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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 NTRS2009

Thermal Insulation Strips Conserve Energy

Launching the space shuttle involves an interesting paradox: While the temperatures inside the shuttle s main engines climb higher than 6,000 F hot enough to boil iron for fuel, the engines use liquid hydrogen, the second coldest liquid on Earth after liquid helium. Maintained below 20 K (-423 F), the liquid hydrogen is contained in the shuttle s rust-colored external tank. The external tank also contains liquid oxygen (kept below a somewhat less chilly 90 K or -297 F) that combines with the hydrogen to create an explosive mixture that along with the shuttle s two, powdered aluminum-fueled solid rocket boosters allows the shuttle to escape Earth s gravity. The cryogenic temperatures of the main engines liquid fuel can cause ice, frost, or liquefied air to build up on the external tank and other parts of the numerous launch fueling systems, posing a possible debris risk when the ice breaks off during launch and causing difficulties in the transfer and control of these cryogenic liquid propellants. Keeping the fuel at the necessary ultra-cold temperatures while minimizing ice buildup and other safety hazards, as well as reducing the operational maintenance costs, has required NASA to explore innovative ways for providing superior thermal insulation systems. To address the challenge, the Agency turned to an insulating technology so effective that, even though it is mostly air, a thin sheet can prevent a blowtorch from igniting a match. Aerogels were invented in 1931 and demonstrate properties that make them the most extraordinary insulating materials known; a 1-inch-thick piece of aerogel provides the same insulation as layering 15 panes of glass with air pockets in between. Derived from silica, aluminum oxide, or carbon gels using a supercritical drying process - resulting in a composition of almost 99-percent air - aerogels are the world s lightest solid (among 15 other titles they hold in the Guinness World Records), can float indefinitely on water if treated to be hydrophobic, and can withstand extremely hot temperatures (from 1,100 F to 3,000 F depending on the type of aerogel) down to cryogenic levels, making this "frozen smoke" ideal for use in space. Because of its low weight and ability to withstand temperature extremes, an aerogel was even used as the space-based catcher s mitt to trap comet particles and space dust for NASA s Stardust mission, launched in 1999. All of this remarkable technology s characteristics were ideal for NASA s purposes except one: The aerogels were extremely brittle. Through a long-term partnership between Kennedy Space Center and Aspen Aerogels Inc., of Northborough, Massachusetts, researchers developed a flexible, durable form of aerogel that NASA has since used as cryogenic insulation for space shuttle launch systems. Through Aspen Aerogels, the technology has made oil pipeline insulation, extreme weather clothing, and infrared shielding for combat helicopters.

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NASA NTRS2006

Shuttle Debris Impact Tool Assessment Using the Modern Design of Experiments

Computational tools have been developed to estimate thermal and mechanical reentry loads experienced by the Space Shuttle Orbiter as the result of cavities in the Thermal Protection System (TPS). Such cavities can be caused by impact from ice or insulating foam debris shed from the External Tank (ET) on liftoff. The reentry loads depend on cavity geometry and certain Shuttle state variables, among other factors. Certain simplifying assumptions have been made in the tool development about the cavity geometry variables. For example, the cavities are all modeled as shoeboxes , with rectangular cross-sections and planar walls. So an actual cavity is typically approximated with an idealized cavity described in terms of its length, width, and depth, as well as its entry angle, exit angle, and side angles (assumed to be the same for both sides). As part of a comprehensive assessment of the uncertainty in reentry loads estimated by the debris impact assessment tools, an effort has been initiated to quantify the component of the uncertainty that is due to imperfect geometry specifications for the debris impact cavities. The approach is to compute predicted loads for a set of geometry factor combinations sufficient to develop polynomial approximations to the complex, nonparametric underlying computational models. Such polynomial models are continuous and feature estimable, continuous derivatives, conditions that facilitate the propagation of independent variable errors. As an additional benefit, once the polynomial models have been developed, they require fewer computational resources to execute than the underlying finite element and computational fluid dynamics codes, and can generate reentry loads estimates in significantly less time. This provides a practical screening capability, in which a large number of debris impact cavities can be quickly classified either as harmless, or subject to additional analysis with the more comprehensive underlying computational tools. The polynomial models also provide useful insights into the sensitivity of reentry loads to various cavity geometry variables, and reveal complex interactions among those variables that indicate how the sensitivity of one variable depends on the level of one or more other variables. For example, the effect of cavity length on certain reentry loads depends on the depth of the cavity. Such interactions are clearly displayed in the polynomial response models.

DeLoach, R.↗
NASA NTRS2006

Porous Media Approach for Modeling Closed Cell Foam

In order to minimize boil off of the liquid oxygen and liquid hydrogen and to prevent the formation of ice on its exterior surface, the Space Shuttle External Tank (ET) is insulated using various low-density, closed-cell polymeric foams. Improved analysis methods for these foam materials are needed to predict the foam structural response and to help identify the foam fracture behavior in order to help minimize foam shedding occurrences. This presentation describes a continuum based approach to modeling the foam thermo-mechanical behavior that accounts for the cellular nature of the material and explicitly addresses the effect of the internal cell gas pressure. A porous media approach is implemented in a finite element frame work to model the mechanical behavior of the closed cell foam. The ABAQUS general purpose finite element program is used to simulate the continuum behavior of the foam. The soil mechanics element is implemented to account for the cell internal pressure and its effect on the stress and strain fields. The pressure variation inside the closed cells is calculated using the ideal gas laws. The soil mechanics element is compatible with an orthotropic materials model to capture the different behavior between the rise and in-plane directions of the foam. The porous media approach is applied to model the foam thermal strain and calculate the foam effective coefficient of thermal expansion. The calculated foam coefficients of thermal expansion were able to simulate the measured thermal strain during heat up from cryogenic temperature to room temperature in vacuum. The porous media approach was applied to an insulated substrate with one inch foam and compared to a simple elastic solution without pore pressure. The porous media approach is also applied to model the foam mechanical behavior during subscale laboratory experiments. In this test, a foam layer sprayed on a metal substrate is subjected to a temperature variation while the metal substrate is stretched to simulate the structural response of the tank during operation. The thermal expansion mismatch between the foam and the metal substrate and the thermal gradient in the foam layer causes high tensile stresses near the metal/foam interface that can lead to delamination.

Ghosn, Louis J.↗
NASA NTRS2008

Using Aerogel-Based Insulation Material To Prevent Foam Loss on the Liquid-Hydrogen Intertank

Uninsulated areas on cryogenic propellant tanks and feedlines cause moisture in the air to condense or ice to form. Flange joints, bracket supports, expansion bellows, and other cavities are uninsulated by design. These areas cannot be sealed because conventional thermal insulation materials would restrict mechanical articulations. Aerogel-based thermal insulation systems are able to seal critical locations such as the liquid-oxygen (LO2) feedline bellows. A new thermal insulation system was also necessary between the intertank wall, flange, and the liquid-hydrogen (LH2) tank dome, where there is a cavity (or crevice) with an exposed 20-K surface. When nitrogen gas is used for purging within the intertank volume, it condenses on this cold surface. Some solid nitrogen may also form on the colder side of the crevice. Voids or discontinuities within the foam can pressurize and cause areas of foam to weaken and break off, reducing thermal efficiency and creating potentially dangerous debris. To prevent this foam loss, we developed a thermal insulation system using bulk-fill aerogel material and demonstrated it with a one-tenth-scale model of the LH2 intertank flange area

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NASA NTRS1989

Liquid Rocket Booster (LRB) for the Space Transportation System (STS) systems study. Appendix E: Pressure-fed booster test bed for the liquid rocket booster study

The stress analysis/structural design of the Pressure-Fed Booster Engine Test Bed using the existing F-1 Test Facility Test Stand at Huntsville, Alabama is described. The analysis has been coded and set up for solution on NASTRAN. A separate stress program was established to take the NASTRAN output and perform stress checks on the members. Joint checks and other necessary additional checks were performed by hand. The notes include a brief description of other programs which assist in reproducing and reviewing the NASTRAN results. The redesign of the test stand members and the stress analysis was performed per the A.I.S.C. Code. Loads on the stand consist of the loaded run tanks; wind loads; seismic loads; live loads consisting of snow and ice: live and dead loads of steel; and loaded pressurant bottle. In combining loads, wind loads and seismic loads were each combined with full live loads. Wind and seismic loads were not combined. No one third increase in allowables was taken for the environmental loads except at decks 147 and 214, where the increase was used when considering the stay rods, brackets and stay beams. Wind and seismic loads were considered from each of the four coordinate directions (i.e. N,S,E,W) to give eight basic conditions. The analysis was run with the pressurant tank mounted at level 125. One seismic condition was also run with the tank mounted at levels 169 and 214. No failures were noted with mounting at level 169, but extensive deck failure with mounting at level 214 (the loadsets used are included on the tape, but no detailed results are included in the package). Decking support beams at levels 147 and 214 are not included in the model. The stress program thus does not reduce strut lengths to the length between support beams (the struts are attached to the beams at intersection points) and gives stress ratios larger than one for some of the struts. The affected members were therefore checked by hand.

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NASA NTRS1987

Performance analysis of advanced spacecraft TPS

The analysis on the feasibility for using metal hydrides in the thermal protection system of cryogenic tanks in space was based on the heat capacity of ice as the phase change material (PCM). It was found that with ice the thermal protection system weight could be reduced by, at most, about 20 percent over an all LI-900 insulation. For this concept to be viable, a metal hydride with considerably more capacity than water would be required. None were found. Special metal hydrides were developed for hydrogen fuel storage applications and it may be possible to do so for the current application. Until this appears promising further effort on this feasibility study does not seem warranted.

Pitts, William C.↗
NASA NTRS2006

Structural Continuum Modeling of Space Shuttle External Tank Foam Insulation

This document is a viewgraph presentation reporting on work in modeling the foam insulation of the Space Shuttle External Tank. An analytical understanding of foam mechanics is required to design against structural failure. The Space Shuttle External Tank is covered primarily with closed cell foam to: Prevent ice, Protect structure from ascent aerodynamic and engine plume heating, and Delay break-up during re-entry. It is important that the foam does not shed unacceptable debris during ascent environment. Therefore a modeling of the foam insulation was undertaken.

Steeve, Brian↗
NASA NTRS2004

Assessment of Technologies for the Space Shuttle External Tank Thermal Protection System and Recommendations for Technology Improvement: Materials Characterization and Analysis - Part 1

The use of foam insulation on the External Tank (ET) was necessitated by the potentially hazardous build up of ice on the vehicle prior to and during launch. This use of foam was initiated on the Saturn V rocket, which, like the Space Shuttle, used cryogenic fuel. Two major types of foam have been used on the ET. The first type is NCFI 24-124, an acreage material that is automatically sprayed on in a controlled environment. It replaced CPR 488 in 1998 and has been used since that time. The other major foams, BX-250 or BX-265, are handsprayed foams that are used to close out regions where the various sections of the ET are attached. The objectives of the present report are to study the chemistries of the various foam materials and to determine how physical and mechanical anomalies might occur during the spray and curing process. To accomplish these objectives, the report is organized as follows. First, the chemistries of the raw materials will be discussed. This will be followed by a discussion of how chemistry relates to void formation. Finally, a TGA-MS will be used to help understand the various foams and how they degrade with the evolution of chemical by-products.

Weiser, Erik S.↗
NASA NTRS2008

Novel Ice Mitigation Methods

After the loss of Columbia, there was great concern in the Space Shuttle program for the impact of debris against the leading edges of the Orbiter wings. It was quickly recognized that, in addition to impacts by foam, ice that formed on the liquid-oxygen bellows running down the outside of the External Tank could break free during launch and hit this sensitive area. A Center Director s Discretionary Fund (CDDF) project would concentrate on novel ideas that were potentially applicable. The most successful of the new concepts for ice mitigation involved shape memory alloy materials. These materials can be bent into a given shape and, when heated, will return to their original shape.

Source record↗
NASA NTRS2015

Determination of Acreage Thermal Protection Foam Loss From Ice and Foam Impacts

A parametric study was conducted to establish Thermal Protection System (TPS) loss from foam and ice impact conditions similar to what might occur on the Space Launch System. This study was based upon the large amount of testing and analysis that was conducted with both ice and foam debris impacts on TPS acreage foam for the Space Shuttle Project External Tank. Test verified material models and modeling techniques that resulted from Space Shuttle related testing were utilized for this parametric study. Parameters varied include projectile mass, impact velocity and impact angle (5 degree and 10 degree impacts). The amount of TPS acreage foam loss as a result of the various impact conditions is presented.

Thermal Protection System↗
NASA NTRS1983

Structural concepts for future space transportation orbiters

Two structural concepts for a fully reusable STS orbiter are compared with respect to weight and the ability to satisfy structural goals. The cryogenic propellant tanks for both concepts use welded, blade-stiffened aluminum skins for leak-free containment and compatibility with LOX and LH2. The tanks are sized primarily by pressure, although some areas are sized by bending and fracture mechanics considerations. The tank concept is regarded as state-of-the-art, even though it requires a closed cell foam insulation with a dry air purge to prevent air liquefaction and ice formation. It is noted that the foam will require testing to verify its design life for use in the STS. One concept has nonintegral tanks suspended inside an insulated aluminum airframe and thrust structure. Here, a durable thermal protection system external insulation is mechanically attached to the airframe, allowing a buckled skin design. The other concept uses a novel structural arrangement consisting of a separate tank/thrust structure that supports a hot advanced-carbon-carbon aeroshell structure.

Taylor, A. H.↗
NASA NTRS1991

A PC-based hardware implementation of the maximum-likelihood classifier for the Shuttle Ice Detection System

A PC-based near-real time implementation of a two-channel maximum-likelihood classifier is described. The statistical distribution of the reflectance characteristics of ice, frost, and water formation on spray-on-foam-insulation, which covers the External Tank surface of the Space Shuttle, is acquired. The classification technique is based on these statistics. The computer, set in either a training or a classifying mode, learns the statistics of the various classes, or produces a color-coded image denoting the respective categories of classification. The classified results are memory-mapped for efficiency. The speed of the classification process is only limited by the speed of the digital frame grabber and the software that interfaces the frame grabber to the monitor. The process took 4 seconds for a 512 x 480 pixel image.

Jaggi, S.↗
NASA NTRS2019

Current NASA In-Situ Resource Utilization (ISRU) Strategic Vision

Perform development to TRL 5/6 through ground demonstration in relevant environment. Perform component/subscale subsystem flight demonstrations on small/mid-size landers. Assess and characterize water in volatiles in lunar polar shadowed regions and craters. Reduce risk of ISRU for mission critical consumables through Integrated End-to-End Flight Demonstrations (pilot scale). Establish initial Human Mission Scale production capability to promote sustainable operations and as anchor for commercial involvement. Identify and characterize polar region environment and resources/volatiles for Science and future Exploration/Commercial applications. Provide ground-truth physical, mineral, and water/volatile resource characteristic information at multiple locations to provide geological context for science-focused theories of volatile placement and initial mining assessments.Test technologies and processes to reduce risk of future extraction/mining systems. Quantify concentration and lateral/vertical distribution of resources/volatiles. Utilize ISRU capabilities to Extend and Enhance Human Lunar Exploration Missions. Provide oxygen (and fuel) to enable reusable human lunar lander (10+ MT/yr O2)Process carbon-based crew waste/trash into gases and propellants; can reduce logistics while minimizing public perception issues (alternative is conversion to radiation shielding). Scavenge unused propellants and hardware from spent landers. Metal extraction from regolith as feedstock for in situ and in space manufacturing demonstrations. Civil engineering and construction aimed at future outpost/infrastructure build-up. Develop and Demonstrate ISRU for Human Mars Missions. ISRU for propellant production (10-15 MT/yr); Liquefy, store, transfer, and refuel ascent vehicle. Use Moon for operational experience and mission validation for Mars: Pre-deployment & remote activation and operation without crew. Storing and transferring mission consumables Landing crew with empty tanks with ISRU propellants already made and waiting. Support/Promote Commercialization of Space. Large scale polar ice mining (100+ MT/yr water)O2/H2 propulsion for landers/cis-lunar transportation with surface and in space depots. In situ construction and energy expansion at mining and human outpost site(s). ISRU Ground Development. Develop and advance ISRU technologies to enable acquisition of resources and processing into mission consumables. Utilize Multi-center collaboration with a portfolio that includes internal NASA work, external contracts, and collaborative agreements/partnerships. Where appropriate, develop lunar ISRU components and subsystems with a Mars-forward application. Engage industry through public-private partnerships to lay the foundation for long-term lunar and space economic development. Spin-in/spin-out technologies for terrestrial applications and industry (mining, oil & gas, alternative energy, construction). Flight Demonstration Path to Operational ISRU. Utilize small demonstrations with near off-the-shelf hardware to obtain critical information quickly on lunar resources and operations. Demonstrate critical technologies and processes that interact with lunar materials and environments. Perform 'pilot plant' demonstrations at architecture relevant scales and durations to reduce the risk for ISRU-provided products for critical human mission applications.

In-situ Resource Utilization↗
NASA NTRS1998

Liquid-Vapor Interface Configurations Investigated in Low Gravity

The Interface Configuration Experiment (ICE) is part of a multifaceted study that is exploring the often striking behavior of liquid-vapor interfaces in low-gravity environments. Although the experiment was posed largely as a test of current mathematical theory, applications of the results should be manifold. In space almost every fluid system is affected, if not dominated, by capillarity (the effects of surface tension). As a result, knowledge of fluid interface behavior, in particular an equilibrium interface shape from which any analysis must begin, is fundamental--from the control of liquid fuels and oxygen in storage tanks to the design and development of inspace thermal systems, such as heat pipes and capillary pumped loops. ICE has increased, and should continue to increase, such knowledge as it probes the specific peculiarities of current theory upon which our present understanding rests. Several versions of ICE have been conducted in the drop towers at the NASA Lewis Research Center, on the space shuttles during the first and second United States Microgravity Laboratory missions (USML-1 and USML-2), and most recently aboard the Russian Mir space station. These studies focused on interfacial problems concerning the existence, uniqueness, configuration, stability, and flow characteristics of liquid-vapor interfaces. Results to date have clearly demonstrated the value of the present theory and the extent to which it can predict the behavior of capillary systems.

Concus, Paul↗
NASA NTRS2019

The World Is Not Enough (WINE) - Space Mining Robot with Steam Propulsion

The World Is Not Enough (WINE) is a concept for a new generation of spacecraft that takes advantage of In-Situ Resource Utilization (ISRU) to explore space. WINE mines to extract water from planetary regolith, capturing the water as ice in a cold trap and heating it to create steam for propulsion. By propulsively "hopping" from location to location, WINE can explore Solar System bodies as well as individual bodies (e.g. WINE could cover much greater distances on Europa or the Moon than a rover, and can reach otherwise inaccessible regions). And by refueling itself as it goes, WINE's range is not limited by consumables. This makes WINE particularly well suited to prospecting and reconnaissance missions. A prototype of WINE was designed, fabricated and tested in a large vacuum chamber. The vehicle was used to demonstrate several of the primary operations that would be required of the WINE spacecraft including: mining and heating regolith to extract water; capturing water as ice in a cold trap; reorienting the vehicle to allow for further mining; pushing captured water into a propulsion tank; and heating propellant to create steam for thrust. All systems demonstrated are fully functional. All tests are conducted with regolith simulant in a vacuum chamber.

Propulsion↗
NASA NTRS2001

New Fluid Prevents Railway Ice

Through a licensing agreement between NASA's Ames Research Center and Midwest Industrial Supply, Inc. (MIS), two MIS products have been enhanced with NASA's anti-icing fluid technology. MIS offers the new fluid in two commercial products, the Zero Gravity(TM) Third Rail Anti-Icer/Deicer and the Ice Free Switch(R). Using NASA's fluid technology, these products form a protective-coating barrier that prevents the buildup of ice and snow. Applying the fluid to the railway components prior to ice or snowstorm works as an anti-icing fluid, remaining in place to melt precipitation as it hits the surface. It also functions as a deicing fluid. If applied to an already frozen switch or rail, it will quickly melt the ice, free the frozen parts, and then remain in place to prevent refreezing. Additional benefits include the ability to cling to vertical rail surfaces and resist the effects of rain and wind. With the Ice Free Switch, it takes only five minutes to treat the switch by spraying, brushing, or pouring on the product. Ice Free Switch requires as little as one gallon per switch whereas other deicing fluids require five to ten gallons of liquid to effectively melt ice. Zero Gravity serves the same anti-icing/deicing purposes but applies fluid to the third rail through a system that is easily installed onto mass transit cars. A tank of fluid and a dispensing system are placed underneath the train car and the fluid is applied as the train runs its route.

Source record↗
NASA NTRS1977

Oil cooling system for a gas turbine engine

A gas turbine engine fuel delivery and control system is provided with means to recirculate all fuel in excess fuel control requirements back to the aircraft fuel tank. This increases the fuel pump heat sink and decreases the pump temperature rise without the addition of valving other than normally employed. A fuel/oil heat exchanger and associated circuitry is provided to maintain the hot engine oil in heat exchange relationship with the cool engine fuel. Where anti-icing of the fuel filter is required, means are provided to maintain the fuel temperature entering the filter at or above a minimum level to prevent freezing thereof. In one embodiment, a divider valve is provided to take all excess fuel from either upstream or downstream of the fuel filter and route it back to the tanks, the ratio of upstream to downstream extraction being a function of fuel pump discharge pressure.

Coffinberry, G. A.↗