Vehicle-scale investigation of a fluorine-hydrogen main tank injection pressurization system Final report, 1 Jul. 1969 - 31 Jul. 1970
Vehicle-scale analysis of fluorine-hydrogen main tank injection pressurization system
Cady, E. C.↗
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Thermal/structural optimization of cryogenic storage systems.
An analytical method has been developed to optimize a cryogenic storage system designed for long term storage of cryogenic propellants. The type of propellant, mission duration, thermal environment, insulation thermal properties, insulation vent time, and the storage system weight penalty imposed by the design pressure were considered as the dependent parameters. The optimum system insulation thickness and vent pressure were then calculated in terms of these parameters. The method was applied to the design of the Space Shuttle Orbiter oxygen and hydrogen tanks to obtain an optimum design. It was determined that for the mission examined, the hydrogen tank optimum design was close to the initial pressure. A continuously vented hydrogen tank, therefore, was close to the optimum design. Also, it was determined that for this particular mission the oxygen tank should not be vented.
Navickas, J.↗
Development and validation of purged thermal protection systems for liquid hydrogen fuel tanks of hypersonic vehicles
An economical, lightweight, safe, efficient, reliable, and reusable insulation system was developed for hypersonic cruise vehicle hydrogen fuel tanks. Results indicate that, a nitrogen purged, layered insulation system with nonpermeable closed-cell insulation next to the cryogenic tank and a high service temperature fibrous insulation surrounding it, is potentially an attractive solution to the insulation problem. For the postulated hypersonic flight the average unit weight of the purged insulation system (including insulation, condensate and fuel boil off) is 6.31 kg/sq m (1.29 psf). Limited cyclic tests of large specimens of closed cell polymethacrylimide foam indicate it will withstand the expected thermal cycle.
Helenbrook, R. D.↗
Seal Analysis for the Ares-I Upper Stage Fuel Tank Manhole Cover
Techniques for studying the performance of Naflex pressure-assisted seals in the Ares-I Upper Stage liquid hydrogen tank manhole cover seal joint are explored. To assess the feasibility of using the identical seal design for the Upper Stage as was used for the Space Shuttle External Tank manhole covers, a preliminary seal deflection analysis using the ABAQUS commercial finite element software is employed. The ABAQUS analyses are performed using three-dimensional symmetric wedge finite element models. This analysis technique is validated by first modeling a heritage External Tank liquid hydrogen tank manhole cover joint and correlating the results to heritage test data. Once the technique is validated, the Upper Stage configuration is modeled. The Upper Stage analyses are performed at 1.4 times the expected pressure to comply with the Constellation Program factor of safety requirement on joint separation. Results from the analyses performed with the External Tank and Upper Stage models demonstrate the effects of several modeling assumptions on the seal deflection. The analyses for Upper Stage show that the integrity of the seal is successfully maintained.
Phillips, Dawn R.↗
Wall and bottom heating of liquid hydrogen in a propellant tank
Liquid hydrogen behavior during propellant tank wall and bottom heating
WALL TEMPERATURE↗
Self-pressurization of a spherical liquid hydrogen storage tank in a microgravity environment
Thermal stratification and self-pressurization of partially filled liquid hydrogen (LH2) storage tanks under microgravity condition is studied theoretically. A spherical tank is subjected to a uniform and constant wall heat flux. It is assumed that a vapor bubble is located in the tank center such that the liquid-vapor interface and tank wall form two concentric spheres. This vapor bubble represents an idealized configuration of a wetting fluid in microgravity conditions. Dimensionless mass and energy conservation equations for both vapor and liquid regions are numerically solved. Coordinate transformation is used to capture the interface location which changes due to liquid thermal expansion, vapor compression, and mass transfer at liquid-vapor interface. The effects of tank size, liquid fill level, and wall heat flux on the pressure rise and thermal stratification are studied. Liquid thermal expansion tends to cause vapor condensation and wall heat flux tends to cause liquid evaporation at the interface. The combined effects determine the direction of mass transfer at the interface. Liquid superheat increases with increasing wall heat flux and liquid fill level and approaches an asymptotic value.
Lin, C. S.↗
Self-pressurization of a spherical liquid hydrogen storage tank in a microgravity environment
Thermal stratification and self-pressurization of partially filled liquid hydrogen (LH2) storage tanks under microgravity condition is studied theoretically. A spherical tank is subjected to a uniform and constant wall heat flux. It is assumed that a vapor bubble is located in the tank center such that the liquid-vapor interface and tank wall form two concentric spheres. This vapor bubble represents an idealized configuration of a wetting fluid in microgravity conditions. Dimensionless mass and energy conservation equations for both vapor and liquid regions are numerically solved. Coordinate transformation is used to capture the interface location which changes due to liquid thermal expansion, vapor compression, and mass transfer at liquid-vapor interface. The effects of tank size, liquid fill level, and wall heat flux on the pressure rise and thermal stratification are studied. Liquid thermal expansion tends to cause vapor condensation and wall heat flux tends to cause liquid evaporation at the interface. The combined effects determine the direction of mass transfer at the interface. Liquid superheat increases with increasing wall heat flux and liquid fill level and approaches an asymptotic value.
Lin, C. S.↗
Structural Arrangement Trade Study. Volume 1: Reusable Hydrogen Composite Tank System (RHCTS) and Graphite Composite Primary Structures (GCPS). Executive summary
This volume is the first of a three volume set that discusses the structural arrangement trade study plan that will identify the most suitable configuration for an SSTO winged vehicle capable of delivering 25,000 lbs to a 220 nm circular orbit at 51.6 deg inclination. The Reusable Hydrogen Composite Tank System (RHCTS), and Graphite Composite Primary Structures most suitable for intertank, wing and thrust structures are identified. This executive summary presents the trade study process, the selection process, requirements used, analysis performed and data generated. Conclusions and recommendations are also presented.
Source record↗
Structural arrangement trade study. Volume 3: Reusable Hydrogen Composite Tank System (RHCTS) and Graphite Composite Primary Structures (GCPS). Addendum
This volume is the third of a 3 volume set that addresses the structural trade study plan that will identify the most suitable structural configuration for an SSTO winged vehicle capable of delivering 25,000 lbs to a 220 nm circular orbit at 51.6 deg inclination. The most suitable Reusable Hydrogen Composite Tank System (RHCTS), and Graphite Composite Tank System (GCPS) composite materials for intertank, wing and thrust structures are identified. Vehicle resizing charts, selection criteria and back-up charts, parametric costing approach and the finite element method analysis are discussed.
Source record↗
X-33 Leading the Way to VentureStar(Trademark) in this Decade
The X-33, reusable space plane technology demonstrator is on course to begin the flights of the X-33 by the end of 2002 that will serve as a basis for industry and government decisions that could lead to VentureStar(Trademark). Lockheed Martin has placed the VentureStar(Trademark) LLC in it's Space Company and is now competing in an industry wide effort that will permit NASA to select a Second Generation RLV source by 2005. This move provides the focus for firm business planning needed to enable the decision by the time X-33 flies in mid 2002 and possibly with upgraded technologies a year or so later. Since the IAF 50th Congress in Amsterdam, most of the major hardware elements of X-33 have been through their assembly and test. The flight liquid oxygen tank was the first major element to complete final assembly. Aerospike Engine qualification testing has progressed successfully through its test objectives and the two flight engines are in preparation to be delivered to the Assembly Facility in Palmdale. All Thermal Protection System (TPS) metallic panels have completed qualification testing and have been delivered to Palmdale and all remaining TPS elements have been assembled and are ready for delivery. Flight Software and Avionics have been delivered and are in integration testing. In November 1999, the first graphite composite liquid hydrogen tank experienced a debond between the tank inner skin and the honeycomb core in testing. This tank had completed its third successful cryogenic and loads testing at MSFC. Replacement liquid hydrogen tanks have completed design and are in fabrication. The resulting delay from this change of design for the liquid hydrogen tank will be approximately two years.
Austin, Robert E.↗
Self-pressurization of a flightweight liquid hydrogen storage tank subjected to low heat flux
Results are presented for an experimental investigation of self-pressurization and thermal stratification of a 4.89 cu m liquid hydrogen (LH2) storage tank subjected to low heat flux (0.35, 2.0, and 3.5 W/sq m) under normal gravity conditions. Tests were performed at fill levels of 83 to 84 percent (by volume). The LH2 tank was representative of future spacecraft tankage, having a low mass-to-volume ratio and high performance multilayer thermal insulation. Results show that the pressure rise rate and thermal stratification increase with increasing heat flux. At the lowest heat flux, the pressure rise rate is comparable to the homogenous rate, while at the highest heat flux, the rate is more than three times the homogeneous rate. It was found that initial conditions have a significant impact on the initial pressure rise rate. The quasi-steady pressure rise rates are nearly independent of the initial condition after an initial transient period has passed.
Hasan, M. M.↗
Internship at NASA Kennedy Space Center's Cryogenic Test laboratory
NASA's Kennedy Space Center (KSC) is known for hosting all of the United States manned rocket launches as well as many unmanned launches at low inclinations. Even though the Space Shuttle recently retired, they are continuing to support unmanned launches and modifying manned launch facilities. Before a rocket can be launched, it has to go through months of preparation, called processing. Pieces of a rocket and its payload may come in from anywhere in the nation or even the world. The facilities all around the center help integrate the rocket and prepare it for launch. As NASA prepares for the Space Launch System, a rocket designed to take astronauts beyond Low Earth Orbit throughout the solar system, technology development is crucial for enhancing launch capabilities at the KSC. The Cryogenics Test Laboratory at Kennedy Space Center greatly contributes to cryogenic research and technology development. The engineers and technicians that work there come up with new ways to efficiently store and transfer liquid cryogens. NASA has a great need for this research and technology development as it deals with cryogenic liquid hydrogen and liquid oxygen for rocket fuel, as well as long term space flight applications. Additionally, in this new era of space exploration, the Cryogenics Test Laboratory works with the commercial sector. One technology development project is the Liquid Hydrogen (LH2) Ground Operations Demonstration Unit (GODU). LH2 GODU intends to demonstrate increased efficiency in storing and transferring liquid hydrogen during processing, loading, launch and spaceflight of a spacecraft. During the Shuttle Program, only 55% of hydrogen purchased was used by the Space Shuttle Main Engines. GODU's goal is to demonstrate that this percentage can be increased to 75%. Figure 2 shows the GODU layout when I concluded my internship. The site will include a 33,000 gallon hydrogen tank (shown in cyan) with a heat exchanger inside the hydrogen tank attached to a refrigerator capable of removing 850 Watts at 20 Kelvin (shown in green). The refrigerator and most of its supporting equipment will be kept in a standard shipping container (shown in pink). Currently, GODU is in the fabrication process and some of the large components have already been purchased.
Holland, Katherine↗
The COLD-SAT experiment for cryogenic fluid management technology
The COLD-SAT spacecraft design experiments are described. COLD-SAT will be placed into an initial 1300 km circular orbit by an Atlas commercial launch vehicle. Electric power, experiment control and data management, attitude control, and propulsive accelarations for the experiments will be provided by the three-axis-controlled spacecraft bus. To provide data on the effects that low gravity levels might have on the heat and mass transfer processes involved, low levels of accelaration will be created. The COLD-SAT experiment will be configured into a module. The spacecraft experiment module will include three liquid hydrogen tanks; fluid transfer, pressurization and venting equipment; and instrumentation. Since the largest tank has helium-purged MLI to prevent ingress and freezing of air on the launchpad, it will contain all the liquid hydrogen at the point of launching. The hydrogen tanking system used for the Centaur upper stage of the Atlas will load and top off this tank. Atlas, with its liquid hydrogen upper stage, large payload fairing, and large launch margin, simplifies COLD-SAT design and integration.
Schuster, J. R.↗
Composites for Cryotank Structures. Present and Future: MSFC Perspective
The development of reusable launch vehicle systems for a single stage to orbit vehicle requires vehicles at liftoff with 85% to 94% of its mass consisting exclusively of propellants. These dry mass requirements drive designs to utilize stronger, lighter weight materials for structures. This technology development focus has allowed the introduction of composite materials in lieu of conventional metallic materials due to their higher specific strengths. Composite materials were successfully used for the liquid hydrogen tanks for the DC-XA, and a multi-lobed liquid hydrogen tank will be employed for the X-33. Another potential non-traditional application for composite materials is for liquid oxygen tanks, which is still being investigated. Traditionally, organic materials have been avoided wherever possible, due the potential fire hazard and the fact that composites fail conventional oxygen compatibility requirements. However, the potential weight savings warrant the investigation of the use of polymeric composite materials in oxygen environments. Since composites fail the conventional, time-proven test methods because they are considered flammable by test, we have embarked on an innovative approach to oxygen compatibility testing and evaluation focused on the use environments and attempts to eliminate or "design away" all potential ignition sources. Oxygen compatibility is defined as the ability of a material to coexist with oxygen and potential ignition sources with an acceptable, manageable degree of risk.
Vaughn, Timothy P.↗
SLS Test Stand Site Selection
Test site selection is a critical element of the design, development and production of a new system. With the advent of the new Space Launch System (SLS), the National Aeronautics and Space Administration (NASA) had a number of test site selection decisions that needed to be made early enough in the Program to support the planned Launch Readiness Date (LRD). This case study focuses on decisions that needed to be made in 2011 and 2012 in preparation for the April 2013 DPMC decision about where to execute the Main Propulsion Test that is commonly referred to as "Green Run." Those decisions relied upon cooperative analysis between the Program, the Test Lab and Center Operations. The SLS is a human spaceflight vehicle designed to carry a crew farther into space than humans have previously flown. The vehicle consists of four parts: the crew capsule, the upper stage, the core stage, and the first stage solid rocket boosters. The crew capsule carries the astronauts, while the upper stage, the core stage, and solid rocket boosters provide thrust for the vehicle. In other words, the stages provide the "lift" part of the lift vehicle. In conjunction with the solid rocket boosters, the core stage provides the initial "get-off-the-ground" thrust to the vehicle. The ignition of the four core stage engines and two solid rocket boosters is the first step in the launch portion of the mission. The solid rocket boosters burn out after about 2 minutes of flight, and are then jettisoned. The core stage provides thrust until the vehicle reaches a specific altitude and speed, at which point the core stage is shut off and jettisoned, and the upper stage provides vehicle thrust for subsequent mission trajectories. The integrated core stage primarily consists of a liquid oxygen tank, a liquid hydrogen tank, and the four core stage engines. For the SLS program, four RS-25 engines were selected as the four core stage engines. The RS-25 engine is the same engine that was used for Space Shuttle. The test plan for the integrated core stage was broken down into several segments: Component testing, system level testing, and element level testing. In this context, components are items such as valves, controllers, sensors, etc. Systems are items such as an entire engine, a tank, or the outer stage body. The core stage itself is considered to be an element. The rocket engines are also considered an element. At the program level, it was decided to perform a single green run test on the integrated core stage prior to shipment of it to Kennedy Space Center (KSC) for use in the EM-1 test flight of the SLS vehicle. A green run test is the first live fire of the new integrated core stage and engine elements - without boosters of course. The SLS Program had to decide where to perform SLS green run testing.
Crowe, Kathryn↗
Filament wound metal lined propellant tanks for future Earth-to-orbit transports
For future Earth-to-orbit transport vehicles, reusability and lighter weights are sought for the main propellant tanks. To achieve this, a filament wound tank with a metal liner and an intermediate layer of foam-filled honeycomb is proposed. A hydrogen tank is used as an example. To accommodate mismatches in the expansion of liner and overwrap a design is proposed wherin the liner is configured so that the extension of the liner under pressure matches the expected contraction of the same liner due to the presence of a cryogen. In operation, the liner is pressurized at a rate such that the pressure strain matches the contraction due to decrease in temperature. As an alternate approach, compressive pre-stress is placed in the liner such that it will not separate from the overwrap. A finite element program is used to show stresses in the liner and overwrap for various tank pressures for the pre-stressed liner concept. A fracture mechanics analysis is made of the liners to determine tank life. The tank concept shown has a similar weight to the Shuttle external hydrogen tank, but the filament wound tank is expected to be reusable. Integration of the propellant tanks into a future transport vehicle is discussed.
Macconochie, Ian O.↗
Summary of Activities for Nondestructive Evaluation of Insulation in Cryogenic Tanks
This project was undertaken to investigate methods to non-intrusively determine the existence and density of perlite insulation in the annular region of the cryogenic storage vessels, specifically considering the Launch Complex 39 hydrogen tanks at Kennedy Space Center. Lack of insulation in the tanks (as existed in the pad B hydrogen tank at Kennedy Space Center) results in an excessive loss of commodity and can pose operational and safety risks if precautions are not taken to relieve the excessive gas build-up. Insulation with a density that is higher than normal (due to settling or compaction) may also pose an operational and safety risk if the insulation prevents the system from moving and responding to expansions and contractions as fluid is removed and added to the tank.
Arens, Ellen↗
Research and Development History of Glass Bubbles Bulk-Fill Thermal Insulation Systems for Large-Scale Cryogenic Liquid Hydrogen Storage Tanks
Based on the published literature record, this document provides an overview of the research and development of glass bubbles bulk-fill thermal insulation systems for cryogenic equipment in general and, in particular, for large-scale cryogenic liquid hydrogen (LH2) storage spheres. Glass bubbles (also known as hollow glass microspheres) are used in place of perlite powder which began use in double-wall cryogenic tanks in the 1930s. Included in this overview is a historical summary, a development timeline, a selected publications list, and the key technical points from those publications.
Cryogenic storage tanks↗