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NASA NTRS2011

Hybrid Composite Cryogenic Tank Structure

A hybrid lightweight composite tank has been created using specially designed materials and manufacturing processes. The tank is produced by using a hybrid structure consisting of at least two reinforced composite material systems. The inner composite layer comprises a distinct fiber and resin matrix suitable for cryogenic use that is a braided-sleeve (and/or a filamentwound layer) aramid fiber preform that is placed on a removable mandrel (outfitted with metallic end fittings) and is infused (vacuum-assisted resin transfer molded) with a polyurethane resin matrix with a high ductility at low temperatures. This inner layer is allowed to cure and is encapsulated with a filamentwound outer composite layer of a distinct fiber resin system. Both inner and outer layer are in intimate contact, and can also be cured at the same time. The outer layer is a material that performs well for low temperature pressure vessels, and it can rely on the inner layer to act as a liner to contain the fluids. The outer layer can be a variety of materials, but the best embodiment may be the use of a continuous tow of carbon fiber (T-1000 carbon, or others), or other high-strength fibers combined with a high ductility epoxy resin matrix, or a polyurethane matrix, which performs well at low temperatures. After curing, the mandrel can be removed from the outer layer. While the hybrid structure is not limited to two particular materials, a preferred version of the tank has been demonstrated on an actual test tank article cycled at high pressures with liquid nitrogen and liquid hydrogen, and the best version is an inner layer of PBO (poly-pphenylenebenzobisoxazole) fibers with a polyurethane matrix and an outer layer of T-1000 carbon with a high elongation epoxy matrix suitable for cryogenic temperatures. A polyurethane matrix has also been used for the outer layer. The construction method is ideal because the fiber and resin of the inner layer has a high strain to failure at cryogenic temperatures, and will not crack or produce leaks. The outer layer serves as more of a high-performance structural unit for the inner layer, and can handle external environments.

DeLay, Thomas↗

NASA NTRS2011

Developing NDE Techniques for Large Cryogenic Tanks

The Shuttle Program requires very large cryogenic ground storage tanks in which to store liquid oxygen and hydrogen. The existing Pads A and B Launch Complex-39 tanks, which will be passed onto future launch programs, are 45 years old and have received minimal refurbishment and only external inspections over the years. The majority of the structure is inaccessible without a full system drain of cryogenic liquid and granular insulation in the annular region. It was previously thought that there was a limit to the number of temperature cycles that the tanks could handle due to possible insulation compaction before undergoing a costly and time consuming complete overhaul; therefore the tanks were not drained and performance issues with these tanks, specifically the Pad B liquid hydrogen tank, were accepted. There is a needind an opportunity, as the Shuttle program ends and work to upgrade the launch pads progresses, to develop innovative non-destructive evaluation (NDE) techniques to analyze the current tanks. Techniques are desired that can aid in determining the extent of refurbishment required to keep the tanks in service for another 20+ years. A nondestructive technique would also be a significant aid in acceptance testing of new and refurbished tanks, saving significant time and money, if corrective actions can be taken before cryogen is introduced to the systems.

Parker, Don↗

NASA NTRS2010

Cryogenic Integration of the 2-14 GHz Eleven Feed in a Wideband Receiver for VLBI2010

The next generation VLBI systems require the design of a wideband receiver covering the 2-14 GHz range, necessitating a wideband feed. Presented here are the 2009 development of a cryogenic 2-14 GHz Eleven feed for reflector radio telescope antennas, including its integration into a cryogenic receiver. The Eleven feed is designed for dual linear polarization and consists of four log-periodic folded dipole arrays. Each pair of arrays is fed by a differential two-wire transmission line connected either to balun or a differential LNA. The present configuration has been measured in many configurations, at various independent labs - corresponding simulations have been done. The results show (across the band) a high polarization efficiency for the feed, with a nearly constant beam width, a reflection coefficient below -10dB, and a constant phase center. Electrical parameters under cryogenic conditions and measured receiver noise temperatures are presented.

Pantaleev, Miroslaw↗

NASA NTRS2011

A Focus on Cryogenic Engineering for the Primordial Inflation Polarization Explorer (PIPER) Mission

Cryogenic engineering involves design and modification of equipment that is used under boiling point of nitrogen which is 77 K. The focus of this paper will be on the design of hardware for cryogenic use and a retrofit that was done to the main laboratory cryostat used to test flight components for the Primordial Inflation Polarization Explorer balloon-borne mission. Data from prior tests showed that there was a superfluid helium leak and a total disassemble of the cryostat was conducted in order to localize and fix the leak. To improve efficiency new fill tubes and clamps with modifications were added to the helium tank. Upon removal of the tank, corrosion was found on the flange face that connects to the helium cold plate and therefore had to be fully replaced and copper plated to prevent future corrosion. Indium seals were also replaced for the four fill tubes, a helium level sensor, and the nitrogen and helium tanks. Four additional shielded twisted pairs of cryogenic wire and a wire harness for the Superconducting Quantum Interference Devices (SQUIDs) were added. Finally, there was also design work done for multiple pieces that went inside the cryostat and a separate probe used to test the SQUIDs. Upon successful completion of the cryostat upgrade, tests were run to check the effectiveness and stability of the upgrades. The post-retrofit tests showed minor leaks were still present and due to this, superfluidity has still not been attained. As such there could still be a possibility of a superfluid leak appearing in the future. Regardless, the copper plating on the helium tank has elongated the need to service it by three to five years.

Rosas, Rogelio↗

NASA NTRS2011

Hazards Induced by Breach of Liquid Rocket Fuel Tanks: Conditions and Risks of Cryogenic Liquid Hydrogen-Oxygen Mixture Explosions

We analyze the data of purposeful rupture experiments with LOx and LH2 tanks, the Hydrogen-Oxygen Vertical Impact (HOVI) tests that were performed to clarify the ignition mechanisms, the explosive power of cryogenic H2/Ox mixtures under different conditions, and to elucidate the puzzling source of the initial formation of flames near the intertank section during the Challenger disaster. We carry out a physics-based analysis of general explosions scenarios for cryogenic gaseous H2/Ox mixtures and determine their realizability conditions, using the well-established simplified models from the detonation and deflagration theory. We study the features of aerosol H2/Ox mixture combustion and show, in particular, that aerosols intensify the deflagration flames and can induce detonation for any ignition mechanism. We propose a cavitation-induced mechanism of self-ignition of cryogenic H2/Ox mixtures that may be realized when gaseous H2 and Ox flows are mixed with a liquid Ox turbulent stream, as occurred in all HOVI tests. We present an overview of the HOVI tests to make conclusion on the risk of strong explosions in possible liquid rocket incidents and provide a semi-quantitative interpretation of the HOVI data based on aerosol combustion. We uncover the most dangerous situations and discuss the foreseeable risks which can arise in space missions and lead to tragic outcomes. Our analysis relates to only unconfined mixtures that are likely to arise as a result of liquid propellant space vehicle incidents.

Osipov, Viatcheslav↗

NASA NTRS2011

Cryogenic Scan Mechanism for Fourier Transform Spectrometer

A compact and lightweight mechanism has been developed to accurately move a Fourier transform spectrometer (FTS) scan mirror (a cube corner) in a near-linear fashion with near constant speed at cryogenic temperatures. This innovation includes a slide mechanism to restrict motion to one dimension, an actuator to drive the motion, and a linear velocity transducer (LVT) to measure the speed. The cube corner mirror is double-passed in one arm of the FTS; double-passing is required to compensate for optical beam shear resulting from tilting of the moving cube corner. The slide, actuator, and LVT are off-the-shelf components that are capable of cryogenic vacuum operation. The actuator drives the slide for the required travel of 2.5 cm. The LVT measures translation speed. A proportional feedback loop compares the LVT voltage with the set voltage (speed) to derive an error signal to drive the actuator and achieve near constant speed. When the end of the scan is reached, a personal computer reverses the set voltage. The actuator and LVT have no moving parts in contact, and have magnetic properties consistent with cryogenic operation. The unlubricated slide restricts motion to linear travel, using crossed roller bearings consistent with 100-million- stroke operation. The mechanism tilts several arc seconds during transport of the FTS mirror, which would compromise optical fringe efficiency when using a flat mirror. Consequently, a cube corner mirror is used, which converts a tilt into a shear. The sheared beam strikes (at normal incidence) a flat mirror at the end of the FTS arm with the moving mechanism, thereby returning upon itself and compensating for the shear

Brasunas, John C.↗

NASA NTRS2006

Rapid-Chill Cryogenic Coaxial Direct-Acting Solenoid Valve

A commercially available cryogenic direct- acting solenoid valve has been modified to incorporate a rapid-chill feature. The net effect of the modifications is to divert some of the cryogenic liquid to the task of cooling the remainder of the cryogenic liquid that flows to the outlet. Among the modifications are the addition of several holes and a gallery into a valve-seat retainer and the addition of a narrow vent passage from the gallery to the atmosphere.

Richard, James↗

NASA NTRS2011

Foam/Aerogel Composite Materials for Thermal and Acoustic Insulation and Cryogen Storage

The invention involves composite materials containing a polymer foam and an aerogel. The composite materials have improved thermal insulation ability, good acoustic insulation, and excellent physical mechanical properties. The composite materials can be used, for instance, for heat and acoustic insulation on aircraft, spacecraft, and maritime ships in place of currently used foam panels and other foam products. The materials of the invention can also be used in building construction with their combination of light weight, strength, elasticity, ability to be formed into desired shapes, and superior thermal and acoustic insulation power. The materials have also been found to have utility for storage of cryogens. A cryogenic liquid or gas, such as N.sub.2 or H.sub.2, adsorbs to the surfaces in aerogel particles. Thus, another embodiment of the invention provides a storage vessel for a cryogen.

Williams, Martha K.↗

NASA NTRS2005

Treatments To Produce Stabilized Aluminum Mirrors for Cryogenic Uses

Five metallurgical treatments have been tested as means of stabilizing mirrors that are made of aluminum alloy 6061 and are intended for use in cryogenic applications. Aluminum alloy 6061 is favored as a mirror material by many scientists and engineers. Like other alloys, it shrinks upon cool-down from room temperature to cryogenic temperature. This shrinkage degrades the optical quality of the mirror surfaces. Hence, the metallurgical treatments were tested to determine which one could be most effective in minimizing the adverse optical effects of cooldown to cryogenic temperatures. Each of the five metallurgical treatments comprises a multistep process, the steps of which are interspersed with the steps of the mirror-fabrication process. The five metallurgical-treatment/fabrication.- process combinations were compared with each other and with a benchmark fabrication process, in which a mirror is made from an alloy blank by (1) symmetrical rough machining, (2) finish machining to within 0.006 in. (. 0.15 mm) of final dimensions, and finally (3) diamond turning to a mirror finish.

Zewari, Wahid↗

NASA NTRS2011

Cryogenic Thermal Distortion Performance Characterization for the JWST ISIM Structure

The James Webb Space Telescope (JWST) Integrated Science Instrument Module (ISIM) Structure is a precision optical metering structure for the JWST science instruments. Optomechanical performance requirements place stringent limits on the allowable thermal distortion of the metering structure between ambient and cryogenic operating temperature (~35 K). This paper focuses on thermal distortion testing and successful verification of performance requirements for the flight ISIM Structure. The ISIM Structure Cryoset Test was completed in Spring 2010 at NASA Goddard Space Flight Center in the Space Environment Simulator Chamber. During the test, the ISIM Structure was thermal cycled twice between ambient and cryogenic (~35 K) temperatures. Photogrammetry was used to measure the Structure in the ambient and cryogenic states for each cycle to assess both cooldown thermal distortion and repeatability. This paper will provide details on the post-processing of the metrology datasets completed to compare measurements with performance requirements.

Johnston, John D.↗

NASA NTRS2005

Flexible Cryogenic Temperature and Liquid-Level Probes

Lightweight, flexible probes have been developed for measuring temperatures at multiple locations in tanks that contain possibly pressurized cryogenic fluids. If the fluid in a given tank is subcritical (that is, if it consists of a liquid and its vapor), then in one of two modes of operation, the temperature measurements made by a probe of this type can be used to deduce the approximate level of the liquid. The temperature sensors are silicon diodes located at intervals along a probe. If the probe is to be used to measure a temperature gradient along a given axis in the tank, then the probe must be mounted along that axis. In the temperature-measurement mode, a constant small electric current is applied to each diode and the voltage across the diode a known function of the current and temperature is measured as an indication of its temperature. For the purpose of this measurement, small electric current signifies a current that is not large enough to cause a significant increase in the measured temperature. More specifically, the probe design calls for a current of 10 A, which, in the cryogenic temperature range of interest, generates heat at a rate of only about 0.01 mW per diode. In the liquid-level-sensing mode, one applies a larger current (30 mA) to each diode so as to heat each diode appreciably (with a power of about 36 mW in the temperature range of interest). Because the liquid cools the diode faster than does the vapor, the temperature of the diode is less when the diode is immersed in the liquid than when it is above the surface of the liquid. Thus, the temperature (voltage) reading from each diode can be used to determine whether the liquid level is above or below the diode, and one can deduce that the liquid level lies between two adjacent diodes, the lower one of which reads a significantly lower temperature. The aforementioned techniques for measuring temperature and deducing liquid level are not new. What is new here are the designs of the probes and of associated external electronic circuitry. In each probe, the diodes and the lead wires are embedded in a strong, lightweight, flexible polyimide strip. Each probe is constructed as an integral unit that includes a multipin input/output plug or socket for solderless connection of the lead wires to the external circuitry. The polyimide strip includes mounting tabs with holes that can accommodate rivets, screws, or other fasteners. Alternatively, a probe can be mounted by use of an epoxy. A probe can be manufactured to almost any length or width, and the diodes can be embedded at almost any desired location along and across the polyimide strip. In designing a probe for a specific application, one seeks a compromise between (1) minimizing the number of diodes in order to minimize the complexity of input/output connections and external electronic circuitry while (2) using enough diodes to obtain the required precision. Optionally, to minimize spurious heating of the cryogenic fluid, the external circuitry can be designed to apply power to the probe only during brief measurement intervals. Assuming that the external circuitry is maintained at a steady temperature, a power-on interval of only a few seconds is sufficient to obtain accurate data on temperatures and/or the height of the liquid/vapor interface.

Haberbusch, Mark↗

NASA NTRS2004

Expandable Purge Chambers Would Protect Cryogenic Fittings

Expandable ice-prevention and cleanliness-preservation (EIP-CP) chambers have been proposed to prevent the accumulation of ice or airborne particles on quick-disconnect (QD) fittings, or on ducts or tubes that contain cryogenic fluids. In the original application for which the EIP-CP chambers were conceived, there is a requirement to be able to disconnect and reconnect the QD fittings in rapid succession. If ice were to form on the fittings by condensation and freezing of airborne water vapor on the cold fitting surfaces, the ice could interfere with proper mating of the fittings, making it necessary to wait an unacceptably long time for the ice to thaw before attempting reconnection. By keeping water vapor away from the cold fitting surfaces, the EIP-CP chambers would prevent accumulation of ice, preserving the ability to reconnect as soon as required. Basically, the role of an EIP-CP chamber would be to serve as an enclosure for a flow of dry nitrogen gas that would keep ambient air away from QD cryogenic fittings. An EIP-CP chamber would be an inflatable device made of a fabriclike material. The chamber would be attached to an umbilical plate holding a cryogenic QD fitting.

Townsend, Ivan I., III↗

NASA NTRS2003

Innovative, High-Pressure, Cryogenic Control Valve: Short Face-to-Face, Reduced Cost

A control valve that can throttle high-pressure cryogenic fluid embodies several design features that distinguish it over conventional valves designed for similar applications. Field and design engineers worked together to create a valve that would simplify installation, trim changes, and maintenance, thus reducing overall cost. The seals and plug stem packing were designed to perform optimally in cryogenic temperature ranges. Unlike conventional high-pressure cryogenic valves, the trim size can be changed independent of the body.

Wilkes, Karlin↗

NASA NTRS2011

Cryogenic 160-GHz MMIC Heterodyne Receiver Module

A cryogenic 160-GHz MMIC heterodyne receiver module has demonstrated a system noise temperature of 100 K or less at 166 GHz. This module builds upon work previously described in Development of a 150-GHz MMIC Module Prototype for Large-Scale CMB Radiation (NPO-47664), NASA Tech Briefs, Vol. 35, No. 8 (August 2011), p. 27. In the original module, the local oscillator signal was saturating the MMIC low-noise amplifiers (LNAs) with power. In order to suppress the local oscillator signal from reaching the MMIC LNAs, the W-band (75 110 GHz) signal had to be filtered out before reaching 140 170 GHz. A bandpass filter was developed to cover 120 170 GHz, using microstrip parallel-coupled lines to achieve the desired filter bandwidth, and ensure that the unwanted W-band local oscillator signal would be sufficiently suppressed. With the new bandpass filter, the entire receiver can work over the 140 180-GHz band, with a minimum system noise temperature of 460 K at 166 GHz. The module was tested cryogenically at 20 K ambient temperature, and it was found that the receiver had a noise temperature of 100 K over an 8-GHz bandwidth. The receiver module now includes a microstrip bandpass filter, which was designed to have a 3-dB bandwidth of approximately 120-170 GHz. The filter was fabricated on a 3-mil-thick alumina substrate. The filter design was based on a W-band filter design made at JPL and used in the QUIET (Q/U Imaging ExperimenT) radiometer modules. The W-band filter was scaled for a new center frequency of 150 GHz, and the microstrip segments were changed accordingly. Also, to decrease the bandwidth of the resulting scaled design, the center gaps between the microstrip lines were increased (by four micrometers in length) compared to the gaps near the edges. The use of the 150-GHz bandpass filter has enabled the receiver module to function well at room temperature. The system noise temperature was measured to be less than 600 K (at room temperature) from 154 to 168 GHz. Additionally, the use of a W-band isolator between the receiver module and the local oscillator source also improved the noise temperature substantially. This may be because the mixer was presented with a better impedance match with the use of the isolator. Cryogenic testing indicates a system noise temperature of 100 K or less at 166 GHz. Prior tests of the MMIC amplifiers alone have resulted in a system noise temperature of 65.70 K in the same frequency range (.160 GHz) when cooled to an ambient temperature of 20 K. While other detector systems may be slightly more sensitive (such as SIS mixers), they require more cooling (to 4 K ambient) and are not as easily scalable to build a large array, due to the need for large magnets and other equipment. When cooled to 20 K, this receiver module achieves approximately 100 K system noise temperature, which is slightly higher than single-amplifier module results obtained at JPL (65.70 K when an amplifier is corrected for back-end noise contributions). If this performance can be realized in practice, and a scalable array can be produced, the impact on cosmic microwave background experiments, astronomical and Earth spectroscopy, interferometry, and radio astronomy in general will be dramatic.

Samoska, Lorene A.↗

NASA NTRS2012

Fabrication of a Cryogenic Bias Filter for Ultrasensitive Focal Plane

A fabrication process has been developed for cryogenic in-line filtering for the bias and readout of ultrasensitive cryogenic bolometers for millimeter and submillimeter wavelengths. The design is a microstripline filter that cuts out, or strongly attenuates, frequencies (10 50 GHz) that can be carried by wiring staged at cryogenic temperatures. The filter must have 100-percent transmission at DC and low frequencies where the bias and readout lines will carry signal. The fabrication requires the encapsulation of superconducting wiring in a dielectric-metal envelope with precise electrical characteristics. Sufficiently thick insulation layers with high-conductivity metal layers fully surrounding a patterned superconducting wire in arrayable formats have been demonstrated. A degenerately doped silicon wafer has been chosen to provide a metallic ground plane. A metallic seed layer is patterned to enable attachment to the ground plane. Thick silicon dioxide films are deposited at low temperatures to provide tunable dielectric isolation without degrading the metallic seed layer. Superconducting wiring is deposited and patterned using microstripline filtering techniques to cut out the relevant frequencies. A low Tc superconductor is used so that it will attenuate power strongly above the gap frequency. Thick dielectric is deposited on top of the circuit, and then vias are patterned through both dielectric layers. A thick conductive film is deposited conformally over the entire circuit, except for the contact pads for the signal and bias attachments to complete the encapsulating ground plane. Filters are high-aspect- ratio rectangles, allowing close packing in one direction, while enabling the chip to feed through the wall of a copper enclosure. The chip is secured in the copper wall using a soft metal seal to make good thermal and electrical contact to the outer shield.

Chervenak, James↗

NASA NTRS2012

Thermal Imaging for Inspection of Large Cryogenic Tanks

The end of the Shuttle Program provides an opportunity to evaluate and possibly refurbish launch support infrastructure at the Kennedy Space Center in support of future launch vehicles. One major infrastructure element needing attention is the cryogenic fuel and oxidizer system and specifically the cryogenic fuel ground storage tanks located at Launch Complex 39. These tanks were constructed in 1965 and served both the Apollo and Shuttle Programs and will be used to support future launch programs. However, they have received only external inspection and minimal refurbishment over the years as there were no operational issues that warranted the significant time and schedule disruption required to drain and refurbish the tanks while the launch programs were ongoing. Now, during the break between programs, the health of the tanks is being evaluated and refurbishment is being performed as necessary to maintain their fitness for future launch programs. Thermography was used as one part of the inspection and analysis of the tanks. This paper will describe the conclusions derived from the thermal images to evaluate anomalous regions in the tanks, confirm structural integrity of components within the annular region, and evaluate the effectiveness of thermal imaging to detect large insulation voids in tanks prior to filling with cryogenic fluid. The use of thermal imaging as a tool to inspect unfilled tanks will be important if the construction of additional storage tanks is required to fuel new launch vehicles.

Arens, Ellen↗

NASA NTRS2012

Concept Design of Cryogenic Propellant Storage and Transfer for Space Exploration

NASA is in the planning and investigation process of developing innovative paths for human space exploration that strengthen the capability to extend human and robotic presence beyond low Earth orbit and throughout the solar system. NASA is establishing the foundations to enable humans to safely reach multiple potential destinations, including the Moon, asteroids, Lagrange points, and Mars and its environs through technology and capability development. To achieve access to these destinations within a reasonable flight time will require the use of high performance cryogenic propulsion systems. Therefore NASA is examining mission concepts for a Cryogenic Propellant Storage and Transfer (CPST) Flight Demonstration which will test and validate key capabilities and technologies required for future exploration elements such as large cryogenic propulsion stages and propellant depots. The CPST project will perform key ground testing in fiscal year 2012 and execute project formulation and implementation leading to a flight demonstration in 2017.

Free, James M.↗

NASA NTRS2012

The Transport of Mass, Energy, and Entropy in Cryogenic Support Struts for Engineering Design

Engineers working to understand and reduce cryogenic boil-off must solve a. variety of transport problems. An important class of nonlinear problems involves the thermal and mechanical design of cryogenic struts. These classic problems are scattered about the literature and typically require too many resources to obtain. So, to save time for practicing engineers, the author presents this essay. Herein, a variety of new, old, and revisited analytical and finite difference solutions of the thermal problem are covered in this essay, along with commentary on approach and assumptions, This includes a few thermal radiation and conduction combined mode solution with a discussion on insulation, optimum emissivity, and geometrical phenomenon. Solutions to cooling and heat interception problems are also presented, including a discussion of the entropy generation. And the literature on the combined mechanical and thermal design of cryogenic support struts is reviewed with an introduction to the associated numerical methods.

Elchert, J. P.↗