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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
NASA NTRS2005

Heat Transfer and Thermal Stability Research for Advanced Hydrocarbon Fuel Technologies

In recent years there has been increased interest in the development of a new generation of high performance boost rocket engines. These efforts, which will represent a substantial advancement in boost engine technology over that developed for the Space Shuttle Main Engines in the early 1970s, are being pursued both at NASA and the United States Air Force. NASA, under its Space Launch Initiative s Next Generation Launch Technology Program, is investigating the feasibility of developing a highly reliable, long-life, liquid oxygen/kerosene (RP-1) rocket engine for launch vehicles. One of the top technical risks to any engine program employing hydrocarbon fuels is the potential for fuel thermal stability and material compatibility problems to occur under the high-pressure, high-temperature conditions required for regenerative fuel cooling of the engine combustion chamber and nozzle. Decreased heat transfer due to carbon deposits forming on wetted fuel components, corrosion of materials common in engine construction (copper based alloys), and corrosion induced pressure drop increases have all been observed in laboratory tests simulating rocket engine cooling channels. To mitigate these risks, the knowledge of how these fuels behave in high temperature environments must be obtained. Currently, due to the complexity of the physical and chemical process occurring, the only way to accomplish this is empirically. Heated tube testing is a well-established method of experimentally determining the thermal stability and heat transfer characteristics of hydrocarbon fuels. The popularity of this method stems from the low cost incurred in testing when compared to hot fire engine tests, the ability to have greater control over experimental conditions, and the accessibility of the test section, facilitating easy instrumentation. These benefits make heated tube testing the best alternative to hot fire engine testing for thermal stability and heat transfer research. This investigation used the Heated Tube Facility at the NASA Glenn Research Center to perform a thermal stability and heat transfer characterization of RP-1 in an environment simulating that of a high chamber pressure, regenerative cooled rocket engine. The first step in the research was to investigate the carbon deposition process of previous heated tube experiments by performing scanning electron microscopic analysis in conjunction with energy dispersive spectroscopy on the tube sections. This analysis gave insight into the carbon deposition process and the effect that test conditions played in the formation of deleterious coke. Furthermore, several different formations were observed and noted. One other crucial finding of this investigation was that in sulfur containing hydrocarbon fuels, the interaction of the sulfur components with copper based wall materials presented a significant corrosion problem. This problem in many cases was more life limiting than those posed by the carbon deposition process. The results of this microscopic analysis was detailed and presented at the December 2003 JANNAF Air-Breathing Propulsion Meeting as a Materials Compatibility and Thermal Stability Analysis of common Hydrocarbon Fuels (reference 1).

DeWitt, Kenneth↗
NASA NTRS2011

Low Cost Nuclear Thermal Rocket Cermet Fuel Element Environment Testing

Deep space missions with large payloads require high specific impulse and relatively high thrust to achieve mission goals in reasonable time frames.1,2 Conventional storable propellants produce average specific impulse. Nuclear thermal rockets capable of producing high specific impulse are proposed. Nuclear thermal rockets employ heat produced by fission reaction to heat and therefore accelerate hydrogen, which is then forced through a rocket nozzle providing thrust. Fuel element temperatures are very high (up to 3000 K), and hydrogen is highly reactive with most materials at high temperatures. Data covering the effects of high-temperature hydrogen exposure on fuel elements are limited.3 The primary concern is the mechanical failure of fuel elements that employ high-melting-point metals, ceramics, or a combination (cermet) as a structural matrix into which the nuclear fuel is distributed. The purpose of the testing is to obtain data to assess the properties of the non-nuclear support materials, as-fabricated, and determine their ability to survive and maintain thermal performance in a prototypical NTR reactor environment of exposure to hydrogen at very high temperatures. The fission process of the planned fissile material and the resulting heating performance is well known and does not therefore require that active fissile material be integrated in this testing. A small-scale test bed designed to heat fuel element samples via non-contact radio frequency heating and expose samples to hydrogen is being developed to assist in optimal material and manufacturing process selection without employing fissile material. This paper details the test bed design and results of testing conducted to date.

Bradley, D. E.↗
NASA NTRS2013

Induction Heating Model of Cermet Fuel Element Environmental Test (CFEET)

Deep space missions with large payloads require high specific impulse and relatively high thrust to achieve mission goals in reasonable time frames. Nuclear Thermal Rockets (NTR) are capable of producing a high specific impulse by employing heat produced by a fission reactor to heat and therefore accelerate hydrogen through a rocket nozzle providing thrust. Fuel element temperatures are very high (up to 3000 K) and hydrogen is highly reactive with most materials at high temperatures. Data covering the effects of high‐temperature hydrogen exposure on fuel elements are limited. The primary concern is the mechanical failure of fuel elements due to large thermal gradients; therefore, high‐melting‐point ceramics‐metallic matrix composites (cermets) are one of the fuels under consideration as part of the Nuclear Cryogenic Propulsion Stage (NCPS) Advance Exploration System (AES) technology project at the Marshall Space Flight Center. The purpose of testing and analytical modeling is to determine their ability to survive and maintain thermal performance in a prototypical NTR reactor environment of exposure to hydrogen at very high temperatures and obtain data to assess the properties of the non‐nuclear support materials. The fission process and the resulting heating performance are well known and do not require that active fissile material to be integrated in this testing. A small‐scale test bed; Compact Fuel Element Environmental Tester (CFEET), designed to heat fuel element samples via induction heating and expose samples to hydrogen is being developed at MSFC to assist in optimal material and manufacturing process selection without utilizing fissile material. This paper details the analytical approach to help design and optimize the test bed using COMSOL Multiphysics for predicting thermal gradients induced by electromagnetic heating (Induction heating) and Thermal Desktop for radiation calculations.

Gomez, C. F.↗
NASA NTRS2013

Induction Heating Model of Cermet Fuel Element Environmental Test (CFEET)

Deep space missions with large payloads require high specific impulse and relatively high thrust to achieve mission goals in reasonable time frames. Nuclear Thermal Rockets (NTR) are capable of producing a high specific impulse by employing heat produced by a fission reactor to heat and therefore accelerate hydrogen through a rocket nozzle providing thrust. Fuel element temperatures are very high (up to 3000 K) and hydrogen is highly reactive with most materials at high temperatures. Data covering the effects of high‐temperature hydrogen exposure on fuel elements are limited. The primary concern is the mechanical failure of fuel elements due to large thermal gradients; therefore, high‐melting‐point ceramics‐metallic matrix composites (cermets) are one of the fuels under consideration as part of the Nuclear Cryogenic Propulsion Stage (NCPS) Advance Exploration System (AES) technology project at the Marshall Space Flight Center. The purpose of testing and analytical modeling is to determine their ability to survive and maintain thermal performance in a prototypical NTR reactor environment of exposure to hydrogen at very high temperatures and obtain data to assess the properties of the non‐nuclear support materials. The fission process and the resulting heating performance are well known and do not require that active fissile material to be integrated in this testing. A small‐scale test bed; Compact Fuel Element Environmental Tester (CFEET), designed to heat fuel element samples via induction heating and expose samples to hydrogen is being developed at MSFC to assist in optimal material and manufacturing process selection without utilizing fissile material. This paper details the analytical approach to help design and optimize the test bed using COMSOL Multiphysics for predicting thermal gradients induced by electromagnetic heating (Induction heating) and Thermal Desktop for radiation calculations.

Gomez, Carlos F.↗
NASA NTRS2012

Solid-State Nuclear Power

A strategy for "Solid-State" Nuclear Power is proposed to guide development of technologies and systems into the second 50 years of nuclear spaceflight. The strategy emphasizes a simple and highly integrated system architecture with few moving parts or fluid loops; the leverage of modern advances in materials, manufacturing, semiconductors, microelectromechanical and nanotechnology devices; and the targeted advancement of high temperature nuclear fuels, materials and static power conversion to enable high performance from simple system topologies.

George, Jeffrey A.↗
NASA NTRS1989

High speed commercial transport fuels considerations and research needs

NASA is currently evaluating the potential of incorporating High Speed Civil Transport (HSCT) aircraft in the commercial fleet in the beginning of the 21st century. NASA sponsored HSCT enabling studies currently underway with airframers and engine manufacturers, are addressing a broad range of technical, environmental, economic, and related issues. Supersonic cruise speeds for these aircraft were originally focused in the Mach 2 to 5 range. At these flight speeds, both jet fuels and liquid methane were considered potential fuel candidates. For the year 2000 to 2010, cruise Mach numbers of 2 to 3+ are projected for aircraft fuel with thermally stable liquid jet fuels. For 2015 and beyond, liquid methane fueled aircraft cruising at Mach numbers of 4+ may be viable candidates. Operation at supersonic speeds will be much more severe than those encountered at subsonic flight. One of the most critical problems is the potential deterioration of the fuel due to the high temperature environment. HSCT fuels will not only be required to provide the energy necessary for flight, but will also be subject to aerodynamic heating and, will be required to serve as the primary heat sink for cooling the engine and airframe. To define fuel problems for high speed flight, a fuels workshop was conducted at NASA Lewis Research Center. The purpose of the workshop was to gather experts on aviation fuels, airframe fuel systems, airport infrastructure, and combustion systems to discuss high speed fuel alternatives, fuel supply scenarios, increased thermal stability approaches and measurements, safety considerations, and to provide directional guidance for future R and D efforts. Subsequent follow-up studies defined airport infrastructure impacts of high speed fuel candidates. The results of these activities are summarized. In addition, an initial case study using modified in-house refinery simulation model Gordian code (1) is briefly discussed. This code can be used to simulate different types of refineries, emphasizing jet fuel production and relative cost factors.

Lee, C. M.↗
NASA NTRS2007

High-Temperature Desulfurization of Heavy Fuel-Derived Reformate Gas Streams for SOFC Applications

Desulfurization of the hot reformate gas produced by catalytic partial oxidation or autothermal reforming of heavy fuels, such as JP-8 and jet fuels, is required prior to using the gas in a solid oxide fuel cell (SOFC). Development of suitable sorbent materials involves the identification of sorbents with favorable sulfidation equilibria, good kinetics, and high structural stability and regenerability at the SOFC operating temperatures (650 to 800 C). Over the last two decades, a major barrier to the development of regenerable desulfurization sorbents has been the gradual loss of sorbent performance in cyclic sulfidation and regeneration at such high temperatures. Mixed oxide compositions based on ceria were examined in this work as regenerable sorbents in simulated reformate gas mixtures and temperatures greater than 650 C. Regeneration was carried out with dilute oxygen streams. We have shown that under oxidative regeneration conditions, high regeneration space velocities (greater than 80,000 h(sup -1)) can be used to suppress sulfate formation and shorten the total time required for sorbent regeneration. A major finding of this work is that the surface of ceria and lanthanan sorbents can be sulfided and regenerated completely, independent of the underlying bulk sorbent. This is due to reversible adsorption of H2S on the surface of these sorbents even at temperatures as high as 800 C. La-rich cerium oxide formulations are excellent for application to regenerative H2S removal from reformate gas streams at 650 to 800 C. These results create new opportunities for compact sorber/regenerator reactor designs to meet the requirements of solid oxide fuel cell systems at any scale.

Flytzani-Stephanopoulos, Maria↗
NASA NTRS1984

Emission FTIR analyses of thin microscopic patches of jet fuel residue deposited on heated metal surface

Deposits laid down in patches on metal strips in a high pressure/high temperature fuel system simulator operated with aerated fuel at varying flow rates were analyzed by emission FTIR in terms of functional groups. Significant differences were found in the spectra and amounts of deposits derived from fuels to which small concentrations of oxygen-, nitrogen-, or sulfur-containing heterocyclics or metal naphthenates were added. The spectra of deposits generated on strips by heating fuels and air in a closed container were very different from those of the flowing fluid deposits. One such closed-container dodecane deposit on silver gave a strong surface-enhanced Raman spectrum.

Lauer, J. L.↗
NASA NTRS2005

Fabrication of High Temperature Cermet Materials for Nuclear Thermal Propulsion

Processing techniques are being developed to fabricate refractory metal and ceramic cermet materials for Nuclear Thermal Propulsion (NTP). Significant advances have been made in the area of high-temperature cermet fuel processing since RoverNERVA. Cermet materials offer several advantages such as retention of fission products and fuels, thermal shock resistance, hydrogen compatibility, high conductivity, and high strength. Recent NASA h d e d research has demonstrated the net shape fabrication of W-Re-HfC and other refractory metal and ceramic components that are similar to UN/W-Re cermet fuels. This effort is focused on basic research and characterization to identify the most promising compositions and processing techniques. A particular emphasis is being placed on low cost processes to fabricate near net shape parts of practical size. Several processing methods including Vacuum Plasma Spray (VPS) and conventional PM processes are being evaluated to fabricate material property samples and components. Surrogate W-Re/ZrN cermet fuel materials are being used to develop processing techniques for both coated and uncoated ceramic particles. After process optimization, depleted uranium-based cermets will be fabricated and tested to evaluate mechanical, thermal, and hot H2 erosion properties. This paper provides details on the current results of the project.

Hickman, Robert↗
NASA NTRS2004

High Temperature Polymers for use in Fuel Cells

NASA Glenn Research Center (GRC) is currently working on polymers for fuel cell and lithium battery applications. The desire for more efficient, higher power density, and a lower environmental impact power sources has led to interest in proton exchanges membrane fuels cells (PEMFC) and lithium batteries. A PEMFC has many advantages as a power source. The fuel cell uses oxygen and hydrogen as reactants. The resulting products are electricity, heat, and water. The PEMFC consists of electrodes with a catalyst, and an electrolyte. The electrolyte is an ion-conducting polymer that transports protons from the anode to the cathode. Typically, a PEMFC is operated at a temperature of about 80 C. There is intense interest in developing a fuel cell membrane that can operate at higher temperatures in the range of 80 C- 120 C. Operating the he1 cell at higher temperatures increases the kinetics of the fuel cell reaction as well as decreasing the susceptibility of the catalyst to be poisoned by impurities. Currently, Nafion made by Dupont is the most widely used polymer membrane in PEMFC. Nafion does not function well above 80 C due to a significant decrease in the conductivity of the membrane from a loss of hydration. In addition to the loss of conductivity at high temperatures, the long term stability and relatively high cost of Nafion have stimulated many researches to find a substitute for Nafion. Lithium ion batteries are popular for use in portable electronic devices, such as laptop computers and mobile phones. The high power density of lithium batteries makes them ideal for the high power demand of today s advanced electronics. NASA is developing a solid polymer electrolyte that can be used for lithium batteries. Solid polymer electrolytes have many advantages over the current gel or liquid based systems that are used currently. Among these advantages are the potential for increased power density and design flexibility. Automobiles, computers, and cell phones require highly efficient power density for lowering emissions and meeting increasing consumer demands. Many of the solutions can be provided by proton exchange membrane fuel cells and lithium batteries. NASA Glenn Research Center has recognized this need, and is presently engaged in a solution. The goals for the summer include mastering synthesis techniques, understanding the reactions occurring during the synthesis, and characterizing the resulting polymer membranes using NMR, DSC, and TGA for the PEMFC and lithium batteries.

Peplowski, Katherine M.↗
NASA NTRS1988

Fracture technology for brittle materials

Ceramics materials have the potential for use in high-temperature, fuel-efficient engines. However, because these materials are brittle, their fracture characteristics must be well documented prior to their application. Thus Lewis is working to understand the fracture and strength properties of brittle ceramic and ceramic matrix materials. An understanding of fracture properties aids both designers who are attempting to design high-temperature structures and materials scientists who seek to design more temperature-resistant materials. Both analytical and experimental approaches to fracture analysis are being taken. Methods for testing fracture toughness, crack growth resistance, and strength are being developed. The failure mechanisms at both room and elevated temperatures are also being investigated. Such investigations aid materials scientists in developing better high-temperature materials. Of concern is the anisotropy of ceramic materials and the experimental verification of ceramic design codes that will allow brittle material behavior to be accurately predicted at high temperature.

Salem, Jonathan A.↗
NASA NTRS1981

The effects of trace impurities in coal-derived liquid fuels on deposition and accelerated high temperature corrosion of cast superalloys

The effects of trace metal impurities in coal-derived liquids on deposition, high temperature corrosion and fouling were examined. Alloys were burner rig tested from 800 to 1100 C and corrosion was evaluated as a function of potential impurities. Actual and doped fuel test were used to define an empirical life prediction equation. An evaluation of inhibitors to reduce or eliminate accelerated corrosion was made. Barium and strontium were found to limit attack. Intermittent application of the inhibitors or silicon additions were found to be effective techniques for controlling deposition without losing the inhibitor benefits. A computer program was used to predict the dew points and compositions of deposits. These predictions were confirmed in deposition test. The potential for such deposits to plug cooling holes of turbine airfoils was evaluated. Tests indicated that, while a potential problem exists, it strongly depended on minor impurity variations.

Lowell, C. E.↗
NASA NTRS2004

New High-Temperature Membranes Developed for Proton Exchange Membrane Fuel Cells

Fuel cells are receiving a considerable amount of attention for potential use in a variety of areas, including the automotive industry, commercial power generation, and personal electronics. Research at the NASA Glenn Research Center has focused on the development of fuel cells for use in aerospace power systems for aircraft, unmanned air vehicles, and space transportation systems. These applications require fuel cells with higher power densities and better durability than what is required for nonaerospace uses. In addition, membrane cost is a concern for any fuel cell application. The most widely used membrane materials for proton exchange membrane (PEM) fuel cells are based on sulfonated perfluorinated polyethers, typically Nafion 117, Flemion, or Aciplex. However, these polymers are costly and do not function well at temperatures above 80 C. At higher temperatures, conventional membrane materials dry out and lose their ability to conduct protons, essential for the operation of the fuel cell. Increasing the operating temperature of PEM fuel cells from 80 to 120 C would significantly increase their power densities and enhance their durability by reducing the susceptibility of the electrode catalysts to carbon monoxide poisoning. Glenn's Polymers Branch has focused on developing new, low-cost membranes that can operate at these higher temperatures. A new series of organically modified siloxane (ORMOSIL) polymers were synthesized for use as membrane materials in a high-temperature PEM fuel cell. These polymers have an organic portion that can allow protons to transport through the polymer film and a cross-linked silica network that gives the polymers dimensional stability. These flexible xerogel polymer films are thermally stable, with decomposition onset as high as 380 C. Two types of proton-conducting ORMOSIL films have been produced: (1) NASA-A, which can coordinate many highly acid inorganic salts that facilitate proton conduction and (2) NASA-B, which has been produced and which incorporates strongly acidic (proton donating) functional groups into the polymer backbone. Both of these polymer films have demonstrated significantly higher proton conductivity than Nafion at elevated temperatures and low relative humidities. An added advantage is that these polymers are very inexpensive to produce because their starting materials are commodity chemicals that are commercially available in large volumes.

Kinder, James D.↗
NASA NTRS2010

Stability of Materials in High Temperature Water Vapor: SOFC Applications

Solid oxide fuel cell material systems require long term stability in environments containing high-temperature water vapor. Many materials in fuel cell systems react with high-temperature water vapor to form volatile hydroxides which can degrade cell performance. In this paper, experimental methods to characterize these volatility reactions including the transpiration technique, thermogravimetric analysis, and high pressure mass spectrometry are reviewed. Experimentally determined data for chromia, silica, and alumina volatility are presented. In addition, data from the literature for the stability of other materials important in fuel cell systems are reviewed. Finally, methods for predicting material recession due to volatilization reactions are described.

Opila, E. J.↗
NASA NTRS2014

Affordable Development and Optimization of CERMET Fuels for NTP Ground Testing

CERMET fuel materials for Nuclear Thermal Propulsion (NTP) are currently being developed at NASA's Marshall Space Flight Center. The work is part of NASA's Advanced Space Exploration Systems Nuclear Cryogenic Propulsion Stage (NCPS) Project. The goal of the FY12-14 project is to address critical NTP technology challenges and programmatic issues to establish confidence in the affordability and viability of an NTP system. A key enabling technology for an NCPS system is the fabrication of a stable high temperature nuclear fuel form. Although much of the technology was demonstrated during previous programs, there are currently no qualified fuel materials or processes. The work at MSFC is focused on developing critical materials and process technologies for manufacturing robust, full-scale CERMET fuels. Prototypical samples are being fabricated and tested in flowing hot hydrogen to understand processing and performance relationships. As part of this initial demonstration task, a final full scale element test will be performed to validate robust designs. The next phase of the project will focus on continued development and optimization of the fuel materials to enable future ground testing. The purpose of this paper is to provide a detailed overview of the CERMET fuel materials development plan. The overall CERMET fuel development path is shown in Figure 2. The activities begin prior to ATP for a ground reactor or engine system test and include materials and process optimization, hot hydrogen screening, material property testing, and irradiation testing. The goal of the development is to increase the maturity of the fuel form and reduce risk. One of the main accomplishmens of the current AES FY12-14 project was to develop dedicated laboratories at MSFC for the fabrication and testing of full length fuel elements. This capability will enable affordable, near term development and optimization of the CERMET fuels for future ground testing. Figure 2 provides a timeline of the development and optimization tasks for the AES FY15-17 follow on program.

Hickman, Robert R.↗
NASA NTRSDate not supplied

Moderator Considerations for Space Nuclear Power and Propulsion Systems

Nuclear reactors have the potential to provide high energy density to enable sustainable surface power and advanced propulsion methods needed for human exploration activities at the moon and mars. Current mission planning is surveying different reactor types for space power and propulsion application. Of these reactor types, the use of a moderator within the reactor can enable reduced enrichment, reduce overall fuel loadings, and minimize the critical size of the reactor compared to unmoderated reference systems. This proceeding summarizes some moderator materials identified for space reactor applications: zirconium hydride, yttrium hydride, beryllium, and beryllium oxide, and the unique design considerations inherent to surface power and nuclear thermal propulsion reactor designs. It was found that there are four key considerations during the moderator selection and design process: nuclear properties, thermophysical & mechanical properties, manufacture & readiness, and environmental compatibility. Surface power reactors can benefit from moderators which minimize overall system mass and are capable of surviving high temperature irradiation environments for years with little degradation. Nuclear thermal propulsion reactors can benefit from moderators which are capable of retaining structural integrity under multiple burns while being exposed to a wide temperature range (40 < T < 500+ K). Moderator materials which exhibit good stability under irradiation and high temperature operation, minimize fuel pitch, and are high readiness are desirable for near term implementation.

nuclear thermal propulsion↗
NASA NTRS1999

Kinetics and Structure of Superagglomerates Produced by Silane and Acetylene

The evolution of smoke in a laminar diffusion flame involves several steps. The first step is particle inception/nucleation in the high-temperature fuel-rich region of the flame followed by surface growth and coagulation/coalescence of the small particles. As the primary spheres grow in size and lose hydrogen, the colliding particles no longer coalesce but retain their identity as a cluster of primary spheres, termed an agglomerate. Finally, in the upper portion of the flame, the particles enter an oxidizing environment which may lead to partial or complete burnout of the agglomerates. Currently there is no quantitative model for describing the growth of smoke agglomerates up to superagglomerates with an overall dimension of 10 microns and greater. Such particles are produced during the burning of acetylene and fuels containing benzene rings such as toluene and polystyrene. In the case of polystyrene, smoke agglomerates in excess of 1 mm have been observed "raining" out from large fires. Evidence of the formation of superagglomerates in a laminar acetylene/air diffusion flame has been recently reported. Acetylene was chosen as the fuel since the particulate loading in acetylene/air diffusion flames is very high. Photographs were obtained by Sorensen using a microsecond xenon lamp of the "stream" of soot just above the flame. For low flow rates of acetylene, only submicrometer soot clusters are produced and they give rise to the homogeneous appearance of the soot stream. When the flow rate is increased to 1.7 cu cm/s, soot clusters up to 10 microns are formed and they are responsible for the graininess and at a flow rate of 3.4 cu cm/s, a web of interconnected clusters as large as the width of the flame is seen. This interconnecting web of superagglomerates is described as a gel state by Sorensen et al (1998). This is the first observation of a gel for a gas phase system. It was observed that this gel state immediately breaks up into agglomerates due to buoyancy induced turbulence and gravitational sedimentation.

Mulholland, G. W.↗
NASA NTRS1998

Measuring Thermal Conductivity and Moisture Absorption of Cryo-Insulation Materials

NASA is seeking to develop thermal insulation material systems suitable for withstanding both extremely high temperatures encountered during atmospheric re-entry heating and aero- braking maneuvers, as well as extremely low temperatures existing in liquid fuel storage tanks. Currently, materials used for the high temperature insulation or Thermal Protection System (TPS) are different from the low temperature, or cryogenic insulation. Dual purpose materials are necessary to the development of reusable launch vehicles (RLV). The present Space Shuttle (or Space Transportation System, STS) employs TPS materials on the orbiter and cryo-insulation materials on the large fuel tank slung under the orbiter. The expensive fuel tank is jettisoned just before orbit is achieved and it burns up while re-entering over the Indian Ocean. A truly completely reusable launch vehicle must store aR cryogenic fuel internally. The fuel tanks will be located close to the outer surface. In fact the outer skin of the craft will probably also serve as the fuel tank enclosure, as in jet airliners. During a normal launch the combined TPS/cryo-insulation system will serve only as a low temperature insulator, since aerodynamic heating is relatively minimal during ascent to orbit. During re-entry, the combined TPS/cryo-insulation system will serve only as a high temperature insulator, since all the cryogenic fuel will have been expended in orbit. However, in the event of an.aborted launch or a forced/emergency early re-entry, the tanks will still contain fuel, and the TPS/cryo-insulation will have to serve as both low and high temperature insulation. Also, on long duration missions, such as to Mars, very effective cryo-insulation materials are needed to reduce bod off of liquid propellants, thereby reducing necessary tankage volume, weight, and cost. The conventional approach to obtaining both low and high temperature insulation, such as is employed for the X-33 and X-34 spacecraft, is to use separate TPS and cryo-insulation materials, which are connected by means of adhesives or stand-offs (spacers). Three concepts are being considered: (1) the TPS is bonded directly to the cryo-insulation which, in turn, is bonded to the exterior of the tank, (2) stand-offs are used to make a gap between the TPS and the cryo-insulation, which is bonded externally to the tank, (3) TPS is applied directly or with stand-offs to the exterior so the tank, and cryo-insulation is applied directly to the interior of the tank. Many potential problems are inherent in these approaches. For example, mismatch between coefficients of thermal expansion of the TPS and cryo-insulation, as well as aerodynamic loads, could lead to failure of the bond. Internal cryo-insulation must be prevent from entering the sump of the fuel turbo-pump. The mechanical integrity of the stand-off structure (if used) must withstand multiple missions. During ground hold (i.e., prior to launch) moisture condensation must be minimized in the gap between the cryo-insulation and the TPS. The longer term solution requires the development of a single material to act as cryo- insulation during ground hold and as TPS during re-entry. Such a material minimizes complexity and weight while improving reliability and reducing cost.

Lambert, Michael A.↗