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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 NTRS2001

Low-Pressure Long-Term Xenon Storage for Electric Propulsion

This Phase 2 effort demonstrated an alternative Xe storage and regulation system using activated carbon (AC) as a secondary storage media (ACSFR). This regulator system is nonmechanical, simple, inexpensive, and lighter. The ACSFR system isolates the thruster from the compressed gas tank, and allows independent multiple setpoint thruster operation. The flow using an ACSFR can also be throttled by applying increments in electrical power. Primary storage of Xe by AC is not superior to compressed gas storage with regard to weight, but AC storage can provide volume reduction, lower pressures in space, and potentially in situ Xe purification. With partial fill designs, a primary AC storage vessel for Xe could also eliminate problems with two-phase storage and regulate pressure. AC could also be utilized in long-term large quantity storage of Xe serving as a compact capture site for boil-off. Several Xe delivery ACSFR protocols between 2 and 45 sccm, and 15 min to 7 hr, were tested with an average flow variance of 1.2 percent, average power requirements of 5 W, and repeatability s of about 0.4 percent. Power requirements are affected by ACSFR bed sizing and flow rate/ duration design points, and these flow variances can be reduced by optimizing PID controller parameters.

Back, Dwight D.↗
NASA NTRS2001

Zero Gravity Cryogenic Vent System Concepts for Upper Stages

The capability to vent in zero gravity without resettling is a technology need that involves practically all uses of sub-critical cryogenics in space, and would extend cryogenic orbital transfer vehicle capabilities. However, the lack of definition regarding liquid/ullage orientation coupled with the somewhat random nature of the thermal stratification and resulting pressure rise rates, lead to significant technical challenges. Typically a zero gravity vent concept, termed a thermodynamic vent system (TVS), consists of a tank mixer to destratify the propellant, combined with a Joule-Thomson (J-T) valve to extract thermal energy from the propellant. Marshall Space Flight Center's (MSFC's) Multipurpose Hydrogen Test Bed (MHTB) was used to test both spray-bar and axial jet TVS concepts. The axial jet system consists of a recirculation pump heat exchanger unit. The spray-bar system consists of a recirculation pump, a parallel flow concentric tube heat exchanger, and a spray-bar positioned close to the longitudinal axis of the tank. The operation of both concepts is similar. In the mixing mode, the recirculation pump withdraws liquid from the tank and sprays it into the tank liquid, ullage, and exposed tank surfaces. When energy extraction is required, a small portion of the recirculated liquid is passed sequentially through the J-T expansion valve, the heat exchanger, and is vented overboard. The vented vapor cools the circulated bulk fluid, thereby removing thermal energy and reducing tank pressure. The pump operates alone, cycling on and off, to destratify the tank liquid and ullage until the liquid vapor pressure reaches the lower set point. At that point, the J-T valve begins to cycle on and off with the pump. Thus, for short duration missions, only the mixer may operate, thus minimizing or even eliminating boil-off losses.

Flachbart, Robin H.↗
NASA NTRS2004

On-Orbit Performance of the Spitzer Space Telescope

The Spitzer Space Telescope (formally known as SIRTF) was successfully launched on August 25, 2003, and has completed its initial in-orbit checkout and science validation and calibration period. The measured performance of the observatory has met or exceeded all of its high-level requirements, it has entered normal operations, and is beginning to return high-quality science data. A superfluid-helium cooled 85 cm diameter telescope provides extremely low infrared backgrounds and feeds three science instruments covering wavelengths ranging from 3.2 to 180 microns. The telescope optical quality is excellent, providing diffraction-limited performance down to wavelengths below 6.5 microns. Based on the first helium mass and boil-off rate measurements, a cryogenic lifetime in excess of 5 years is expected. This presentation will provide a summary of the overall performance of the observatory, with an emphasis on those performance parameters that have the greatest impact on its ultimate science return.

Roellig, Thomas↗
NASA NTRS2004

Thermal Insulation Testing Method and Apparatus

A test apparatus and method of its use for evaluating various performance aspects of a test specimen is disclosed. A chamber within a housing contains a cold mass tank with a contact surface in contact with a first surface of a test specimen. The first surface of the test specimen is spaced from the second surface of the test specimen by a thickness. The second surface of the test specimen is maintained at a a constant temperature by a liquid disposed within the cold mass tank. A boil-off flow rate of the gas is monitored and provided to a processor along with the temperature of the first and second surfaces of the test specimen. The processor calculates thermal insulation values of the test specimen including comparative values for heat flux and apparent thermal conductivity k-value). The test specimen may be placed in any vacuum pressure level ranging from about 0.01 millitorr to 1,000,000 millitorr with different residual gases as desired. The test specimen may be placed under a mechanical load with the cold mass tank and another factors may be imposed upon the test specimen so as to simulate the actual use conditions.

Fesmire, James E.↗
NASA NTRS2005

A Shape Memory Alloy Based Cryogenic Thermal Conduction Switch

Shape memory alloys (SMAs) can produce large strains when deformed (e.g., up to 8%). Heating results in a phase transformation and associated recovery of all the accumulated strain. This strain recovery can occur against large forces, resulting in their use as actuators. Thus an SMA element can integrate both sensory and actuation functions, by inherently sensing a change in temperature and actuating by undergoing a shape change as a result of a temperature-induced phase transformation. Two aspects of our work on cryogenic SMAs are addressed here. First - a shape memory alloy based cryogenic thermal conduction switch for operation between dewars of liquid methane and liquid oxygen in a common bulkhead arrangement is discussed. Such a switch integrates the sensor element and the actuator element and can be used to create a variable thermal sink to other cryogenic tanks for liquefaction, densification, and zero boil-off systems for advanced spaceport applications. Second - fabrication via arc-melting and subsequent materials testing of SMAs with cryogenic transformation temperatures for use in the aforementioned switch is discussed.

Notardonato, W. U.↗
NASA NTRS2005

Technology Challenges for Deep-Throttle Cryogenic Engines for Space Exploration

Historically, cryogenic rocket engines have not been used for in-space applications due to their additional complexity, the mission need for high reliability, and the challenges of propellant boil-off. While the mission and vehicle architectures are not yet defined for the lunar and Martian robotic and human exploration objectives, cryogenic rocket engines offer the potential for higher performance and greater architecture/mission flexibility. In-situ cryogenic propellant production could enable a more robust exploration program by significantly reducing the propellant mass delivered to low earth orbit, thus warranting the evaluation of cryogenic rocket engines versus the hypergolic bi-propellant engines used in the Apollo program. A multi-use engine. one which can provide the functionality that separate engines provided in the Apollo mission architecture, is desirable for lunar and Mars exploration missions because it increases overall architecture effectiveness through commonality and modularity. The engine requirement derivation process must address each unique mission application and each unique phase within each mission. The resulting requirements, such as thrust level, performance, packaging, bum duration, number of operations; required impulses for each trajectory phase; operation after extended space or surface exposure; availability for inspection and maintenance; throttle range for planetary descent, ascent, acceleration limits and many more must be addressed. Within engine system studies, the system and component technology, capability, and risks must be evaluated and a balance between the appropriate amount of technology-push and technology-pull must be addressed. This paper will summarize many of the key technology challenges associated with using high-performance cryogenic liquid propellant rocket engine systems and components in the exploration program architectures. The paper is divided into two areas. The first area describes how the mission requirements affect the engine system requirements and create system level technology challenges. An engine system architecture for multiple applications or a family of engines based upon a set of core technologies, design, and fabrication approaches may reduce overall programmatic cost and risk. The engine system discussion will also address the characterization of engine cycle figures of merit, configurations, and design approaches for some in-space vehicle alternatives under consideration. The second area evaluates the component-level technology challenges induced from the system requirements. Component technology issues are discussed addressing injector, thrust chamber, ignition system, turbopump assembly, and valve design for the challenging requirements of high reliability, robustness, fault tolerance, deep throttling, reasonable performance (with respect to weight and specific impulse).

Brown, Kendall K.↗
NASA NTRS2005

In-Space Cryogenic Propellant Depot Stepping Stone

An In-Space Cryogenic Propellant Depot (ISCPD) is an important stepping stone to provide the capability to preposition, store, manufacture, and later use the propellants for Earth-Neighborhood campaigns and beyond. An in-space propellant depot will provide affordable propellants and other similar consumables to support the development of sustainable and affordable exploration strategies as well as commercial space activities. An in-space propellant depot not only requires technology development in key areas such as zero boil-off storage and fluid transfer, but in other areas such as lightweight structures, highly reliable connectors, and autonomous operations. These technologies can be applicable to a broad range of propellant depot concepts or specific to a certain design. In addition, these technologies are required for spacecraft and orbit transfer vehicle propulsion and power systems, and space life support. Generally, applications of this technology require long-term storage, on-orbit fluid transfer and supply, cryogenic propellant production from water, unique instrumentation and autonomous operations. This paper discusses the reasons why such advances are important to future affordable and sustainable operations in space. This paper also discusses briefly R&D objectives comprising a promising approach to the systems planning and evolution into a meaningful stepping stone design, development, and implementation of an In-Space Cryogenic Propellant Depot. The success of a well-planned and orchestrated approach holds great promise for achieving innovation and revolutionary technology development for supporting future exploration and development of space.

Howell, Joe T.↗
NASA NTRS2006

Cryogenic Tank Modeling for the Saturn AS-203 Experiment

A computational fluid dynamics (CFD) model is developed for the Saturn S-IVB liquid hydrogen (LH2) tank to simulate the 1966 AS-203 flight experiment. This significant experiment is the only known, adequately-instrumented, low-gravity, cryogenic self pressurization test that is well suited for CFD model validation. A 4000-cell, axisymmetric model predicts motion of the LH2 surface including boil-off and thermal stratification in the liquid and gas phases. The model is based on a modified version of the commercially available FLOW3D software. During the experiment, heat enters the LH2 tank through the tank forward dome, side wall, aft dome, and common bulkhead. In both model and test the liquid and gases thermally stratify in the low-gravity natural convection environment. LH2 boils at the free surface which in turn increases the pressure within the tank during the 5360 second experiment. The Saturn S-IVB tank model is shown to accurately simulate the self pressurization and thermal stratification in the 1966 AS-203 test. The average predicted pressurization rate is within 4% of the pressure rise rate suggested by test data. Ullage temperature results are also in good agreement with the test where the model predicts an ullage temperature rise rate within 6% of the measured data. The model is based on first principles only and includes no adjustments to bring the predictions closer to the test data. Although quantitative model validation is achieved or one specific case, a significant step is taken towards demonstrating general use of CFD for low-gravity cryogenic fluid modeling.

Grayson, Gary D.↗
NASA NTRS2007

Thermal Analysis on Cryogenic Liquid Hydrogen Tank on an Unmanned Aerial Vehicle System

Thermal analyses are performed on the liquid hydrogen (LH2) tank designed for an unmanned aerial vehicle (UAV) powered by solar arrays and a regenerative proton-exchange membrane (PEM) fuel cell. A 14-day cruise mission at a 65,000 ft altitude is considered. Thermal analysis provides the thermal loads on the tank system and the boiling-off rates of LH2. Different approaches are being considered to minimize the boiling-off rates of the LH2. It includes an evacuated multilayer insulation (MLI) versus aerogel insulation on the LH2 tank and aluminum versus stainless steel spacer rings between the inner and outer tank. The resulting boil-off rates of LH2 provided by the one-dimensional model and three-dimensional finite element analysis (FEA) on the tank system are presented and compared to validate the results of the three-dimensional FEA. It concludes that heat flux through penetrations by conduction is as significant as that through insulation around the tank. The tank system with MLI insulation and stainless steel spacer rings result in the lowest boiling-off rate of LH2.

Wang, Xiao-Yen↗
NASA NTRS2006

NASA's Spitzer Space Telescope's Operational Mission Experience

New Generation of Detector Arrays(100 to 10,000 Gain in Capability over Previous Infrared Space Missions). IRAC: 256 x 256 pixel arrays operating at 3.6 microns, 4.5 microns, 5.8 microns, 8.0 microns. MIPS: Photometer with 3 sets of arrays operating at 24 microns, 70 microns and 160 microns. 128 x 128; 32 x 32 and 2 x 20 arrays. Spectrometer with 50-100 micron capabilities. IRS: 4 Array (128x128 pixel) Spectrograph, 4 -40 microns. Warm Launch Architecture: All other Infrared Missions launched with both the telescope and scientific instrument payload within the cryostat or Dewar. Passive cooling used to cool outer shell to approx.40 K. Cryogenic Boil-off then cools telescope to required 5.5K. Earth Trailing Heliocentric Orbit: Increased observing efficiency, simplification of observation planning, removes earth as heat source.

space telescopes↗
NASA NTRS2007

Cryogenic Technology Development for Exploration Missions

This paper reports the status and findings of different cryogenic technology research projects in support of the President s Vision for Space Exploration. The exploration systems architecture study is reviewed for cryogenic fluid management needs. It is shown that the exploration architecture is reliant on the cryogenic propellants of liquid hydrogen, liquid oxygen and liquid methane. Needs identified include: the key technologies of liquid acquisition devices, passive thermal and pressure control, low gravity mass gauging, prototype pressure vessel demonstration, active thermal control; as well as feed system testing, and Cryogenic Fluid Management integrated system demonstration. Then five NASA technology projects are reviewed to show how these needs are being addressed by technology research. Projects reviewed include: In-Space Cryogenic Propellant Depot; Experimentation for the Maturation of Deep Space Cryogenic Refueling Technology; Cryogenic Propellant Operations Demonstrator; Zero Boil-Off Technology Experiment; and Propulsion and Cryogenic Advanced Development. Advances are found in the areas of liquid acquisition of liquid oxygen, mass gauging of liquid oxygen via radio frequency techniques, computational modeling of thermal and pressure control, broad area cooling thermal control strategies, flight experiments for resolving low gravity issues of cryogenic fluid management. Promising results are also seen for Joule-Thomson pressure control devices in liquid oxygen and liquid methane and liquid acquisition of methane, although these findings are still preliminary.

Chato, David J.↗
NASA NTRS2004

Thermal insulation testing method and apparatus

A test apparatus and method of its use for evaluating various performance aspects of a test specimen is disclosed. A chamber within a housing contains a cold mass tank with a contact surface in contact with a first surface of a test specimen. The first surface of the test specimen is spaced from the second surface of the test specimen by a thickness. The second surface of the test specimen is maintained at a desired warm temperature. The first surface is maintained at a constant temperature by a liquid disposed within the cold mass tank. A boil-off flow rate of the gas is monitored and provided to a processor along with the temperature of the first and second surfaces of the test specimen. The processor calculates thermal insulation values of the test specimen including comparative values for heat flux and apparent thermal conductivity (k-value). The test specimen may be placed in any vacuum pressure level ranging from about 0.01 millitorr to 1,000,000 millitorr with different residual gases as desired. The test specimen may be placed under a mechanical load with the cold mass tank and another factors may be imposed upon the test specimen so as to simulate the actual use conditions.

Fesmire, James E.↗
NASA NTRS2007

Cryogenic Fluid Management Technologies for Advanced Green Propulsion Systems

In support of the Exploration Vision for returning to the Moon and beyond, NASA and its partners are developing and testing critical cryogenic fluid propellant technologies that will meet the need for high performance propellants on long-term missions. Reliable knowledge of low-gravity cryogenic fluid management behavior is lacking and yet is critical in the areas of tank thermal and pressure control, fluid acquisition, mass gauging, and fluid transfer. Such knowledge can significantly reduce or even eliminate tank fluid boil-off losses for long term missions, reduce propellant launch mass and required on-orbit margins, and simplify vehicle operations. The Propulsion and Cryogenic Advanced Development (PCAD) Project is performing experimental and analytical evaluation of several areas within Cryogenic Fluid Management (CFM) to enable NASA's Exploration Vision. This paper discusses the status of the PCAD CFM technology focus areas relative to the anticipated CFM requirements to enable execution of the Vision for Space Exploration.

Motil, Susan M.↗
NASA NTRS2008

GFSSP Training Course Lectures

GFSSP has been extended to model conjugate heat transfer Fluid Solid Network Elements include: a) Fluid nodes and Flow Branches; b) Solid Nodes and Ambient Nodes; c) Conductors connecting Fluid-Solid, Solid-Solid and Solid-Ambient Nodes. Heat Conduction Equations are solved simultaneously with Fluid Conservation Equations for Mass, Momentum, Energy and Equation of State. The extended code was verified by comparing with analytical solution for simple conduction-convection problem The code was applied to model: a) Pressurization of Cryogenic Tank; b) Freezing and Thawing of Metal; c) Chilldown of Cryogenic Transfer Line; d) Boil-off from Cryogenic Tank.

Majumdar, Alok K.↗
NASA NTRS2006

Low-Cost Propellant Launch From a Tethered Balloon

A document presents a concept for relatively inexpensive delivery of propellant to a large fuel depot in low orbit around the Earth, for use in rockets destined for higher orbits, the Moon, and for remote planets. The propellant is expected to be at least 85 percent of the mass needed in low Earth orbit to support the NASA Exploration Vision. The concept calls for the use of many small ( 10 ton) spin-stabilized, multistage, solid-fuel rockets to each deliver 250 kg of propellant. Each rocket would be winched up to a balloon tethered above most of the atmospheric mass (optimal altitude 26 2 km). There, the rocket would be aimed slightly above the horizon, spun, dropped, and fired at a time chosen so that the rocket would arrive in orbit near the depot. Small thrusters on the payload (powered, for example, by boil-off gases from cryogenic propellants that make up the payload) would precess the spinning rocket, using data from a low-cost inertial sensor to correct for small aerodynamic and solid rocket nozzle misalignment torques on the spinning rocket; would manage the angle of attack and the final orbit insertion burn; and would be fired on command from the depot in response to observations of the trajectory of the payload so as to make small corrections to bring the payload into a rendezvous orbit and despin it for capture by the depot. The system is low-cost because the small rockets can be mass-produced using the same techniques as those to produce automobiles and low-cost munitions, and one or more can be launched from a U.S. territory on the equator (Baker or Jarvis Islands in the mid-Pacific) to the fuel depot on each orbit (every 90 minutes, e.g., any multiple of 6,000 per year).

Wilcox, Brian↗
NASA NTRS2004

Composite-Material Tanks with Chemically Resistant Liners

Lightweight composite-material tanks with chemically resistant liners have been developed for storage of chemically reactive and/or unstable fluids . especially hydrogen peroxide. These tanks are similar, in some respects, to the ones described in gLightweight Composite-Material Tanks for Cryogenic Liquids h (MFS-31379), NASA Tech Briefs, Vol. 25, No. 1 (January, 2001), page 58; however, the present tanks are fabricated by a different procedure and they do not incorporate insulation that would be needed to prevent boil-off of cryogenic fluids. The manufacture of a tank of this type begins with the fabrication of a reusable multisegmented aluminum mandrel in the shape and size of the desired interior volume. One or more segments of the mandrel can be aluminum bosses that will be incorporated into the tank as end fittings. The mandrel is coated with a mold-release material. The mandrel is then heated to a temperature of about 400 F (approximately equal to 200 C) and coated with a thermoplastic liner material to the desired thickness [typically approxiamtely equal to 15 mils (approximately equal to 0.38 mm)] by thermal spraying. In the thermal-spraying process, the liner material in powder form is sprayed and heated to the melting temperature by a propane torch and the molten particles land on the mandrel. The sprayed liner and mandrel are allowed to cool, then the outer surface of the liner is chemically and/or mechanically etched to enhance bonding of a composite overwrap. The etched liner is wrapped with multiple layers of an epoxy resin reinforced with graphite fibers; the wrapping can be done either by manual application of epoxy-impregnated graphite cloth or by winding of epoxy-impregnated filaments. The entire assembly is heated in an autoclave to cure the epoxy. After the curing process, the multisegmented mandrel is disassembled and removed from inside, leaving the finished tank. If the tank is to be used for storing hydrogen peroxide, then the liner material should be fluorinated ethylene/propylene (FEP), and one or more FEP O ring(s) should be used in the aluminum end fitting(s). This choice of materials is dictated by experimental observations that pure aluminum and FEP are the only materials suitable for long-term storage of hydrogen peroxide and that other materials tend to catalyze the decomposition of hydrogen peroxide to oxygen and water. Other thermoplastic liner materials that are suitable for some applications include nylon 6 and polyethylene. The processing temperatures for nylon 6 are lower than those for FEP. Nylon 6 is compatible with propane, natural gas, and other petroleum-based fuels. Polyethylene is compatible with petroleum- based products and can be used for short-term storage of hydrogen peroxide.

DeLay, Thomas K.↗
NASA NTRS2003

System for Testing Thermal Insulation of Pipes

An apparatus and method have been developed for measuring the rates of leakage of heat into pipes carrying liquids, the purpose of the measurements being to quantify the thermal performance of the insulation system. The apparatus is designed primarily for testing pipes used to carry cryogenic liquids, but can also be used for measuring the thermal performance of other insulated pipes or piping systems. The basic measurement principle is straightforward: The outer surface of the pipe insulation is maintained at a fixed warmer temperature. The interior of the pipe is maintained in a narrow fixed lower-temperature range by means of a regular liquid (e.g., water) that is pumped through the pipe at a known flow rate or a cryogenic liquid (e.g., nitrogen) that is saturated at atmospheric pressure and replenished until steady-state conditions are achieved. In the case of water or another liquid pumped through, the inlet and outlet temperatures are measured and heat-leak power is calculated as the mass flow rate of the liquid multiplied by the specific heat of the liquid multiplied by the inlet-to-outlet temperature rise of the liquid. In the case of liquid nitrogen or another low-temperature boiling liquid, the heat-leak power is calculated as the rate of boil-off multiplied by the latent heat of vaporization of the liquid. Then the thermal-insulation performance of the pipe system can be calculated as a function of the measured heat-leak power, the inner and outer boundary temperatures, and the dimensions of the pipe. The apparatus can test as many as three pipes simultaneously. The pipes can have inner diameters up to .15 cm and outer diameters up to .20 cm. The lengths of the pipes may vary; typical lengths are of the order of 18 m. Two thermal guard boxes . one for each end of the pipe(s) under test . are used to make the inlet and outlet fluid connections to the pipe(s) (see figure). The connections include bellows that accommodate thermal expansion and contraction of the pipes. The guard boxes and pipe(s) are positioned so that the pipe(s) slope upward from the upstream to the downstream end at an angle of at least 2 . The upward slope allows vapor bubbles to accumulate at the downstream end. The thermal guard boxes keep the ends of the pipes at the lower interior temperature to prevent spurious lengthwise leakage of heat into the pipes. It is important to prevent this spurious heat leakage because, if it were allowed to occur, it could contribute a large error in the measured heat-leak power. The upstream thermal guard box includes a heat exchanger through which liquid flowing into the pipe(s) is subcooled to the saturation temperature corresponding to the ambient pressure. Conversely, this heat exchanger can also be used to warm the flowing liquid to a desired fixed temperature. The apparatus includes a temperature control device that is placed around each pipe under test. Each device is operated under thermostatic control to maintain the outer surface of the pipe insulation at the specified test temperature. All measurements are recorded on a portable data-acquisition system.

Fesmire, James E.↗
NASA NTRS2007

Thermal Performance Testing of Cryogenic Insulation Systems

Efficient methods for characterizing thermal performance of materials under cryogenic and vacuum conditions have been developed. These methods provide thermal conductivity data on materials under actual-use conditions and are complementary to established methods. The actual-use environment of full temperature difference in combination with vacuum-pressure is essential for understanding insulation system performance. Test articles include solids, foams, powders, layered blankets, composite panels, and other materials. Test methodology and apparatus design for several insulation test cryostats are discussed. The measurement principle is liquid nitrogen boil-off calorimetry. Heat flux capability ranges from approximately 0.5 to 500 watts per square meter; corresponding apparent thermal conductivity values range from below 0.01 up to about 60 mW/m- K. Example data for different insulation materials are also presented. Upon further standardization work, these patented insulation test cryostats can be available to industry for a wide range of practical applications.

Fesmire, James E.↗