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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Helium recovery system at IB3A

The growing demand for sustainable cryogenic operations at Fermilab has underscored the need to improve helium management, particularly at the Industrial Building 3A (IB3A) test facility. IB3A characterizes and tests superconductors, cables, and coils for projects such as the HL-LHC AUP and Mu2e, yet currently relies on 500 L Dewars whose boil-off is vented to atmosphere, wasting a critical, non-renewable resource and increasing the cost of testing. A project is therefore under way to link IB3A to an existing purification and liquefaction station in a neighboring building through a dedicated pipeline. Captured helium will be transferred, purified, reliquefied, and returned for reuse, cutting losses and operating costs. This paper details the first two project phases: "Design and Engineering" and "Procurement and Installation." The design phase finalizes pipeline specifications, establishes flow-control requirements, and resolves integration challenges with existing cryogenic infrastructure. The procurement and installation phase covers material sourcing, pipeline construction, and deployment of control and monitoring systems to assure reliable, efficient operation. Key technical hurdles-route optimization, pressure drop mitigation, and interface compatibility-are discussed alongside implemented solutions. Implementing the pipeline and upgrading IB3A will dramatically reduce helium consumption and therefore testing cost, strengthening Fermilab's capacity to support frontier science far into the future.

Porwisiak, D. [Fermilab; Wroclaw Tech. U.]↗
NASA NTRS2007

CFD Modeling of Helium Pressurant Effects on Cryogenic Tank Pressure Rise Rates in Normal Gravity

A recently developed computational fluid dynamics modeling capability for cryogenic tanks is used to simulate both self-pressurization from external heating and also depressurization from thermodynamic vent operation. Axisymmetric models using a modified version of the commercially available FLOW-3D software are used to simulate actual physical tests. The models assume an incompressible liquid phase with density that is a function of temperature only. A fully compressible formulation is used for the ullage gas mixture that contains both condensable vapor and a noncondensable gas component. The tests, conducted at the NASA Marshall Space Flight Center, include both liquid hydrogen and nitrogen in tanks with ullage gas mixtures of each liquid's vapor and helium. Pressure and temperature predictions from the model are compared to sensor measurements from the tests and a good agreement is achieved. This further establishes the accuracy of the developed FLOW-3D based modeling approach for cryogenic systems.

Grayson, Gary↗
NASA NTRS1975

Dewar technology study

The development of a Dewar system for handling liquid helium under weightless conditions is described. Porous plug designs for the prevention of superfluid creep out of the dewar through the vent line were evaluated. For the purpose of designing a neck to provide a transition from the cold cavity to the outside, the loads carried by the neck and equipment supports were studied. Temperature, pressure, and mass flow instrumentation for monitoring Dewar performance were also evaluated. In addition, multilayer blankets consisting of aluminized Mylar separated by Dacron net sheets were designed to insulate the pressure vessel. The dewar system is suggested for use with the star tracking telescope aboard the relativity satellite.

Davis, W.↗
DOE OSTI2022

Conceptual Design of the Transformational Challenge Reactor

The Transformational Challenge Reactor is a 3-MW(thermal) helium-cooled experimental nuclear reactor designed using an additive manufacturing–informed agile design process. This design process leverages rapid prototyping and advanced materials from emerging additive manufacturing technologies, key characteristics that enable rapid design maturation. The resulting core design incorporates a blend of advanced reactor technologies into an intermediate-spectrum microreactor, including conventionally manufactured tristructural isotropic (TRISO) fuel particles in an advanced manufactured SiC fuel element and a solid yttrium hydride moderator encapsulated in steel. Matured during the design effort, these technologies are incorporated with additively manufactured steel support and fluidic structures to form a 75-cm-outer-diameter cylindrical active core region. Below and above the active core region are axial SiC reflectors, which are housed inside the reactor pressure vessel. The reactor is controlled with an annular shroud actuated external to the pressure vessel in the gap between the pressure vessel and a steel radial reflector. A safety rod is at the center of the core to shut down the reactor when necessary. Helium pressurized at 5 MPa is forced into the pressure vessel below the core and around the core to the top plenum before it is forced down through the axial reflectors and the active core region. The primary pressurized helium loop is operated up to 500°C and includes the pressure vessel, the circulator, and the hot side of a helium-to-air heat exchanger. The secondary loop rejects all heat from the primary loop to ambient air through a heat exchanger. A vented temporary confinement building contains the entire primary loop, with penetrations for a stack, cooling, and the secondary ambient air loop. Finally, this is the first advanced nuclear microreactor designed using additive manufacturing technologies, demonstrating their applicability in an accelerated advanced design process.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS1976

Experiments on the properties of superfluid helium in zero gravity

The paper describes a research program designed to study the behavior of superfluid liquid helium in low and zero gravity in order to determine the properties which are critically important to its use as a stored cryogen for cooling scientific instruments aboard spacecraft for periods up to several months. The experiment program consists of a series of flights of an experiment package on a free-fall trajectory both on an aircraft and on a rocket. The objectives are to study thickness of thin films of helium as a function of acceleration, heat transfer in thin films, heat transfer across copper-liquid helium interfaces, fluid dynamics of bulk helium in high and low accelerations and under various conditions of rotations, alternate methods of separation of liquid and vapor phases and of efficient venting of the vapor, and undesirable thermomechanical oscillations in the vent pipes. Preliminary results from aircraft tests are discussed.

Mason, P.↗
NASA NTRS1999

Rapid Chill and Fill of a Liquid Hydrogen Tank Demonstrated

The NASA Lewis Research Center, in conjunction with Boeing North American, has been supporting the High Energy Upper Stage (HEUS) program by performing feasibility studies at Lewis Supplemental Multilayer Insulation Research Facility (SMIRF). These tests were performed to demonstrate the feasibility of chilling and filling a tank with liquid hydrogen in under 5 minutes. The goal of the HEUS program is to release a satellite from the shuttle cargo bay and then use a cryogenic (high-energy) upper stage to allow the satellite to achieve final orbit. Because of safety considerations, the propellant tanks for the upper stage will be launched warm and dry. They will be filled from the shuttle's external tank during the mission phase after the solid rocket boosters have jettisoned and prior to jettison of the external tank. Data from previous shuttle missions have been analyzed to ensure that sufficient propellant would be available in the external tank to fill the propellant tank of the proposed vehicle upper stage. Because of mission time-line considerations, the propellant tanks for the upper stage will have to be chilled down and filled in approximately 5 minutes. An existing uninsulated flight weight test tank was installed inside the vacuum chamber at SMIRF, and the chamber was evacuated to the 10(exp -5) torr range to simulate space vacuum conditions in the cargo bay with the doors open. During prerun operations, the facility liquid hydrogen (LH2) supply piping was prechilled with the vent gas bypassing the test article. The liquid hydrogen supply dewar was saturated at local ambient pressure and then pressurized with ambient temperature gaseous helium to the test pressure. A control system was used to ensure that the liquid hydrogen supply pressure was maintained at the test pressure.

Kudlac, Maureen T.↗
NASA NTRS2000

Technologies for Refueling Spacecraft On-Orbit

This paper discusses the current technologies for on-orbit refueling of spacecraft. The findings of 55 references are reviewed and summarized. Highlights include: (1) the Russian Progress system used by the International Space Station; (2) a flight demonstration of superfluid helium transfer; and (3) ground tests of large cryogenic systems. Key technologies discussed include vapor free liquid outflow, control of fluid inflow to prevent liquid venting, and quick disconnects for on-orbit mating of transfer lines.

Chato, David J.↗
NASA NTRS1964

Helium tube separates nitrogen gas from liquid nitrogen

To prevent a boiloff problem, liquid nitrogen flowing from a storage tank to a container, is separated into liquid and gaseous components. This is accomplished by centrifugal and venting action, using a section of perforated helical aluminum tubing.

Stephens, J. B.↗
NASA NTRS2004

Analytical Modeling and Test Correlation of Variable Density Multilayer Insulation for Cryogenic Storage

A unique foam/multilayer insulation (MLI) combination concept for orbital cryogenic storage was experimentally evaluated using a large-scale hydrogen tank. The foam substrate insulates for ground-hold periods and enables a gaseous nitrogen purge as opposed to helium. The MLI, designed for an on-orbit storage period for 45 days, includes several unique features including a variable layer density and larger but fewer perforations for venting during ascent to orbit. Test results with liquid hydrogen indicated that the MLI weight or tank heat leak is reduced by about half in comparison with standard MLI. The focus of this effort is on analytical modeling of the variable density MLI (VD-MLI) on-orbit performance. The foam/VD-MLI model is considered to have five segments. The first segment represents the optional foam layer. The second, third, and fourth segments represent three different MLI layer densities. The last segment is an environmental boundary or shroud that surrounds the last MLI layer. Two approaches are considered: a variable density MLI modeled layer by layer and a semiempirical model or "modified Lockheed equation." Results from the two models were very comparable and were within 5-8 percent of the measured data at the 300 K boundary condition.

Hastings, L. J.↗
DOE OSTI2020

IHS-60 Stored Energy Analysis

The IHS-60 consists of a General Purpose Heat Source (GPHS) Fueled Clad (FC) that has been hot isostatically pressed to eliminate the gap between the iridium clad and the fuel pellet, thus preventing differential motion between the pellet and the clad in shock and vibration environments. The vented FC is enclosed within a Molybdenum barrier comprising the liner body and the lower support member. The slip- t Molybdenum liner members serve as a mechanical barrier to plutonia contact of the tantalum alloy (T-111) strength member in the event the iridium clad should fail. The slip- t liner is not a barrier to gaseous transport, so a tantalum getter is installed near the vent region of the FC to preclude potential oxygen transport to the T-111 interior surface. The T-111 strength member encloses the Molybdenum liner assembly and provides for both helium gas retention and isotope fuel containment under impact and external pressure environments. It is surrounded by an outer clad of Hastelloy-S which protects the strength member from external oxidation and corrosive sources during nominal operation and in the event of off-nominal operation or accidents. Both the strength member and outer clad parts are closed with seal welds. The strength member and outer clad are the primary containment members of the 60-Watt IHS. The iridium clad contains the fuel pellet during nominal operation and mild accident environments, but it is not considered to be a primary containment member.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1985

Cryogenic propellant management: Integration of design, performance and operational requirements

The integration of the design features of the Shuttle elements into a cryogenic propellant management system is described. The implementation and verification of the design/operational changes resulting from design deficiencies and/or element incompatibilities encountered subsequent to the critical design reviews are emphasized. Major topics include: subsystem designs to provide liquid oxygen (LO2) tank pressure stabilization, LO2 facility vent for ice prevention, liquid hydrogen (LH2) feedline high point bleed, pogo suppression on the Space Shuttle Main Engine (SSME), LO2 low level cutoff, Orbiter/engine propellant dump, and LO2 main feedline helium injection for geyser prevention.

Worlund, A. L.↗
NASA NTRS1991

A liquid/gas phase separator for He-I and He-II

A liquid/gas phase separator has been developed which separates both liquid He-I and He-II from their vapor. The phase separator was designed for the Superfluid Helium On Orbit Transfer (SHOOT) Flight Demonstration both to cool the liquid He after launch (at temperatures between 2.8 and 4.3 K) to the operating temperature of 1.4 K and as a low rate vent on orbit to maintain operating temperature. The phase separator is made of high-purity copper disks held apart by 6 micron Kevlar fibers. It works on the principle of conducting heat from within the dewar to vaporize liquid as it is throttled in the slits to efficiently cool the remaining liquid. Laboratory tests have demonstrated perfect phase separation for both He at its saturated vapor pressure from 1.2 to 4.3 K and for He-II at 2.13 K at pressures from 4.6 to 112 kPa. The performance of this phase separator during lab testing as well as expected performance in space is discussed.

Shirron, P. J.↗
NASA NTRS1988

Liquid helium servicing from the Space Station

The current concept of liquid helium resupply from the Space Station is discussed with regard to user and Space Station requirements, as well as requirements of the liquid helium servicing facility itself. A number of trade-offs which will affect both the hardware and the operation of the facility are presented. A total of 12 potential users have been identified. The users are divided into two groups: large volume users which are serviced every one to two years and small volume users which are serviced every few months. Both groups have a very strong impact on the definition of the liquid helium servicing facility. The facility components will be based on results of the Superfluid Helium On Orbit Transfer flight demonstration being conducted by NASA. Currently, the Space Station design includes a customer servicing bay which provides electrical power, thermal and contamination control, and connections for control and data handling systems. Restrictions on venting and vibrational disturbances on the Space Station may preclude servicing during quiescent periods when accelerations are minimal.

Breon, S. R.↗
NASA NTRS1998

Pressurization, Pneumatic, and Vent Subsystems of the X-34 Main Propulsion System

In pressurization systems, regulators and orifices are use to control the flow of the pressurant. For the X-34 Main Propulsion System, three pressurization subsystem design configuration options were considered. In the first option, regulators were used while in the other options, orifices were considered. In each design option, the vent/relief system must be capable of relieving the pressurant flow without allowing the tank pressure to rise above proof, therefore, impacts on the propellant tank vent system were investigated and a trade study of the pressurization system was conducted. The analysis indicated that design option using regulators poses least risk. Then, a detailed transient thermal/fluid analysis of the recommended pressurization system was performed. Helium usage, thermodynamic conditions, and overpressurization of each propellant tank were evaluated. The pneumatic and purge subsystem is used for pneumatic valve actuation, Inter-Propellant Seal purges, Engine Spin Start, and engine purges at the required interface pressures, A transient analysis of the pneumatic and purge subsystem provided helium usage and flow rates to Inter-Propellant Seal and engine interfaces. Fill analysis of the helium bottles of pressurization and pneumatic subsystems during ground operation was performed. The required fill time and the stored

Hedayat, A.↗
NASA NTRS1993

Water cooling system for an air-breathing hypersonic test vehicle

This study provides concepts for hypersonic experimental scramjet test vehicles which have low cost and low risk. Cryogenic hydrogen is used as the fuel and coolant. Secondary water cooling systems were designed. Three concepts are shown: an all hydrogen cooling system, a secondary open loop water cooled system, and a secondary closed loop water cooled system. The open loop concept uses high pressure helium (15,000 psi) to drive water through the cooling system while maintaining the pressure in the water tank. The water flows through the turbine side of the turbopump to pump hydrogen fuel. The water is then allowed to vent. In the closed loop concept high pressure, room temperature, compressed liquid water is circulated. In flight water pressure is limited to 6000 psi by venting some of the water. Water is circulated through cooling channels via an ejector which uses high pressure gas to drive a water jet. The cooling systems are presented along with finite difference steady-state and transient analysis results. The results from this study indicate that water used as a secondary coolant can be designed to increase experimental test time, produce minimum venting of fluid and reduce overall development cost.

Petley, Dennis H.↗
NASA NTRS1975

Centaur zero gravity coast and engine restart demonstration on the Titan/Centaur (TC-2) extended mission

The Centaur propellant management and thermal control techniques required for zero gravity coasting were successfully demonstrated during an extended mission following spacecraft separation on the TC-2 flight. As part of the demonstration, two successful engine starts were accomplished. The first engine start followed a one-hour zero gravity coast, and the second engine start followed a three-hour zero gravity coast. All of the Centaur systems performed satisfactorily, the design parameters for zero gravity coasting were verified, and no significant problems were encountered. The flight results showed that the propellant location and behavior, propellant heating, and tank pressure rise rates observed during the zero-gravity coasts were less severe than expected. Consequently, the majority of the propellants remained at the tank bottom, the propellant collection times were very short, and more than 7 hours of coast could have been achieved before a tank venting was required. The tank pressurization prior to the engine starts provided boost pump Net Positive Suction Head values well in excess of the values required. The LO2 tank pressurization was accomplished by a new bubbler method that greatly reduced the helium usage.

Lacovic, R. F.↗
NASA NTRS2001

Large-Scale Liquid Hydrogen Testing of Variable Density Multilayer Insulation with a Foam Substrate

The multipurpose hydrogen test bed (MHTB), with an 18-cu m liquid hydrogen tank, was used to evaluate a combination foam/multilayer combination insulation (MLI) concept. The foam element (Isofoam SS-1171) insulates during ground hold/ascent flight, and allowed a dry nitrogen purge as opposed to the more complex/heavy helium purge subsystem normally required. The 45-layer MLI was designed for an on-orbit storage period of 45 days. Unique WI features include a variable layer density, larger but fewer double-aluminized Mylar perforations for ascent to orbit venting, and a commercially established roll-wrap installation process that reduced assembly man-hours and resulted in a roust, virtually seamless MLI. Insulation performance was measured during three test series. The spray-on foam insulation (SOFI) successfully prevented purge gas liquefaction within the MLI and resulted in the expected ground hold heat leak of 63 W/sq m. The orbit hold tests resulted in heat leaks of 0.085 and 0.22 W/sq m with warm boundary temperatures of 164 and 305 K, respectively. Compared to the best previously measured performance with a traditional MLI system, a 41-percent heat leak reduction with 25 fewer MLI layers was achieved. The MHTB MLI heat leak is half that calculated for a constant layer density MLI.

Martin, J. J.↗
NASA NTRS1991

SHOOT performance testing

The Superfluid Helium On-Orbit Transfer (SHOOT) Flight Demonstration is a shuttle attached payload designed to demonstrate the technology necessary to resupply liquid helium dewars in space. Many SHOOT components will also have use in other aerospace cryogenic systems. The first of two SHOOT dewar systems has been fabricated. The ground performance testing of this dewar is described. The performance tests include measurements of heat leak, impedances of the two vent lines, heat pulse mass gauging accuracy, and superfluid transfer parameters such as flow rate and efficiency. A laboratory dewar was substituted for the second flight dewar for the transfer tests. These tests enable a precise analytical model of the transfer process to be verified. SHOOT performance is thus quantified, except for components such as the liquid acquisition devices and a phase separator which cannot be verified in one gravity.

Dipirro, M. J.↗