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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS2018

Off-Nominal Planning for the Cryogenic Vacuum Test of the JWST Optical Telescope Element/Integrated Science Instrument Module at JSC

The cryogenic thermal vacuum/thermal balance test of the James Webb Space Telescope (JWST) combined Optical Telescope Element (OTE)/Integrated Science Instrument Module (ISIM), known as the OTIS, at the Johnson Space Center (JSC) Chamber A in 2017 was likely the most complex test ever performed by NASA for an unmanned mission. The test of the combined flight Optical Telescope and ISIM elements was prefaced by years of modifications to chamber facilities, and included three extensive precursor tests of non-flight and flight hardware to establish safe and optimal test operational procedures. One critical part of the test preparation was planning for off-nominal events that could arise, including appropriate responses. In some cases, assurance of personnel and payload safety required modification of original test hardware and procedures which had to be validated before the final test could begin. This planning proved especially prescient for the OTIS test, as Hurricane Harvey struck the Houston area during the test in August 2017, and consequences for the precious payload could have been severe. This paper describes the extent of the thermal off-nominal planning undertaken for the OTIS test, including including safing for hurricanes, and some real-life effects of Hurricane Harvey on the test conduct. Documentation of the consequences and mitigations for these events are discussed. The importance of off-nominal planning for future thermal vacuum/thermal balance tests is illustrated.

Off-Nominal Planning↗
NASA NTRS1984

Fastener load tests and retention systems tests for cryogenic wind-tunnel models

A-286 stainless steel screws were tested to determine the tensile load capability and failure mode of various screw sizes and types at both cryogenic and room temperature. Additionally, five fastener retention systems were tested by using A-286 screws with specimens made from the primary metallic alloys that are currently used for cryogenic models. The locking system effectiveness was examined by simple no-load cycling to cryogenic temperatures (-275 F) as well as by dynamic and static loading at cryogenic temperatures. In general, most systems were found to be effective retention devices. There are some differences between the various devices with respect to ease of application, cleanup, and reuse. Results of tests at -275 F imply that the cold temperatures act to improve screw retention. The improved retention is probably the result of differential thermal contraction and/or increased friction (thread-binding effects). The data provided are useful in selecting screw sizes, types, and locking devices for model systems to be tested in cryogenic wind tunnels.

Wallace, J. W.↗
NASA NTRS1990

The SHOOT cryogenic components - Testing and applicability to other flight programs

Cryogenic components and techniques for the superfluid helium on-orbit transfer (SHOOT) flight demonstration are described. Instrumentation for measuring liquid quantity, position, flow rate, temperature, and pressure has been developed using the data obtained from the IRAS, Cosmic Background Explorer, and Spacelab 2 helium dewars. Topics discussed include valves and burst disks, fluid management devices, structural/thermal components, instrumentation, and ground support equipment and performance test apparatus.

Dipirro, Michael J.↗
NASA NTRS1983

LaNi5 hydride cryogenic refrigerator test results

A complete LaNi5 hydrogen absorption cryogenic refrigerator system was developed. The system uses low temperature waste heat of approximately 100 C as a power source, and has no moving parts other than self operating valves. The cycle continues automatically by an electronic sequencing timing mechanism for the three compressors which are phased such that a constant supply of high pressure hydrogen gas is provided. It is indicated that with a fully clean hydrogen system, hundreds of thousand cycles should be attainable, even though some degradation may eventually occur. Simple vacuum reactivation of the hydride of moving parts, other than self operating, long life valves, the refrigerators predicted life is extremely long.

Jones, J. A.↗
NASA NTRS2005

Thermal Insulation Test Apparatuses

The National Aeronautics and Space Administration (NASA) seeks to license its Thermal Insulation Test Apparatuses. Designed by the Cryogenics Test Laboratory at the John F. Kennedy Space Center (KSC) in Florida, these patented technologies (U.S. Patent Numbers: Cryostat 1 - 6,742,926, Cryostat 2 - 6,487,866, and Cryostat 4 - 6,824,306) allow manufacturers to fabricate and test cryogenic insulation at their production and/or laboratory facilities. These new inventions allow for the thermal performance characterization of cylindrical and flat specimens (e.g., bulk-fill, flat-panel, multilayer, or continuously rolled) over the full range of pressures, from high vacuum to no vacuum, and over the full range of temperatures from 77K to 300K. In today's world, efficient, low-maintenance, low-temperature refrigeration is taking a more significant role, from the food industry, transportation, energy, and medical applications to the Space Shuttle. Most countries (including the United States) have laws requiring commercially available insulation materials to be tested and rated by an accepted methodology. The new Cryostat methods go beyond the formal capabilities of the ASTM methods to provide testing for real systems, including full-temperature differences plus full-range vacuum conditions.

Berman, Brion↗
NASA NTRS2015

Zero Boil-Off System Testing

Cryogenic propellants such as liquid hydrogen (LH2) and liquid oxygen (LO2) are a part of NASA's future space exploration plans due to their high specific impulse for rocket motors of upper stages. However, the low storage temperatures of LH2 and LO2 cause substantial boil-off losses for long duration missions. These losses can be eliminated by incorporating high performance cryocooler technology to intercept heat load to the propellant tanks and modulating the cryocooler temperature to control tank pressure. The technology being developed by NASA is the reverse turbo-Brayton cycle cryocooler and its integration to the propellant tank through a distributed cooling tubing network coupled to the tank wall. This configuration was recently tested at NASA Glenn Research Center in a vacuum chamber and cryoshroud that simulated the essential thermal aspects of low Earth orbit, its vacuum and temperature. This test series established that the active cooling system integrated with the propellant tank eliminated boil-off and robustly controlled tank pressure.

Reverse turbo-Brayton cycle↗
NASA NTRS2017

Liquid Nitrogen Zero Boiloff Testing

Cryogenic propellants such as liquid hydrogen (LH2) and liquid oxygen (LO2) are a part of NASAs future space exploration due to their high specific impulse for rocket motors of upper stages suitable for transporting 10s to 100s of metric tons of payload mass to destinations outside of low earth orbit and for their return. However, the low storage temperatures of LH2 and LO2 cause substantial boil-off losses for missions with durations greater than several months. These losses can be eliminated by incorporating high performance cryocooler technology to intercept heat load to the propellant tanks and modulating the cryocooler to control tank pressure. The active thermal control technology being developed by NASA is the reverse turbo-Brayton cycle cryocooler and its integration to the propellant tank through a distributed cooling tubing network coupled to the tank wall. This configuration was recently tested at NASA Glenn Research Center, in a vacuum chamber and cryo-shroud that simulated the essential thermal aspects of low Earth orbit, its vacuum and temperature. Testing consisted of three passive tests with the active cryo-cooler system off, and 7 active tests, with the cryocooler powered up. The test matrix included zero boil-off tests performed at 90 full and 25 full, and several demonstrations at excess cooling capacity and reduced cooling capacity. From this, the tank pressure response with varied cryocooler power inputs was determined. This test series established that the active cooling system integrated with the propellant tank eliminated boil-off and robustly controlled tank pressure.

Cryogenic fluid management↗
NASA NTRSDate not supplied

Role of Cryogenic Aerodynamic Testing for Current and Future Technologies

The motivation for cryogenic wind tunnels originated during the 1960s from an internationally recognized need for a high Reynolds number test capability based on experiences with preflight predictions of aerodynamic characteristics and an anticipated need in support of research and development for future aerospace vehicle systems. More specifically, the motivation for a flight (or near flight) Reynolds number ground test facility was captured in the foreword to reference 1 which states:“...AGARD held a Specialists’ Meeting in Paris on ‘Transonic Aerodynamics’ in recognition of the fact that the absence of adequate theoretical methods and wind tunnels of high enough Reynolds number had already led to costly shortcomings in the transonic performance of certain combat and transport aircraft.” Preflight prediction of flight characteristics is a necessary process for the developer of any aerospace vehicle, and introduces significant risk to the success of the vehicle. Whether the vehicle customer is commercial or governmental, the final full-scale vehicle must meet certain requirements to be certified as safe, and certain performance requirements to be economically successful. Aircraft companies strive to know the flight characteristics and performance of their vehicle with high confidence prior to flight, thus enabling optimal design trades and elimination of any costly modifications to the aircraft during and after initial flight testing. The problems of predicting flight characteristics across the full flight envelope prior to flight have been and continue to be challenging. Much has changed since the US National Transonic Facility (NTF) became operational in the 1980s, followed by the European Transonic Windtunnel (ETW) in 1990s, not the least of which has been the advancement and positive impact of computational fluid dynamics (CFD) on aircraft design and development. Today, the need for integrated CFD and ground-based high Reynolds number test and evaluation capability remains as aerodynamics will always be central to defining an aircraft directly as well as providing critical input to other disciplines. Today the economic stakes of being surprised during flight tests are higher than ever. This oral-only presentation describes the past, current, and future role of high Reynolds number aerodynamic testing in aerospace vehicle design and development. Discussion of relevant flow physics, past experiences with preflight prediction, and future needs, challenges, and opportunities is included. 1.“Facilities and Techniques for Aerodynamic Testing at Transonic Speeds and High Reynolds Number,” AGARD CP-83-71, 1971.

Aerodynamics↗
NASA NTRS2015

Zero Boil-Off System Testing

Cryogenic propellants such as liquid hydrogen (LH2) and liquid oxygen (LO2) are a part of NASA's future space exploration due to their high specific impulse for rocket motors of upper stages suitable for transporting 10s to 100s of metric tons of payload mass to destinations outside of low earth orbit and for their return. However, the low storage temperatures of LH2 and LO2 cause substantial boil-off losses for missions with durations greater than several months. These losses can be eliminated by incorporating high performance cryocooler technology to intercept heat load to the propellant tanks and modulating the cryocooler to control tank pressure. The active thermal control technology being developed by NASA is the reverse turbo-Brayton cycle cryocooler and its integration to the propellant tank through a distributed cooling tubing network coupled to the tank wall. This configuration was recently tested at NASA Glenn Research Center, in a vacuum chamber and cryoshroud that simulated the essential thermal aspects of low Earth orbit, its vacuum and temperature. Testing consisted of three passive tests with the active cryocooler system off, and 7 active tests, with the cryocooler powered up. The test matrix included zero boil-off tests performed at 90 full and 25 full, and several demonstrations at excess cooling capacity and reduced cooling capacity. From this, the tank pressure response with varied cryocooler power inputs was determined. This test series established that the active cooling system integrated with the propellant tank eliminated boil-off and robustly controlled tank pressure.

Plachta, David W.↗
NASA NTRS2019

SINDA/FLUINT and Thermal Desktop Multi-Node Settled and Unsettled Propellant Tank Modeling of Zero Boil Off Test

Cryogenic propellant storage tank self-pressurization involves complex physical phenomena which are usually analytically modelled via complex multidimensional CFD (Computational Fluid Dynamics) codes. Unfortunately these codes, even when modelling axisymmetric domains, may take weeks or longer to obtain transient pressure and temperature information for relatively short periods of time (several seconds to several hours). Propellant tank storage end-to-end mission simulations can last a duration of days to weeks to months. Multi-node modelling of propellant tanks is a viable alternative to traditional CFD modelling and presents the advantage of greatly reduced run times on the order of hours and days compared to the weeks or longer for CFD codes. A multi-node model represents the fluid within the storage tank, as well as the storage tank itself, as a fluid-thermal network. This type of setup is not necessarily geometrically based. This can be accomplished using a commercial generalized fluid-thermal network code, such as SINDA/FLUINT (SF). The advantage of using a fluid-thermal network code like SF lies in its extensive ability to model the external environment of the storage tank through the graphical user interface, Thermal Desktop (TD). The total heat load into the tank may be a function of heaters and a complex radiative environment as well. Thermal Desktop may be used to address the detailed radiative environment of the tank as well as building a geometrically accurate depiction of the storage tank itself.

Thermal Desktop↗
NASA NTRS2019

SINDA/FLUINT and Thermal Desktop Multi-Node Settled and Unsettled Propellant Tank Modeling of Zero Boil Off Test

Cryogenic propellant storage tank self-pressurization involves complex physical phenomena which are usually analytically modelled via complex multidimensional CFD codes. Unfortunately these codes, even when modelling axisymmetric domains, may takes weeks or longer to obtain transient pressure and temperature information for relatively short periods of time (several seconds to several hours). Propellant tank storage end-to-end mission simulations can last a duration of days to weeks to months. Multi-node modelling of propellant tanks is a viable alternative to traditional CFD modelling and presents the advantage of greatly reduced run times on the order of hours and days compared to the weeks or longer for CFD codes. A multi-node model represents the fluid within the storage tank, as well as the storage tank itself, as a fluid-thermal network. This type of setup is not necessarily geometrically based. This can be accomplished using a commercial generalized fluid-thermal network code, such as SINDA/FLUINT (SF). The advantage of using a fluid-thermal network code like SF lies in its extensive ability to model the external environment of the storage tank through the graphical user interface, Thermal Desktop (TD). The total heat load into the tank may be a function of heaters and a complex radiative environment as well. Thermal Desktop may be used to address the detailed radiative environment of the tank as well as building a geometrically accurate depiction of the storage tank itself.

Sakowski, Barbara↗
NASA NTRS2002

Miniature Joule Thomson (JT) CryoCoolers for Propellant Management

A proof-of-concept project is proposed here that would attempt to demonstrate how miniature cryocoolers can be used to chill the vacuum jacket line of a propellant transfer line and thus to achieve transfer line pre-chill, zero boil off and possible propellant densification. The project would be performed both at UCF and KSC, with all of the cryogenic testing taking place in the KSC cryogenic test bed. A LN2 line available in that KSC test facility would serve to simulate a LOX transfer line. Under this project, miniature and highly efficient cold heads would be designed. Two identical cold heads will be fabricated and then integrated with a JT-type cryogenic system (consisting of a common compressor and a common external heat exchanger). The two cold heads will be integrated into the vacuum jacket of a LN2 line in the KSC cryo lab, where the testing will take place.

Kapat, Jay↗
NASA NTRS1983

Dimensional stability considerations for cryogenic metals

Work performed as part of an effort to identify, and where possible separate out, some of the factors that contribute to dimensional stability in cryogenic wind tunnel models is reported. Initial problems were encountered with two dimensional models made of 15-5 PH stainless steel, which warped significantly after being subjected to cryogenic testing in the 0.3 Meter Transonic Cryogenic Tunnel. Subsequently, an effort was undertaken to investigate the mechanisms that could cause model warpage during cryogenic testing. The two basic mechanisms that can lead to warpage are (1) metallurgical structural instability in which one phase transforms partially or fully into a second phase which has a different crystal structure and volume, and (2) deformation due to the creation, or relief, of unbalanced induced or residual stresses. In the case of the 15-5 PH airfoils, it is highly probable that metallurgical instability was responsible for most of the observed warpage. A particular specimen configuration was established for use in the systematic evaluation of the factors influencing warpage. Preliminary studies of a specimen made of VASCOMAX 200 suggest the possibility of manipulating the stresses in the surface layers by appropriate combinations of milling and grinding steps. This opens up the possibility of correcting or establishing the required surface profile of an airfoil.

Wigley, D. A.↗
NASA NTRS2020

USM3D Analyses in Support of the NASA Langley 0.3-Meter Transonic Cryogenic Tunnel Test of Boundary-Layer Thickener Configurations

A wind tunnel test was performed in the 0.3-Meter Cryogenic Transonic Tunnel at the NASA Langley Research Center to investigate the impact of various boundary layer thickeners on the height and shape of the boundary layer on the aft portion of a semispan fuselage. The present work discusses USM3D analyses that were performed in support of the wind tunnel test. The results consisted of comparisons between USM3D and experimental data for the baseline configuration and two boundary layer thickening configurations. The comparisons considered surface pressure distributions, boundary layer profiles, and calculated boundary layer thicknesses. Additionally, a grid refinement study was performed for each of the three configurations, which illustrated general improvement in the comparisons with increasing grid refinement. Overall, the comparisons show favorable agreement between the USM3D predictions and the experimental data.

Bozeman, Michael D., Jr.↗
NASA NTRS2015

Thermal Insulation Systems Testing

This document is a handout guide to the standard thermal insulation systems testing capabilities of the Cryogenics Test Laboratory at NASA Kennedy Space Center.

Thermal materials↗