Catalog Entries; Expectation-Based Control of Noise and Chaos; Radio Heating of Lunar Soil to Release Gases; Using Electrostriction to Manipulate Ullage in Microgravity; Equations for Scoring Rules When Data Are Missing; Insulating Material for Next-Generation Spacecraft; and Pseudorandom Switching for Adding Radar to the AFF Sensor.

Source record↗

NASA NTRS2011

An Overview of Thermal Distortion Modeling, Analysis, and Model Validation for the JWST ISIM Structure

The James Webb Space Telescope (JWST) is a large, infrared-optimized space telescope consisting of the following elements: (1) Optical telescope element (OTE) (2) Integrated science instrument module (ISIM) (3) Spacecraft (4) Sunshield The Integrated Science Instrument Module (ISIM) consists of the JWST science instruments (NIRCam, MIRI, NIRSpec), a fine guidance sensor (FGS), the ISIM Structure, and thermal and electrical subsystems. JWST's instruments are designed to work primarily in the infrared range of the electromagnetic spectrum, and the instruments and telescope operate at cryogenic temperatures (approximately 35 K for the instruments). The development and validation of a thermal distortion modeling and analysis capability for the JWST ISIM Structure was successfully completed. The modeling and analysis approach was grounded in initial constituent materials testing and benchmarked to test results at the composite bonded joint, subassembly, and fullscale flight hardware levels. Comparison of analysis predictions and test results from this series of incremental cryogenic thermal distortion tests demonstrates that the model validation goals are achieved.

Johnston, John↗

NASA NTRSDate not supplied

Summary of Testing Results for the Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER)

Testing was completed on the Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER) between August 2019 and January 2020. SHIIVER was designed to be a test bed for the scaling of cryogenic fluid management technologies as applied to large upper stages and long duration in-space stages. The baseline SHIIVER design consists of uninsulated structural skirts attached to a propellant tank insulated with polyurethane Spray-On Foam Insulation (SOFI). The initial testing of the SHIIVER hardware was with liquid hydrogen and sought to demonstrate the use of boil-off vapor to intercept heat on a structural skirt, multilayer insulation (MLI) on the tank domes, and the radio frequency mass gauge (RFMG). Testing was completed in four stages: a baseline thermal vacuum test prior to installation of the MLI on the tank domes, a thermal vacuum test after the MLI installation, a reverberant acoustic test, and a subsequent thermal vacuum test to verify that no damage occurred during the reverberant acoustic testing. Each thermal vacuum test with chamber wall at ambient temperature and vacuum level in the 10-6 torr range was conducted continuously between approximately 90% full and 25% full. Test results showed that the vapor cooling reduced the heat load to the tank by approximately 10%, but the boil-off by less than 3% at 50% full, with and without MLI installed on the domes. The MLI installed on the domes reduced the heat load to the tank by approximately 40% at all fill levels, but the boil-off by approximately 25% at 90% full and 45% below 65% full. The RFMG performed well over all fill ranges, and several RF tank modes were used to gauge the mass of fluid in the tank. SHIIVER was then exposed to an acoustic environment of 147 dB OASPL (overall sound pressure level) in a reverberant chamber. The acoustic environment envelopes the upper stage internal acoustic level of several different modern launch vehicles. No structural or thermal performance changes were observed after exposure to the acoustic environment. Final thermal vacuum testing after the acoustic testing showed no degradation to the MLI due to the acoustic environment as measured via system heat loads

SHIIVER↗

NASA NTRS2004

JWST ISIM Distortion Analysis Challenge

Very tight distortion requirements are imposed on the JWST's ISM structure due to the sensitivity of the telescope's mirror segment and science instrument positioning. The ISIM structure is a three dimensional truss with asymmetric gusseting and metal fittings. One of the primary challenges for ISIM's analysis team is predicting the thermal distortion of the structure both from the bulk cooldown from ambient to cryo, and the smaller temperature changes within the cryogenic operating environment. As a first cut to estimate thermal distortions, a finite element model of bar elements was created. Elements representing joint areas and metal fittings use effective properties that match the behavior of the stack-up of the composite tube, gusset and adhesive under mechanical and thermal loads. These properties were derived by matching tip deflections of a solid model simplified T-joint. Because of the structure s asymmetric gusseting, this effective property model is a first attempt at predicting rotations that cannot be captured with a smeared CTE approach. In addition to the finite element analysis, several first order calculations have been performed to gauge the feasibility of the material design. Because of the stringent thermal distortion requirements at cryogenic temperatures, a composite tube material with near zero or negative CTE is required. A preliminary hand analysis of the contribution of the various components along the distortion path between FGS and the other instruments, neglecting second order effects were examined. A plot of bounding tube longitudinal and transverse CTEs for thermal stability requirements was generated to help determine the feasibility of meeting these requirements. This analysis is a work in progress en route to a large degree of freedom hi-fidelity FEA model for distortion analysis. Methods of model reduction, such as superelements, are currently being investigated.

Cifie, Emmanuel↗

NASA NTRS1979

Research in structures and materials for future space transportation systems - An overview

The paper provides a review of some of the advances of the past decade in structures and materials that have application to future space transportation systems. The paper concentrates on metallic thermal protection systems and structures which could provide the structural efficiency, reliability, and durability dictated by future space utilization requirements. The need for completely reusable, on-board cryogenic fuel tanks is cited as the most challenging technical opportunity and potential thermostructural concepts for tanks are identified. Other critical areas needing technology advances are discussed. Finally, the unique research opportunities offered by the Shuttle Orbiter experiments program for testing structures and thermal protection systems are explored.

Kelly, H. N.↗

NASA NTRS1973

Vacuum system for an infrared calibration facility.

Calibration facilities for large aperture (up to 56 cm diam) infrared radiometers require commeasurable size vacuum chambers with full thermal shrouding and ultraclean pumping systems. Such a facility has been fabricated and is described in detail. The chamber is 106 cm in diameter and 4.87 m long. It utilizes integral ion pumping for operation in the 1 microtorr region. Economic considerations and time constraints of the total system program required local fabrication and, therefore, nonproprietary-type flange sealing.The sealing mechanism used was the flat flange with aluminum wire effecting the seal. Included in the discussion is the description of the cryogen distribution system which allows complete constant temperature control of the several shroud structures.

Uhlin, J.↗

NASA NTRS1977

Rigid cable support for blind installations

Mechanical support structure, originally designed for use with electrical cables, can support hydraulic, pneumatic, and cryogenic lines where bends are required, assemblies are inaccessible, and conduits are impractical. Support is also light in weight and offers means of damping vibration.

Abbott, J. R.↗

NASA NTRS1986

Scene simulation for passive IR systems

The development of large mosaic detector arrays will allow for the construction of staring long wave infrared (LWIR) sensors which can observe large fields of view instantaneously and continuously. In order to evaluate and exercise these new systems, it will be necessary to provide simulated scenes of many moving targets against an infrared clutter background. Researchers are currently developing a projector/screen system. This system is comprised of a mechanical scanner, a diffuse screen, and a miniature blackbody. A prototype of the mechanical scanner, which is comprised of four independently driven scanners, has been designed, fabricated, and evaluated under room and cryogenic vacuum conditions. A large diffuse screen has been constructed and tested for structural integrity under cryogenic/vacuum thermal cycling. Construction techniques have been developed for the fabrication of miniature high-temperature blackbody sources. Finally, a concept has been developed to use this miniature blackbody to produce a spectrally tailorable source.

Holt, J. D.↗