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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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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

Probabilistic Risk Assessment of Aging Layered Pressure Vessels

The National Aeronautics and Space Administration (NASA) operates approximately 300 aging layered pressure vessels that were designed and manufactured prior to ASME Boiler and Pressure Vessel (B&PV) code requirements. In order to make decisions regarding the continued fitness-for-service of these non-code carbon steel vessels, it is necessary to perform a relative risk of failure assessment for each vessel. However, risk assessment of these vessels is confounded by uncertainties and variabilities related to the use of proprietary materials in fabrication, missing construction records, geometric discontinuities, weld residual stresses, and complex service stress gradients in and around the welds. Therefore, a probabilistic framework that can capture these uncertainties and variabilities has been developed to assess the fracture risk of flaws in regions of interest, such as longitudinal and circumferential welds, using the NESSUS® probabilistic modeling software and NASGRO® fracture mechanics software. In this study, the probabilistic framework was used to predict variability in the stress intensity factor associated with different reference flaws located in the head-to-shell circumferential welds of a 4-layer and 14-layer pressure vessel. The probabilistic studies predict variability in flaw behavior and the important uncertain parameters for each reference flaw location.

Riha, D. S.↗
NASA NTRS1995

Advanced Dependent Pressure Vessel (DPV) nickel-hydrogen spacecraft cell and battery design

The dependent pressure vessel (DPV) nickel-hydrogen (NiH2) battery is being developed as a potential spacecraft battery design for both military and commercial satellites. Individual pressure vessel (IPV) NiH2 batteries are currently flying on more than 70 Earth orbital satellites and have accumulated more than 140,000,000 cell-hours in actual spacecraft operation. The limitations of standard NiH2 IPV flight battery technology are primarily related to the internal cell design and the battery packaging issues associated with grouping multiple cylindrical cells. The DPV cell design offers higher specific energy and reduced cost, while retaining the established IPV NiH2 technology flight heritage and database. The advanced cell design offers a more efficient mechanical, electrical and thermal cell configuration and a reduced parts count. The internal electrode stack is a prismatic flat-plate arrangement. The flat individual cell pressure vessel provides a maximum direct thermal path for removing heat from the electrode stack. The cell geometry also minimizes multiple-cell battery packaging constraints by using an established end-plateltie-rod battery design. A major design advantage is that the battery support structure is efficiently required to restrain only the force applied to a portion of the end cell. As the cells are stacked in series to achieve the desired system voltage, this increment of the total battery weight becomes small. The geometry of the DPV cell promotes compact, minimum volume packaging and places all cell terminals along the length of the battery. The resulting ability to minimize intercell wiring offers additional design simplicity and significant weight savings. The DPV battery design offers significant cost and weight savings advantages while providing minimal design risks. Cell and battery level design issues will be addressed including mechanical, electrical and thermal design aspects. A design performance analysis will be presented at both the cell and battery level. The DPV is capable of delivering up to 76 Watt-hours per kilogram (Wh/kg) at the cell level and 70 Wh/kg at the full battery level. This represents a 40 percent increase in specific energy at the cell level and a 60 percent increase in specific energy at the battery level compared to current IPV NiH2 technology.

Coates, Dwaine↗
NASA NTRS1991

Pressure vessel burst test program. II

The current status is disucssed of a program to study the characteristics of blast waves and fragmentation generated by ruptured gas-filled pressure vessels. Current methods for assessing vessel safety and burst parameters are briefly reviewed, and pneumatic burst testing operations and testing results are examined. A comparison is made with current methods for burst assessment. It is tentatively concluded that, at close distances, vessel burst overpressures are less than those of high-explosive (HE) blasts with equivalent energy and are greater than HE far from the vessel. The impulse appears to be the same for both vessel bursts and equivalent energy HE blasts. The functional relationship between shock velocity and overpressure ratio appears to be the same for vessel bursts as for HE blasts. The initial shock overpressure appears to be much less than vessel pressure and may be found using the one-dimensional shock tube equation.

Cain, Maurice R.↗
NASA NTRS2007

Asymmetric Bulkheads for Cylindrical Pressure Vessels

Asymmetric bulkheads are proposed for the ends of vertically oriented cylindrical pressure vessels. These bulkheads, which would feature both convex and concave contours, would offer advantages over purely convex, purely concave, and flat bulkheads (see figure). Intended originally to be applied to large tanks that hold propellant liquids for launching spacecraft, the asymmetric-bulkhead concept may also be attractive for terrestrial pressure vessels for which there are requirements to maximize volumetric and mass efficiencies. A description of the relative advantages and disadvantages of prior symmetric bulkhead configurations is prerequisite to understanding the advantages of the proposed asymmetric configuration: In order to obtain adequate strength, flat bulkheads must be made thicker, relative to concave and convex bulkheads; the difference in thickness is such that, other things being equal, pressure vessels with flat bulkheads must be made heavier than ones with concave or convex bulkheads. Convex bulkhead designs increase overall tank lengths, thereby necessitating additional supporting structure for keeping tanks vertical. Concave bulkhead configurations increase tank lengths and detract from volumetric efficiency, even though they do not necessitate additional supporting structure. The shape of a bulkhead affects the proportion of residual fluid in a tank that is, the portion of fluid that unavoidably remains in the tank during outflow and hence cannot be used. In this regard, a flat bulkhead is disadvantageous in two respects: (1) It lacks a single low point for optimum placement of an outlet and (2) a vortex that forms at the outlet during outflow prevents a relatively large amount of fluid from leaving the tank. A concave bulkhead also lacks a single low point for optimum placement of an outlet. Like purely concave and purely convex bulkhead configurations, the proposed asymmetric bulkhead configurations would be more mass-efficient than is the flat bulkhead configuration. In comparison with both purely convex and purely concave configurations, the proposed asymmetric configurations would offer greater volumetric efficiency. Relative to a purely convex bulkhead configuration, the corresponding asymmetric configuration would result in a shorter tank, thus demanding less supporting structure. An asymmetric configuration provides a low point for optimum location of a drain, and the convex shape at the drain location minimizes the amount of residual fluid.

Ford, Donald B.↗
NASA NTRS1997

New Developments in Nickel-Hydrogen Dependent Pressure Vessel (DPV) Cell and Battery Design

THe Dependent Pressure Vessel (DPV) Nickel-Hydrogen (NiH2) design is being developed as an advanced battery for military and commercial, aerospace and terrestrial applications. The DPV cell design offers high specific energy and energy density as well as reduced cost, while retaining the established Individual Pressure Vessel (IPV) technology flight heritage and database. This advanced DPV design also offers a more efficient mechanical, electrical and thermal cell and battery configuration and a reduced part count. The DPV battery design promotes compact, minimum volume packaging and weight efficiency, and delivers cost and weight savings with minimal design risk.

Caldwell, Dwight B.↗
NASA NTRS1977

Recent advances in lightweight, filament-wound composite pressure vessel technology

A review of recent advances is presented for lightweight, high performance composite pressure vessel technology that covers the areas of design concepts, fabrication procedures, applications, and performance of vessels subjected to single cycle burst and cyclic fatigue loading. Filament wound fiber/epoxy composite vessels were made from S glass, graphite, and Kevlar 49 fibers and were equipped with both structural and nonstructural liners. Pressure vessels structural efficiencies were attained which represented weight savings, using different liners, of 40 to 60 percent over all titanium pressure vessels. Significant findings in each area are summarized.

Lark, R. F.↗
NASA NTRS2016

Non-Axisymmetric Inflatable Pressure Structure (NAIPS) Concept that Enables Mass Efficient Packageable Pressure Vessels with Sealable Openings

Achieving minimal launch volume and mass are always important for space missions, especially for deep space manned missions where the costs required to transport mass to the destination are high and volume in the payload shroud is limited. Pressure vessels are used for many purposes in space missions including habitats, airlocks, and tank farms for fuel or processed resources. A lucrative approach to minimize launch volume is to construct the pressure vessels from soft goods so that they can be compactly packaged for launch and then inflated en route or at the final destination. In addition, there is the potential to reduce system mass because the packaged pressure vessels are inherently robust to launch loads and do not need to be modified from their in-service configuration to survive the launch environment. A novel concept is presented herein, in which sealable openings or hatches into the pressure vessels can also be fabricated from soft goods. To accomplish this, the structural shape is designed to have large regions where one principal stress is near zero. The pressure vessel is also required to have an elongated geometry for applications such as airlocks.

Doggett, William R.↗
NASA NTRS1974

Polymer-lined filament-wound pressure vessels for nitrogen containment

A program has been started to develop fatigue-resistant polymeric liners for a filament-wound pressure vessel to contain nitrogen gas at room temperature. First, nitrogen permeation of butyl rubber sheet coated with Saran and Parylene C was studied in flat specimens. Then four 10-cm-diam cylindrical pressure vessels were prepared with chlorobutyl rubber liners coated with the same materials. These vessels were valved off after nitrogen gas pressurization to approximately 65% (approximately 11.7 MPa or 1700 psig) of their expected failure pressure. One vessel leaked. The other three vessels showed an average pressure loss of less than 1% per month. These pressure vessels have an average performance factor of approximately 370 kPa-cu m/kg (1,500,000 in.) based on composite mass.

Hamstad, M. A.↗
NASA NTRS1974

Polymer-lined filament-wound pressure vessels for nitrogen containment

A program has been started to develop fatigue-resistant polymeric liners for a filament-wound pressure vessel to contain nitrogen gas at room temperature. First, nitrogen permeation of butyl rubber sheet coated with Saran and Parylene C was studied in flat specimens. Then four 10-cm-diam cylindrical pressure vessels were prepared with chlorobutyl rubber liners coated with the same materials. These vessels were valved off after nitrogen gas pressurization to approximately 65% of their expected failure pressure. One vessel leaked. The other three vessels showed an average pressure loss of less than 1% per month. These pressure vessels have an average performance factor of about 370 kPa x cu m/kg based on composite mass.

Hamstad, M. A.↗
NASA NTRS1993

J-integral patch for finite element analysis of dynamic fracture due to impact of pressure vessels

Prediction of whether a pressurized cylinder will fail catastrophically when impacted by a projectile has important applications ranging from perforation of an airplane's skin by a failed turbine blade to meteorite impact of a space station habitation module. This report summarizes the accomplishment of one task for a project whose aim is to simulate numerically the outcome of a high velocity impact of pressure vessels. A finite element patch covering the vicinity of a growing crack has been constructed to estimate the J-integral (crack driving force) during the impact. Explicit expressions for the J-integral through the nodal values of displacement, strain, and stress have been written. The patch is to be used repeatedly to estimate the amount of crack growth during the time of the impact. The resulting crack size is to be compared to an estimated critical crack size for the pressurized cylinder.

Kunin, Boris I.↗
NASA NTRS1977

Recent advances in lightweight, filament-wound composite pressure vessel technology

A review of recent advances is presented for lightweight, high-performance composite pressure vessel technology that covers the areas of design concepts, fabrication procedures, applications, and performance of vessels subjected to single-cycle burst and cyclic fatigue loading. Filament-wound fiber/epoxy composite vessels were made from S-glass, graphite, and Kevlar 49 fibers and were equipped with both structural and nonstructural liners. Pressure vessel structural efficiencies were attained which represented weight savings, using different liners, of 40 to 60 percent over all-titanium pressure vessels. Significant findings in each area are summarized including data from current NASA-Lewis Research Center contractual and in-house programs.

Lark, R. F.↗
NASA NTRS1973

Improved fireman's compressed air breathing system pressure vessel development program

Prototype high pressure glass filament-wound, aluminum-lined pressurant vessels suitable for use in a fireman's compressed air breathing system were designed, fabricated, and acceptance tested in order to demonstrate the feasibility of producing such high performance, lightweight units. The 4000 psi tanks have a 60 standard cubic foot (SCF) air capacity, and have a 6.5 inch diamter, 19 inch length, 415 inch volume, weigh 13 pounds when empty, and contain 33 percent more air than the current 45 SCF (2250 psi) steel units. The current steel 60 SCF (3000 psi) tanks weigh approximately twice as much as the prototype when empty, and are 2 inches, or 10 percent shorter. The prototype units also have non-rusting aluminum interiors, which removes the hazard of corrosion, the need for internal coatings, and the possibility of rust particles clogging the breathing system.

King, H. A.↗
DOE OSTI2020

Smart Composite Pressure Vessels (SCPV) with Integrated Health Monitoring

The U.S. Department of Energy (DOE) is promoting and developing more energy efficient and environmentally friendly technologies that will enable America to use less petroleum. Hydrogen fuel cells – which directly convert the chemical energy in hydrogen to electricity with only water and heat as byproducts – are a very attractive solution that can enable this to happen. To date, DOE's efforts have culminated in commercial demonstration of on-board vehicular hydrogen storage systems that can allow for a driving range of greater than 300 miles. This requires storing 5 Kgs of hydrogen onboard a light vehicle. In order to store this quantity of hydrogen, the hydrogen gas needs to be stored in a composite overwrapped pressure vessel (COPV) at a very high internal pressure. The objective of the program was to demonstrate continuous and predictable health-monitoring of composite pressure vessels. A higher confidence in the operational safety of the vessels will lead to reduced burst factor of safety imposed by regulatory standards and hence will help reduce the structural wall thickness that drives the cost of the vessel. Highly optimized Type III (metal lined) and Type IV (polymer lined) COPVs that are manufactured using filament winding process have been designed and qualified for the above mentioned application. However, the main structural component of the COPVs is carbon fiber and the high cost of carbon fiber composite in a pressure vessel is a primary challenge in reducing the cost of gaseous hydrogen storage. Continuous and remote monitoring of structural health of the COPVs as well as optimization of the strength translation of carbon fibers have the potential to allow for reduced factor of safety, thereby reduced amount of carbon and associated cost of the vessel. In the current program, the project team including Steelhead Composites (SHC), University of Tennessee, Knoxville (UTK), Teijin Carbon America, Oak Ridge National Laboratory (ORNL) and LUNA designed, fabricated, and tested smart composite pressure vessels with integrated sensors. Iterative loops of design and testing using coupons, subscale STEB vessels and full size vessels proved that a new generation of high performance carbon fiber can be used for efficient design of Type 3 vessels for H2 storage. Novel analysis techniques were developed to predict the initiation and propagation of interlaminar damage inside the composite shell due to impact damage, a real threat in practical operation. Such an analysis scheme is typically not used in tank design but is an essential tool for health monitoring of composite vessels. Remote sensing of the key signatures of the tank’s operating parameters such as pressure, acceleration and humidity was demonstrated using a unique device that can wirelessly transmit and stream the data to a remote server. Fiber optic sensors were successfully integrated during fabrication of the tanks. These sensors provide a wealth of information regarding the structural health of the vessel when it is subsequently pressurized or subjected to impact damage. Excellent correlation was demonstrated between the fiber optic sensor and mechanical strain gage data, and between the measurements and analytical predictions.

08 HYDROGEN↗
NASA NTRS2017

Some Observations on Damage Tolerance Analyses in Pressure Vessels

AIAA standards S080 and S081 are applicable for certification of metallic pressure vessels (PV) and composite overwrap pressure vessels (COPV), respectively. These standards require damage tolerance analyses with a minimum reliable detectible flaw/crack and demonstration of safe life four times the service life with these cracks at the worst-case location in the PVs and oriented perpendicular to the maximum principal tensile stress. The standards require consideration of semi-elliptical surface cracks in the range of aspect ratios (crack depth a to half of the surface length c, i.e., (a/c) of 0.2 to 1). NASA-STD-5009 provides the minimum reliably detectible standard crack sizes (90/95 probability of detection (POD) for several non-destructive evaluation (NDE) methods (eddy current (ET), penetrant (PT), radiography (RT) and ultrasonic (UT)) for the two limits of the aspect ratio range required by the AIAA standards. This paper tries to answer the questions: can the safe life analysis consider only the life for the crack sizes at the two required limits, or endpoints, of the (a/c) range for the NDE method used or does the analysis need to consider values within that range? What would be an appropriate method to interpolate 90/95 POD crack sizes at intermediate (a/c) values? Several procedures to develop combinations of a and c within the specified range are explored. A simple linear relationship between a and c is chosen to compare the effects of seven different approaches to determine combinations of aj and cj that are between the (a/c) endpoints. Two of the seven are selected for evaluation: Approach I, the simple linear relationship, and a more conservative option, Approach III. For each of these two Approaches, the lives are computed for initial semi-elliptic crack configurations in a plate subjected to remote tensile fatigue loading with an R-ratio of 0.1, for an assumed material evaluated using NASGRO (registered 4) version 8.1. These calculations demonstrate that for this loading, using Approach I and the initial detectable crack sizes at the (a/c) endpoints in 5009 specified for the ET and UT NDE methods, the smallest life is not at the two required limits of the (a/c) range, but rather is at an intermediate configuration in the range (a/c) of 0.4 to 0.6. Similar analyses using both Approach I and III with the initial detectable crack size at the (a/c) endpoints in 5009 for PT NDE showed the smallest life may be at an (a/c) endpoint or an intermediate (a/c), depending upon which Approach is used. As such, analyses that interrogate only the two (a/c) values of 0.2 and 1 may result in unconservative life predictions. The standard practice may need to be revised based on these results.

Raju, Ivatury S.↗
NASA NTRS2015

Multipurpose Pressure Vessel Scanner and Photon Doppler Velocimetry

Critical flight hardware typically undergoes a series of nondestructive evaluation methods to screen for defects before it is integrated into the flight system. Conventionally, pressure vessels have been inspected for flaws using a technique known as fluorescent dye penetrant, which is biased to inspector interpretation. An alternate method known as eddy current is automated and can detect small cracks better than dye penetrant. A new multipurpose pressure vessel scanner has been developed to perform internal and external eddy current scanning, laser profilometry, and thickness mapping on pressure vessels. Before this system can be implemented throughout industry, a probability of detection (POD) study needs to be performed to validate the system's eddy current crack/flaw capabilities. The POD sample set will consist of 6 flight-like metal pressure vessel liners with defects of known size. Preparation for the POD includes sample set fabrication, system operation, procedure development, and eddy current settings optimization. For this, collaborating with subject matter experts was required. This technical paper details the preparation activities leading up to the POD study currently scheduled for winter 2015/2016. Once validated, this system will be a proven innovation for increasing the safety and reliability of necessary flight hardware. Additionally, testing of frangible joint requires Photon Doppler Velocimetry (PDV) and Digital Image Correlation instrumentation. There is often noise associated with PDV data, which necessitates a frequency modulation (FM) signal-to-noise pre-test. Generally, FM radio works by varying the carrier frequency and mixing it with a fixed frequency source, creating a beat frequency which is represented by audio frequency that can be heard between about 20 to 20,000 Hz. Similarly, PDV reflects a shifted frequency (a phenomenon known as the Doppler Effect) from a moving source and mixes it with a fixed source frequency, which results in a beat frequency. However, for PDV, discerning the signal from the noise is difficult without a moving source to induce the modulation. A rotating wheel is currently being used as the moving source but its configuration is impractical and has cumbersome placement inside the current frangible joint test cell. As a way to combat this problem and verify a satisfactory signal-to-noise ratio, a reflective moving crystal piezo will be used to modulate a beat frequency, and an absorptive target will be used to block the signal in order to determine any back reflection coming from the probe and discern the true signal-to-noise ratio. The piezo will be mounted and inserted onto the test table on an extendable telescopic antenna grounded by a magnetic base in the test zone. This piezo configuration will be more compatible within the test zone and allow for easy removal of the disk following acceptable signal verification and prior to frangible joint tests.

Ellis, Tayera↗