Onboard Monitoring Method for Detection of Damage to Carbon Fiber Composite Overwrap on Hydrogen Fuel Tanks
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Two insulation systems for tanks containing liquid methane in supersonic cruise-type aircraft were designed and tested after an extensive materials investigation. One system is an external insulation and the other is an internal wet-type insulation system. Tank volume was maximized by making the tank shape approach a rectangular parallelopiped. One tank was designed to use the external insulation and the other tank to use the internal insulation. Performance of the external insulation system was evaluated on a full-scale tank under the temperature environment of -320 F to 700 F and ambient pressures of ground-level atmospheric to 1 psia. Problems with installing the internal insulation on the test tank prevented full-scale evaluation of performance; however, small-scale testing verified thermal conductivity, temperature capability, and installed density.
Test results indicated superiority of certain polyether-based polyurethanes as protective coatings and suggested that baffle-materials with one of these coatings should have useful life approximately twice that of uncoated foams now in use.
Heat transfer rates and pressures were measured on a 0.0175-scale model of the space shuttle external tank (ET), model MCR0200. Tests were conducted with the ET model separately and while mated with a 0.0175-scale model of the orbiter, model 21-OT (Grumman). The tests were conducted in the AEDC-VKF Hypervelocity Wind Tunnel (F) at Mach numbers 16 and 19. The primary data consisted of the interaction heating rates experienced by the ET while mated with the orbiter in the flight configuration. Data were taken for a range of Reynolds numbers from 50,000 to 65,000 under laminar flow conditions.
A concept for a fail-safe thermal protection system was developed. From screening tests, approximately 30 foams, adhesives, and reinforcing fibers using 0.3-meter square liquid nitrogen cold plate, CPR 452 and Stafoam AA1602, both reinforced with 10 percent by weight of 1/16 inch milled OCF Style 701 Fiberglas, were selected for further tests. Cyclic tests with these materials in 2-inch thicknesses bonded on a 0.6-meter square cold plate with Crest 7410 adhesive systems, were successful. Zero permeability gas barriers were identified and found to be compatible with the insulating concept.
Organic foams were tested to determine their suitability for insulating liquid hydrogen tanks of subsonic aircraft. The specimens, including nonreinforced foams and foams with chopped glass reinforcements, flame retardants, and vapor barriers, were scaled to simulate stress conditions in large tanks. The tests were conducted within aluminum tank compartments filled with liquid hydrogen and the boil-off rate was used as the criterion of thermal performance. It was found that while all insulations deteriorated with increased cycles, two nonreinforced polyurethane foams showed no structural deterioration after 4200 thermal cycles (equivalent to 15 years of airline service). It was also found that fiberglass reinforcement and flame retardants impaired thermal performance and reduced useful life of the foams. Vapor barriers enhanced structural integrity without any deterioration in thermal properties.
F-15 rotary balance data was analyzed, and the influence of control deflections, Reynolds number and airplane components, i.e., body, wing, horizontal and vertical tails, as well as conformal tanks, on the aerodynamics up to 90 degrees angle of attack are discussed. Steady state spin mode predictions using these data are presented, which show excellent correlation with spin tunnel and flight test results. Generally, the data shows damped yawing moment slopes with rotation at all angles of attack, and good control effectiveness. Differences in the rotary aerodynamics due to the addition of conformal tanks are minimal. The small differences in the region of the flat spin do, however, indicate that the resulting spin mode would be slightly flatter and faster for a conformal tank equipped airplane. The addition of conformal tanks make the airplane more departure susceptible.
A two dimensional finite difference thermal model was developed to predict the effects of heating profile, fill level, and cryogen type prior to experimental testing the Generic Research Cryogenic Tank (GRCT). These numerical predictions will assist in defining test scenarios, sensor locations, and venting requirements for the GRCT experimental tests. Boiloff rates, tank-wall and fluid temperatures, and wall heat fluxes were determined for 20 computational test cases. The test cases spanned three discrete fill levels and three heating profiles for hydrogen and nitrogen.
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