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A method and apparatus for gelling liquid propane and other liquefied gasses includes a temperature controlled churn mixer, vacuum pump, liquefied gas transfer tank, and means for measuring amount of material entering the mixer. The apparatus and method are particularly useful for the production of high quality rocket fuels and propellants.
This project is a collaborative effort to mature an iodine propulsion system while reducing risk and increasing fidelity of a technology demonstration mission concept. 1 The FY 2014 tasks include investments leveraged throughout NASA, from multiple mission directorates, as a partnership with NASA Glenn Research Center (GRC), a NASA Marshall Space Flight Center (MSFC) Technology Investment Project, and an Air Force partnership. Propulsion technology is often a critical enabling technology for space missions. NASA is investing in technologies to enable high value missions with very small and low-cost spacecraft, even CubeSats. However, these small spacecraft currently lack any appreciable propulsion capability. CubeSats are typically deployed and drift without any ability to transfer to higher value orbits, perform orbit maintenance, or deorbit. However, the iodine Hall system can allow the spacecraft to transfer into a higher value science orbit. The iodine satellite (iSAT) will be able to achieve a (Delta)V of >500 m/s with <1 kg of solid iodine propellant, which can be stored in an unpressurized benign state prior to launch. The iSAT propulsion system consists of the 200 W Hall thruster, solid iodine propellant tank, a power processing unit, and the necessary valves and tubing to route the iodine vapor. The propulsion system is led by GRC, with critical hardware provided by the Busek Co. The propellant tank begins with solid iodine unpressurized on the ground and in-flight before operations, which is then heated via tank heaters to a temperature at which solid iodine sublimates to iodine vapor. The vapor is then routed through tubing and custom valves to control mass flow to the thruster and cathode assembly. 2 The thruster then ionizes the vapor and accelerates it via magnetic and electrostatic fields, resulting in thrust with a specific impulse >1,300 s. The iSAT spacecraft, illustrated in figure 1, is currently a 12U CubeSat. The spacecraft chassis will be constructed from aluminum with a finish to prevent iodine-driven corrosion. The iSAT spacecraft includes full three-axis control using wheels, magnetic torque rods, inertial management unit, and a suite of sensors and optics. The spacecraft will leverage heat generated by spacecraft components and radiators for a passive thermal control system.
This AIAA Short Course lecture will present an overview of different experiments and computational modeling work that has been done to examine different aspects of pressurization and pressure control of a Cryogenic propellant tank. The lecture will cover several large-scale ground-based liquid Hydrogen cryogenic self-pressurization experiments that were performed at NASA Glenn and NASA Marshall, LN2 Nitrogen autogenous pressurization experiments, pressure control experiments using both subcooled jet mixing and subcooled droplet injection, and experiments that examined pressure drops that occur during tank sloshing. Numerical modeling and simulations that were done in association to these experiments as part of a comprehensive model validation effort will also be presented and discussed. Finally, the results of two simulant fluid pressurization and pressure control microgravity investigations performed as part of the Tank Pressure Control Experiment (TCPE) and The Zero-Boil-Off Tank (ZBOT)Experiment will also be presented.
Future NASA architectures have baselined cryogenic propulsion systems as well as cryogenic fluid management to support lunar missions and ultimately to support future missions to Mars. These missions will require chilling hardware down prior to engine restart as well as chilling lines and tanks prior to transferring and refueling these propulsion elements in orbit. In lieu of expensive tests conducted on-orbit, accurate predictive computational models of these chilldown processes can be used to reduce system and propellant mass as well as mission risk. To gain confidence in these computational models, appropriate anchoring and validation to experimental data in a relevant environment needs to be performed. Recent ground and sub-orbital flight experiments conducted by the Japan Aerospace Exploration Agency (JAXA) investigated chilldown of a complex channel resembling a turbopump bearing cavity at low flow rates. This work presents Computational Fluid Dynamics (CFD) model development of the chilldown experiment employing two-phase flow boiling models available in commercial CFD software STAR-CCM+ using Volume of Fluid (VOF) and the traditional Euler-Euler multiphase flow solvers. Comparisons of the numerical and experimental results under normal and low-gravity conditions are presented. An assessment of solid wall temperatures and phase distribution yielded important insights into multiphase solver choice, dependence on gravity environment, and challenges associated with cryogenic flow boiling prediction and validation.
This paper addresses the need to understand the physics and chemistry involved in propellant combustion processes in micro-scale combustors for propulsion systems on micro-spacecraft. These spacecraft are planned to have a mass less than 50 kilograms with attitude control estimated to be in the 10 milli-Newton thrust class. These combustors are anticipated to be manufactured using Micro Electrical Mechanical Systems (MEMS) technology and are expected to have diameters approaching the quenching diameter of the propellants. Combustors of this size are expected to benefit significantly from surface catalysis processes. Miniature flame tube apparatus is chosen for this study because microtubes can be easily fabricated from known catalyst materials and their simplicity in geometry can be used in fundamental simulations to more carefully characterize the measured heat transfer and pressure losses for validation purposes. Experimentally, we investigate the role of catalytically active surfaces within 0.4 and 0.8 mm internal diameter micro-tubes, with special emphases on ignition and extinction processes in fuel rich gaseous hydrogen and gaseous oxygen. Flame thickness and reaction zone thickness calculations predict that the diameters of our test apparatus are below the quenching diameter of the propellants in sub-atmospheric tests. Temperature and pressure rises in resistively heated platinum and palladium micro-tubes are used as an indication of exothermic reactions. Specific data on mass flow versus preheat temperature required to achieve ignition are presented.
Atmospheric mining in the outer solar system has been investigated as a means of fuel production for high energy propulsion and power. Fusion fuels such as Helium 3 (3He) and deuterium can be wrested from the atmospheres of Uranus and Neptune and either returned to Earth or used in-situ for energy production. Helium 3 and deuterium were the primary gases of interest with hydrogen being the primary propellant for nuclear thermal solid core and gas core rocket-based atmospheric flight. A series of analyses were undertaken to investigate resource capturing aspects of atmospheric mining in the outer solar system. This included the gas capturing rate, storage options, and different methods of direct use of the captured gases. While capturing 3He, large amounts of hydrogen and 4He are produced. Analyses of orbital transfer vehicles (OTVs), landers, and the issues with in-situ resource utilization (ISRU) mining factories are included. Preliminary observations are presented on near-optimal selections of moon base orbital locations, OTV power levels, and OTV and lander rendezvous points. For analyses of round trip OTV flights from Uranus to Miranda or Titania, a 10-Megawatt electric (MWe) OTV power level and a 200-metric ton (MT) lander payload were selected based on a relative short OTV trip time and minimization of the number of lander flights. A similar optimum power level is suggested for OTVs flying from low orbit around Neptune to Thalassa or Triton. Several moon base sites at Uranus and Neptune and the OTV requirements to support them are also addressed.
Atmospheric mining in the outer solar system has been investigated as a means of fuel production for high energy propulsion and power. Fusion fuels such as Helium 3 (3He) and deuterium can be wrested from the atmospheres of Uranus and Neptune and either returned to Earth or used in-situ for energy production. Helium 3 and deuterium were the primary gases of interest with hydrogen being the primary propellant for nuclear thermal solid core and gas core rocket-based atmospheric flight. A series of analyses were undertaken to investigate resource capturing aspects of atmospheric mining in the outer solar system. This included the gas capturing rate, storage options, and different methods of direct use of the captured gases. While capturing 3He, large amounts of hydrogen and 4He are produced. Analyses of orbital transfer vehicles (OTVs), landers, and the issues with in-situ resource utilization (ISRU) mining factories are included. Preliminary observations are presented on near-optimal selections of moon base orbital locations, OTV power levels, and OTV and lander rendezvous points. For analyses of round trip OTV flights from Uranus to Miranda or Titania, a 10- Megawatt electric (MWe) OTV power level and a 200 metricton (MT) lander payload were selected based on a relative short OTV trip time and minimization of the number of lander flights. A similar optimum power level is suggested for OTVs flying from low orbit around Neptune to Thalassa or Triton. Several moon base sites at Uranus and Neptune and the OTV requirements to support them are also addressed.
The engine operating characteristics were examined. Inlet pressure effects, tank pressurization effects, steady-state specific impulse, and the steady-state cycle were studied. The propellant flow schematic and operating sequence are presented. Engine hardware drawings are included.
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An advanced exploration probe has been proposed by the Center for Space Nuclear Research (CSNR) to acquire detailed data from the Martian surface and subsurface, ‘hop’ large distances to multiple sites in short periods of time and perform this task repeatedly. Although several similar flying vehicles have been proposed utilizing various power sources and complex designs, e.g. solar-electric and chemical-based, the CSNR’s Mars Hopper is based on a radioisotope thermal rocket (RTR) concept. The Mars Hopper’s design relies on the high specific energies [J/kg] of radioisotopes and enhances their low specific power [W/kg] through the use of a thermal capacitance material to store thermal energy over time. During operation, the RTR transfers the stored thermal energy to a flowing gas, which is then expanded through a converging-diverging nozzle, producing thrust. Between flights, the platform will have ample time to perform in-depth science at each location while the propellant tanks and thermal capacitor recharge. Recharging the propellant tanks is accomplished by sublimation freezing of the ambient CO2 atmosphere with a cryocooler, followed by heating and pressurization to yield a liquid storage state. The proposed Mars Hopper will undergo a ballistic flight, consuming the propellant in both ascent and descent, and by using multiple hopper platforms, information can be gathered on a global scale, enabling better resource resolution and providing valuable information for a possible Mars sample-return mission. The CSNR, collaborating with the Idaho National Laboratory (INL) and three universities (University of Idaho, Utah State University and Oregon State University), has identified key components and sub-systems necessary for the proposed hopper. Current project activities include the development of a lab-scale prototypic Mars Hopper and test facility, along with computational fluid dynamics (CFD)/thermal-hydraulic models to yield a better understanding of the heat transfer process and complex nature of turbulent CO2 flow. Laboratory experimentation will aid design iterations and the development of both tethered and free-flying terrestrial hoppers that utilize an electrically heated core. The knowledge base acquired from these activities will refine the Mars Hopper’s future performance and optimize the RTR core components prior to constructing the final design.
The orbits attained by kick motor solid propellant particulates are modeled, and an estimate is made of the number of particulates which will remain in orbit. The fuel, Al2O3, is burned while inserting spacecraft into a transfer orbit and again while circularizing the GEO station. It is shown that 23 percent of 1 micron particles deorbit immediately, while most particles enter a retrograde orbit. The resulting flux is an order of magnitude larger than the micrometeoroid flux. The pressures exerted by solar radiation ensure that only 5 percent of the original flux is still in orbit after the first year. The estimates provided are valid for a large number of transfer orbit operations, but will vary widely over the short term.
This report reviews the state of the art of thermal-hydraulic analysis codes and presents a new code, Program ELM, for analysis of fuel elements. ELM is a concise computational tool for modeling the steady-state thermal-hydraulics of propellant flow through fuel element coolant channels in a nuclear thermal rocket reactor with axial coolant passages. The program was developed as a tool to swiftly evaluate various heat transfer coefficient and friction factor correlations generated for turbulent pipe flow with heat addition which have been used in previous programs. Thus, a consistent comparison of these correlations was performed, as well as a comparison with data from the NRX reactor experiments from the Nuclear Engine for Rocket Vehicle Applications (NERVA) project. This report describes the ELM Program algorithm, input/output, and validation efforts and provides a listing of the code.
The Space Shuttle has three main engines that are used for propulsion into orbit. These engines are fed propellants by four turbopumps on each engine. A main element in the turbopump is the bearings supporting the rotor that spins the turbine blades and the pump impeller. These bearings are required to spin at very high speeds, support radial and thrust loads, and have high wear resistance without the benefit of lubrication. The liquid hydrogen and oxygen propellants flow through the bearings to cool the surfaces. The volatile nature of the propellants excludes any conventional means of lubrication. Lubrication for these bearings is provided by the ball separator inside the bearing. The separator is a composite material that supplies a transfer film of lubrication to the rings and balls. New separator materials and lubrication schemes have been investigated at Marshall Space Flight Center in a bearing test rig with promising results. Hybrid bearings with silicon nitride balls have also been evaluated. The use of hybrid, silicon nitride ball bearings in conjunction -with better separator materials has shown excellent results. The work that Marshall has done is being utilized in turbopumps flying on the space shuttle fleet and will be utilized in future space travel. This result of this work is valuable for all aerospace and commercial applications where high-speed bearings are used.
The Cryogenic Fluid Management (CFM) Project's primary objective is to develop storage, transfer, and handling technologies for cryogens that will support the enabling of high performance cryogenic propulsion systems, lunar surface systems and economical ground operations. Such technologies can significantly reduce propellant launch mass and required on-orbit margins, reduce or even eliminate propellant tank fluid boil-off losses for long term missions, and simplify vehicle operations. This paper will present the status of the specific technologies that the CFM Project is developing. The two main areas of concentration are analysis models development and CFM hardware development. The project develops analysis tools and models based on thermodynamics, hydrodynamics, and existing flight/test data. These tools assist in the development of pressure/thermal control devices (such as the Thermodynamic Vent System (TVS), and Multi-layer insulation); with the ultimate goal being to develop a mature set of tools and models that can characterize the performance of the pressure/thermal control devices incorporated in the design of an entire CFM system with minimal cryogen loss. The project does hardware development and testing to verify our understanding of the physical principles involved, and to validate the performance of CFM components, subsystems and systems. This database provides information to anchor our analytical models. This paper describes some of the current activities of the NASA's Cryogenic Fluid Management Project.
This paper presents a two-phase computational fluid dynamics (CFD) model for simulating autogenous pressurization and expulsion in a cryogenic liquid hydrogen storage tank, utilizing a volume-of-fluid (VOF) approach combined with the kinetics-based Schrage equation to accurately capture the phase boundary and interfacial heat, mass, and momentum transfer between liquid and vapor phases. The model is validated against experimental data from NASA's K-site tank facility, specifically experimental case 225, which involved pressurization and controlled expulsion of liquid hydrogen. Various turbulence models are evaluated to assess their influence on model accuracy. The CFD simulations successfully replicate key thermodynamic behaviors observed during the experiments, including pressure evolution, temperature profiles, and phase-change dynamics at the vapor-liquid interface. The predicted tank pressures, temperatures, and pressurant requirements agree with experimental data, with pressurant mass predictions within 16\% of observed values. This study highlights the importance of selecting appropriate turbulence models to accurately simulate complex flow and heat transfer phenomena during tank pressurization and expulsion. By enhancing the accuracy and reliability of CFD models for liquid hydrogen under cryogenic conditions, this research contributes to developing efficient cryogenic propellant management strategies for future space missions.
A 1030:1 carbon steel, heat-sink nozzle was tested. The test conditions included a nominal chamber pressure of 2413 kN/sq m and a mixture ratio range of 2.78 to 5.49. The propellants were gaseous oxygen and gaseous hydrogen. Outer wall temperature measurements were used to calculate the inner wall temperature and the heat flux and heat rate to the nozzle at specified axial locations. The experimental heat fluxes were compared to those predicted by the Two-Dimensional Kinetics (TDK) computer model analysis program. When laminar boundary layer flow was assumed in the analysis, the predicted values were within 15% of the experimental values for the area ratios of 20 to 975. However, when turbulent boundary layer conditions were assumed, the predicted values were approximately 120% higher than the experimental values. A study was performed to determine if the conditions within the nozzle could sustain a laminar boundary layer. Using the flow properties predicted by TDK, the momentum-thickness Reynolds number was calculated, and the point of transition to turbulent flow was predicted. The predicted transition point was within 0.5 inches of the nozzle throat. Calculations of the acceleration parameter were then made to determine if the flow conditions could produce relaminarization of the boundary layer. It was determined that if the boundary layer flow was inclined to transition to turbulent, the acceleration conditions within the nozzle would tend to suppress turbulence and keep the flow laminar-like.
A 1030:1 carbon steel, heat-sink nozzle was tested. The test conditions included a nominal chamber pressure of 2413 kN/sq m and a mixture ratio range of 2.78 to 5.49. The propellants were gaseous oxygen and gaseous hydrogen. Outer wall temperature measurements were used to calculate the inner wall temperature and the heat flux and heat rate to the nozzle at specified axial locations. The experimental heat fluxes were compared to those predicted by the Two-Dimensional Kinetics (TDK) computer model analysis program. When laminar boundary layer flow was assumed in the analysis, the predicted values were within 15 percent of the experimental values for the area ratios of 20 to 975. However, when turbulent boundary layer conditions were assumed, the predicted values were approximately 120 percent higher than the experimental values. A study was performed to determine if the conditions within the nozzle could sustain a laminar boundary layer. Using the flow properties predicted by TDK, the momentum-thickness Reynolds number was calculated, and the point of transition to turbulent flow was predicted. The predicted transition point was within 0.5 inches of the nozzle throat. Calculations of the acceleration parameter were then made to determine if the flow conditions could produce relaminarization of the boundary layer. It was determined that if the boundary layer flow was inclined to transition to turbulent, the acceleration conditions within the nozzle would tend to suppress turbulence and keep the flow laminar-like.
Tradeoffs between electric propulsion system mass ratio and transfer time from LEO to GEO were conducted parametrically for various thruster efficiency, specific impulse, and other propulsion parameters. A computer model was developed for performing orbit transfer calculations which included the effects of aerodynamic drag, radiation degradation, and occultation. The tradeoff results showed that thruster technology areas for integrated propulsion should be directed towards improving primary thruster efficiency in the range from 1500 to 2500 seconds, and be continued towards reducing specific mass. Comparison of auxiliary propulsion systems showed large total propellant mass savings with integrated electric auxiliary propulsion. Stationkeeping is the most demanding on orbit propulsion requirement. At area densities above 0.5 sq m/kg, East-West stationkeeping requirements from solar pressure exceed North-South stationkeeping requirements from gravitational forces. A solar array pointing strategy was developed to minimize the effects of atmospheric drag at low altitude, enabling electric propulsion to initiate orbit transfer at Shuttle's maximum cargo carrying altitude. Gravity gradient torques are used during ascent to sustain the spacecraft roll motion required for optimum solar array illumination. A near optimum cover glass thickness of 6 mils was established for LEO to GEO transfer.