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Precision Cleaning Verification of Fluid Components by Air/Water Impingement and Total Carbon Analysis

NASA personnel at Kennedy Space Center's Material Science Laboratory have developed new environmentally sound precision cleaning and verification techniques for systems and components found at the center. This technology is required to replace existing methods traditionally employing CFC-113. The new patent-pending technique of precision cleaning verification is for large components of cryogenic fluid systems. These are stainless steel, sand cast valve bodies with internal surface areas ranging from 0.2 to 0.9 m(exp 2). Extrapolation of this technique to components of even larger sizes (by orders of magnitude) is planned. Currently, the verification process is completely manual. In the new technique, a high velocity, low volume water stream impacts the part to be verified. This process is referred to as Breathing Air/Water Impingement and forms the basis for the Impingement Verification System (IVS). The system is unique in that a gas stream is used to accelerate the water droplets to high speeds. Water is injected into the gas stream in a small, continuous amount. The air/water mixture is then passed through a converging-diverging nozzle where the gas is accelerated to supersonic velocities. These droplets impart sufficient energy to the precision cleaned surface to place non-volatile residue (NVR) contaminants into suspension in the water. The sample water is collected and its NVR level is determined by total organic carbon (TOC) analysis at 880 C. The TOC, in ppm carbon, is used to establish the NVR level. A correlation between the present gravimetric CFC-113 NVR and the IVS NVR is found from experimental sensitivity factors measured for various contaminants. The sensitivity has the units of ppm of carbon per mg-ft(exp 2) of contaminant. In this paper, the equipment is described and data are presented showing the development of the sensitivity factors from a test set including four NVR's impinged from witness plates of 0.05 to 0.75 m(exp 2).

Barile, Ronald G.↗

STS-66 Space Shuttle mission report

The primary objective of this flight was to accomplish complementary science objectives by operating the Atmospheric Laboratory for Applications and Science-3 (ATLAS-3) and the Cryogenic Infrared Spectrometers and Telescopes for the Atmosphere-Shuttle Pallet Satellite (CRISTA-SPAS). The secondary objectives of this flight were to perform the operations of the Shuttle Solar Backscatter Ultraviolet/A (SSBUV/A) payload, the Experiment of the Sun Complementing the Atlas Payload and Education-II (ESCAPE-II) payload, the Physiological and Anatomical Rodent Experiment/National Institutes of Health Rodents (PARE/NIH-R) payload, the Protein Crystal Growth-Thermal Enclosure System (PCG-TES) payload, the Protein Crystal Growth-Single Locker Thermal Enclosure System (PCG-STES), the Space Tissue/National Institutes of Health Cells STL/N -A payload, the Space Acceleration Measurement Systems (SAMS) Experiment, and Heat Pipe Performance Experiment (HPPE) payload. The 11-day plus 2 contingency day STS-66 mission was flown as planned, with no contingency days used for weather avoidance or Orbiter contingency operations. Appendix A lists the sources of data from which this report was prepared, and Appendix B defines all acronyms and abbreviations used in the report.

Fricke, Robert W., Jr.↗

A Combined Computational, Experimental, and Technology Development Approach to In-Space Laser Manufacturing Maturation at NASA Marshall Space Flight Center

In-space manufacturing (ISM) is emerging as a field vital to continued access and capabilities in the space environment. NASA Marshall Space Flight Center (MSFC) is advancing the frontier of in-space laser manufacturing (ISLM) techniques through work initially focused on maturing laser beam welding (LBW) and laser forming (LF) for use in space. Such techniques proffer the ability to assemble and join structures in space from sheet metal or other stock – extant satellites, in situ resource utilization of Lunar regolith, etc. – by forming to desired shapes and then joining via in-space welding (ISW). ISLM processes are useful for assembly, joining, modification, and repair of structures in free space and on the Lunar surface such as large observatories, antennas, trusses, blast/thermal/radiation shields, pressure vessels, and more. However, these techniques are not yet qualified & certified (Q&C) for regular application in space. It would be prohibitively expensive, laborious, and time-consuming to perform Q&C via traditional experimental approaches as data collection & experimentation in space is resource-intensive. As such, benchmark experiments and focused, properly instrumented technology demonstration efforts in space can collect sufficient data that – when combined with verified computational models in an integrated computational materials engineering (ICME) approach – can validate ICME tools capable of translating more readily obtained ground data to in-space, in situ, computationally informed Q&C of ISLM techniques. Several ISLM projects at MSFC are obtaining the data required to validate ICME tools through both ground and flight experiments. A parabolic flight experiment of LBW under vacuum is manifested for August 2024, including both microgravity and Lunar gravity profiles. This collaboration with the Ohio State University is investigating common aerospace alloys such as 316L stainless steel, 2219 aluminum alloy, and Ti64 titanium alloy. In situ data collection includes videography, thermography, and reference thermocouples to build a thermal model of the welds. This will elucidate the relevant physics when combined with post-flight microstructural examination and mechanical testing. MSFC is also progressing towards a suborbital flight experiment of LBW under vacuum, which could provide reams of data on ISW during sustained, high-quality reduced gravity. The effect of combined thermal (cryogenic and high-temperature) and vacuum exposure on both LBW (NASA-funded) and LF (DARPA-funded) is being investigated through ground experiments. In addition to the copious data collected during these ground experiments, ruggedization of LBW hardware will also be pursued. The datasets from these experiments will be used to validate computational models which will inform future ISLM efforts in an ICME framework. A variety of techniques across lengths scales, from CALPHAD-driven thermodynamics & kinetics to phase field modeling of solidification to kinetic Monte Carlo simulations of grain evolution at the mesoscale, will be employed to accelerate the infusion and eventual Q&C of LBW and LF for use in space. The development of data-driven surrogate models to bridge ground to flight experiments and thereby reduce the need for resource-intensive experiments in space will also be investigated. These ICME techniques, surrogate models, and datasets from ground testing can also be employed to advance manufacturing in terrestrial environments.

in-space welding↗

Cryogenic and Simulated Fuel Jet Breakup in Argon, Helium and Nitrogen Gas Flows

Two-phase flow atomization of liquid nitrogen jets was experimentally investigated. They were co-axially injected into high-velocity gas flows of helium, nitrogen and argon, respectively, and atomized internally inside a two-fluid fuel nozzle. Cryogenic sprays with relatively high specific surface areas were produced, i.e., ratios of surface area to volume were fairly high. This was indicated by values of reciprocal Sauter mean diameters, RSMD's, as measured with a scattered- light scanning instrument developed at NASA Lewis Research Center. Correlating expressions were derived for the three atomizing gases over a gas temperature range of 111 to 422 K. Also, the correlation was extended to include waterjet breakup data that had been previously obtained in simulating fuel jet breakup in sonic velocity gas flow. The final correlating expression included a new dimensionless molecular-scale acceleration group. It was needed to correlate RSMD data, for LN2 and H2O sprays, with the fluid properties of the liquid jets and atomizing gases used in this investigation.

Ingebo, Robert D.↗

Dynamic Response Assessment for the MEMS Accelerometer Under Severe Shock Loads

NASA Goddard Space Flight Center (GSFC) has evaluated the dynamic response of a commercial-off-the-shelf (COTS) microelectromechanical systems (MEMS) device made by Analog Device, Inc. The device is designated as ADXL250 and is designed mainly for sensing dynamic acceleration. It is also used to measure the tilting angle of any system or component from its original level position. The device has been in commercial use (e.g., in automobile airbag deployment system as a dual-axial accelerometer and in the electronic game play-station as a tilting sensor) with success, but NASA needs an in-depth assessment of its performance under severe dynamic shock environments. It was realized while planning this evaluation task that two assessments would be beneficial to NASA's missions: (1) severe dynamic shock response under nominal thermal environments; and (2) general dynamic performance under cryogenic environments. The first evaluation aims at obtaining a good understanding of its micromachined structure within a framework of brittle fracture dynamics, while the second evaluation focuses on the structure integrity under cryogenic temperature conditions. The information we gathered from the manufacturer indicated that the environmental stresses under NASA's evaluation program have been far beyond what the device has experienced with commercial applications, for which the device was designed. Thus NASA needs the outcome of this evaluation in order to make the selection for possible use for its missions. This paper provides details of the first evaluation the dynamic response under severe multi-axial single-pulse shock load. It was performed using finite element tools with nonlinear dynamics procedures.

Fan, Mark S.↗

Real-Time Modeling of Thermal Interactions in Cryogenic Ball Bearings

Based on the integration of classical differential equations of motion of bearing elements, a real-time dynamic simulation of ball bearing performance is coupled with simultaneous modeling of thermal interactions between the bearing elements. The transient heat generations are time averaged over a significantly larger time step before they are used to compute the changes in bearing temperature fields. Such an averaging algorithm eliminates the numerical difficulties associated with simultaneous integration of mechanical thermal differential equations with vastly different time scales. Under stable operation, the step change in temperatures at each thermal time step converges to a steady-state solution. Following is a list of accomplishments in the present investigation: (1) A real-time dynamic performance of both 440C and hybrid ball bearings in a LOX environment is modeled in both transient and steady-state time domains, as the inner race accelerates to a prescribed operating speed. (2) The frictional interactions at the ball to race contacts are modeled by experimentally measured traction coefficients as a function of slide-to-roll ratios. (3) Bearing heat generation, as defined by the heat transferred to circulating LOX, is validated against experimental values determined by measured LOX temperatures under prescribed pressures and flow rates. The predicted heat generation is in good agreement with the experimental values. (4) The steady-state solutions are shown to be independent of initial conditions. This establishes convergence of the numerical integration of a differential equation of motion of the bearing elements. (5) Churning and drag losses in the circulating LOX constitutes the majority of bearing heat generation under the experimental test conditions. (6) The heat dissipated in frictional interactions in hybrid bearings is significantly lower in hybrid bearings in comparison to that simulated in all-steel bearings, while the churning and drag losses are relatively unchanged.

Gupta, P. K.↗

High-acceleration mass drivers

High-acceleration mass drivers are discussed including the MD2 model of axial geometry, with individually powered drive coils of 13.1 cm diameter. Timing is derived through the interruption of light beams by the moving armature (bucket). Electric power is provided by the resonant discharge of sector capacitor banks through silicon-controlled rectifiers in a two-phase, quadrature circuit. The bucket flies in vacuum, guided by passive dynamic eddy-current magnetic forces, those currents flowing in strip conductors lining the inside of a nonconducting vacuum pipe. Quantitative measurements are obtained with a solid bucket carrying two superconducting coils with a current density of 25 kA/sq cm. A cryogenic station for cooling the bucket to liquid helium temperature is connected to the vacuum pipe.

Oneill, G. K.↗

Reciprocating Feed System Development Status

The reciprocating feed system (RFS) is an alternative means of providing high pressure propellant flow at low cost and system mass, with high fail-operational reliability. The RFS functions by storing the liquid propellants in large, low-pressure tanks and then expelling each propellant through two or three small, high-pressure tanks. Each RFS tank is sequentially filled, pressurized, expelled, vented, and refilled so as to provide a constant, or variable, mass flow rate to the engine. This type of system is much lighter than a conventional pressure fed system in part due to the greatly reduced amount of inert tank weight. The delivered payload for an RFS is superior to that of conventional pressure fed systems for conditions of high total impulse and it is competitive with turbopump systems, up to approximately 2000 psi. An advanced version of the RFS uses autogenous pressurization and thrust augmentation to achieve higher performance. In this version, the pressurization gases are combusted in a small engine, thus making the pressurization system, in effect, part of the propulsion system. The RFS appears to be much less expensive than a turbopump system, due to reduced research and development cost and hardware cost, since it is basically composed of small high- pressure tanks, a pressurization system, and control valves. A major benefit is the high reliability fail-operational mode; in the event of a failure in one of the three tank-systems, it can operate on the two remaining tanks. Other benefits include variable pressure and flow rates, ease of engine restart in micro-gravity, and enhanced propellant acquisition and control under adverse acceleration conditions. We present a system mass analysis tool that accepts user inputs for various design and mission parameters and calculates such output values payload and vehicle weights for the conventional pressure fed system, the RFS, the Autogenous Pressurization Thrust Augmentation (APTA) RFS, and turbopump systems. Using this tool, a preliminary design of a representative crew exploration vehicle (CEV) has been considered. The design parameters selected for a representative system were modeled after the orbital maneuvering system (OMS) on the Shuttle Orbiter, with an increase of roughly a factor of ten in the delta- V capability and a greater thrust (30,000 lbs, vs. 12,000 lbs). Both storable and cryogenic propellants were considered. Results show that a RFS is a low mass alternative to conventional pressure fed systems, with a substantial increase in payload capability and that it is weight-competitive with turbopump systems at low engine pressure (a few hundred psi); at high engine pressures, the APTA RFS appears to offer the highest payload. We also present the status of the RFS test bed fabrication, assembly, and checkout. This test bed is designed to provide flow rates appropriate for engines in the roughly 10,000 to 30,000 lb thrust range.

Trewek, Mary↗

A numerical solution of the Navier-Stokes equations for supercritical fluid thermodynamic analysis

An explicit numerical solution of the compressible Navier-Stokes equations is applied to the thermodynamic analysis of supercritical oxygen in the Apollo cryogenic storage system. The wave character is retained in the conservation equations which are written in the basic fluid variables for a two-dimensional Cartesian coordinate system. Control-volume cells are employed to simplify imposition of boundary conditions and to ensure strict observance of local and global conservation principles. Non-linear real-gas thermodynamic properties responsible for the pressure collapse phenomonon in supercritical fluids are represented by tabular and empirical functions relating pressure and temperature to density and internal energy. Wall boundary conditions are adjusted at one cell face to emit a prescribed mass flowrate. Scaling principles are invoked to achieve acceptable computer execution times for very low Mach number convection problems. Detailed simulations of thermal stratification and fluid mixing occurring under low acceleration in the Apollo 12 supercritical oxygen tank are presented which model the pressure decay associated with de-stratification induced by an ordinary vehicle maneuver and heater cycle operation.

Heinmiller, P. J.↗

Computational Modeling of Magnetically Actuated Propellant Orientation

Unlike terrestrial applications where gravity positions liquid at the "bottom" of the tank, the location of liquid propellant in spacecraft tanks is uncertain unless specific actions are taken or special features are built into the tank. Some mission events require knowledge of liquid position prior to a particular action: liquid must be positioned over the tank outlet prior to starting the main engines and must be moved away from the tank vent before vapor can be released overboard to reduce pressure. It may also be desirable to positively position liquid to improve propulsion system performance: moving liquid away from the tank walls will dramatically decrease the rate of heat transfer to the propellant, suppressing the boil-off rate, thereby reducing overall mission propellant requirements. The process of moving propellant to a desired position is referred to as propellant orientation or reorientation. Propulsive reorientation relies on small auxiliary thrusters to accelerate the tank. The inertia of the liquid causes it to collect in the aft-end of the tank if the acceleration is forward. Liquid Acquisition Devices (LAD's) rely on surface tension to hold the liquid within special geometries, (i.e. vanes, wire-mesh channels, start-baskets), to positively position propellants. Both of these technologies add significant weight and complexity to the spacecraft and can be limiting systems for long duration missions. The subject of the present research is an alternate technique for positively positioning liquid within spacecraft propellant tanks: magnetic fields. LOX is paramagnetic (attracted toward a magnet) and LH2 is diamagnetic (repelled from a magnet). Order-of-magnitude analyses, performed in the 1960's to determine required magnet size, concluded that the magnets would be prohibitively massive and this option has remained dormant during the intervening years. Recent advances in high-temperature superconducting materials hold the promise of electromagnets with sufficient performance to support cryogenic propellant management tasks. In late 1992, NASA MSFC began a new investigation in this technology commencing with the design of the Magnetically-Actuated Propellant Orientation (MAPO) experiment. A mixture of ferrofluid and water is used to simulate the paramagnetic properties of LOX and the experiment is being flown on the KC-135 aircraft to provide a reduced gravity environment. The influence of a 0.4 Tesla ring magnet on flow into and out of a subscale Plexiglas tank is being recorded on video tape. The most efficient approach to evaluating the feasibility of MAPO is to compliment the experimental program with development of a computational tool to model the process of interest. The goal of the present research is to develop such a tool. Once confidence in its fidelity is established by comparison to data from the MAPO experiment, it can be used to assist in the design of future experiments and to study the parameter space of the process. Ultimately, it is hoped that the computational model can serve as a design tool for full-scale spacecraft applications.

Hochstein, John I.↗

Studies on Normal and Microgravity Annular Two Phase Flows

Two-phase gas-liquid flows occur in a wide variety of situations. In addition to normal gravity applications, such flows may occur in space operations such as active thermal control systems, power cycles, and storage and transfer of cryogenic fluids. Various flow patterns exhibiting characteristic spatial and temporal distribution of the two phases are observed in two-phase flows. The magnitude and orientation of gravity with respect to the flow has a strong impact on the flow patterns observed and on their boundaries. The identification of the flow pattern of a flow is somewhat subjective. The same two-phase flow (especially near a flow pattern transition boundary) may be categorized differently by different researchers. Two-phase flow patterns are somewhat simplified in microgravity, where only three flow patterns (bubble, slug and annular) have been observed. Annular flow is obtained for a wide range of gas and liquid flow rates, and it is expected to occur in many situations under microgravity conditions. Slug flow needs to be avoided, because vibrations caused by slugs result in unwanted accelerations. Therefore, it is important to be able to accurately predict the flow pattern which exists under given operating conditions. It is known that the wavy liquid film in annular flow has a profound influence on the transfer of momentum and heat between the phases. Thus, an understanding of the characteristics of the wavy film is essential for developing accurate correlations. In this work, we review our recent results on flow pattern transitions and wavy films in microgravity.

Balakotaiah, V.↗

NASA Tech Briefs, June 2005

Topics covered include: Apparatus Characterizes Transient Voltages in Real Time; Measuring Humidity in Sealed Glass Encasements; Adaptable System for Vehicle Health and Usage Monitoring; Miniature Focusing Time-of-Flight Mass Spectrometer; Cryogenic High-Sensitivity Magnetometer; Wheel Electrometer System; Carbon-Nanotube Conductive Layers for Thin-Film Solar Cells; Patch Antenna Fed via Unequal-Crossed-Arm Aperture; LC Circuits for Diagnosing Embedded Piezoelectric Devices; Nanowire Thermoelectric Devices; Code for Analyzing and Designing Spacecraft Power System Radiators; Decision Support for Emergency Operations Centers; NASA Records Database; Real-Time Principal- Component Analysis; Fuzzy/Neural Software Estimates Costs of Rocket- Engine Tests; Multicomponent, Rare-Earth-Doped Thermal-Barrier Coatings; Reactive Additives for Phenylethynyl-Containing Resins; Improved Gear Shapes for Face Worm Gear Drives; Alternative Way of Shifting Mass to Move a Spherical Robot; Parylene C as a Sacrificial Material for Microfabrication; In Situ Electrochemical Deposition of Microscopic Wires; Improved Method of Manufacturing SiC Devices; Microwave Treatment of Prostate Cancer and Hyperplasia; Ferroelectric Devices Emit Charged Particles and Radiation; Dusty-Plasma Particle Accelerator; Frozen-Plug Technique for Liquid-Oxygen Plumbing; Shock Waves in a Bose-Einstein Condensate; Progress on a Multichannel, Dual-Mixer Stability Analyzer; Development of Carbon- Nanotube/Polymer Composites; Thermal Imaging of Earth for Accurate Pointing of Deep-Space Antennas; Modifications of a Composite-Material Combustion Chamber; Modeling and Diagnostic Software for Liquefying- Fuel Rockets; and Spacecraft Antenna Clusters for High EIRP.

Source record↗

Transition from Pool to Flow Boiling: The Effect of Reduced Gravity

Applications of boiling heat transfer in space can be found in the areas of thermal management, fluid handling and control, power systems, on-orbit storage and supply systems for cryogenic propellants and life support fluids, and for cooling of electronic packages for power systems associated with various instrumentation and control systems. Recent interest in exploration of Mars and other planets, and the concepts of in-situ resource utiliLation on Mars highlights the need to understand the effect of gravity on boiling heat transfer at gravity levels varying from 1>= g/g(sub e) >=10(exp -6). The objective of the proposed work was to develop a mechanistic understanding of nucleate boiling and critical heat flux under low and micro-gravity conditions when the velocity of the imposed flow is small. For pool boiling, the effect of reduced gravity is to stretch both the length scale as well as the time scale for the boiling process. At high flow velocities, the inertia of the liquid determines the time and the length scales and as such the gravitational acceleration plays little role. However, at low velocities and at low gravity levels both liquid inertia and buoyancy are of equal importance. At present, we have little understanding of the interacting roles of gravity and liquid inertia on the nucleate boiling process. Little data that has been reported in the literature does not have much practical value in that it can not serve as a basis for design of heat exchange components to be used in space. Both experimental and complete numerical simulations of the low velocity, low-gravity nucleate boiling process were carried out. A building block type of approach was used in that first the growth and detachment process of a single bubble and flow and heat transfer associated with the sliding motion of the bubble over the heater surface after detachment was studied. Liquid subcooling and flow velocity were varied parametrically. The experiments were conducted at 1 g(sub e), while varying the orientation of surface with respect to the gravity vector. In the laboratory experiments, holographic interferometry was used to obtain data on velocity and temperature fields associated with a bubble prior to, and after detachment and during sliding motion. A test rig for conducting experiments in the KC-135 was developed, but experiments could not be conducted due to the unavailability of the aircraft prior to completion of the project. Numerical simulations modeling the micro and macro regions of the bubble were carried out in three dimensions. The results of the experiments were used to validate analytical/numerical models.

Dhir, Vijay K.↗

An Accelerated Development, Reduced Cost Approach to Lunar/Mars Exploration Using a Modular NTR-Based Space Transportation System

The results of integrated systems and mission studies are presented which quantify the benefits and rationale for developing a common, modular lunar/Mars space transportation system (STS) based on nuclear thermal rocket (NTR) technology. At present NASA's Exploration Program Office (ExPO) is considering chemical propulsion for an 'early return to the Moon' and NTR propulsion for the more demanding Mars missions to follow. The time and cost to develop these multiple systems are expected to be significant. The Nuclear Propulsion Office (NPO) has examined a variety of lunar and Mars missions and heavy lift launch vehicle (HLLV) options in an effort to determine a 'standardized' set of engine and stage components capable of satisfying a wide range of Space Exploration Initiative (SEI) missions. By using these components in a 'building block' fashion, a variety of single and multi-engine lunar and Mars vehicles can be configured. For NASA's 'First Lunar Outpost' (FLO) mission, an expendable NTR stage powered by two 50 klbf engines can deliver approximately 96 metric tons (t) to translunar injection (TLI) conditions for an initial mass in low earth orbit (IMLEO) of approximately 198 t compared to 250 t for a cryogenic chemical TLI stage. The NTR stage liquid hydrogen (LH2) tank has a 10 m diameter, 14.5 m length, and 66 t LH2 capacity. The NTR utilizes a UC-ZrC-graphite 'composite' fuel with a specific impulse (Isp) capability of approximately 900 s and an engine thrust-to-weight ratio of approximately 4.3. By extending the size and LH2 capacity of the lunar NTR stage to approximately 20 m and 96 t, respectively, a single launch Mars cargo vehicle capable of delivering approximately 50 t of surface payload is possible. Three 50 klbf NTR engines and the two standardized LH2 tank sizes developed for lunar and Mars cargo vehicle applications would be used to configure the Mars piloted vehicle for a mission as early as 2010. The paper describes the features of the 'common' NTR-based moon/Mars STS, examines performance sensitivities resulting from different 'mission mode' assumptions, and quantifies potential schedule and cost benefits resulting from this modular moon/Mars NTR vehicle approach.

Borowski, S.↗

Cryogenic On-Orbit Liquid Depot Storage, Acquisition, and Transfer Satellite (COLD-SAT)

The Cryogenic On-Orbit Liquid Depot Storage, Acquisition, and Transfer Satellite (COLD-SAT) will perform subcritical liquid hydrogen handling experiments under low gravity conditions to provide engineering data for future space transportation missions. Comprising the four Class 1 enabling experiments are tank press control, tank chilldown, tank no-vent fill, and liquid acquisition device fill/refill. The nine Class 2 enhancing experiments are tanker thermal performance, pressurization, low-gravity setting and outflow, liquid acquisition device performance, transfer line chilldown, outflow subcooling, low-gravity vented fill, fluid dumping, and advanced instrumentation. Consisting of an experiment module mated to a spacecraft bus, COLD-SAT will be placed in an initial 1300 km circular orbit by an Atlas commercial launch vehicle, and will perform experiments in a semi-autonomous mode for a period of up to six months. The three-axis controlled spacecraft bus provides electric power, control and data management, communications, and attitude control along with propulsive acceleration levels ranging from 10(exp -6) to 10(exp -4) g. It is desired to understand the effects that low acceleration levels might have on the heat and mass transfer processes involved in some of the experiments. The experiment module contains the three liquid hydrogen tanks, valves, pressurization and pumping equipment, and instrumentation. Within the highly insulated tanks are specialized fluid management equipment that might be used in future space transportation systems. At launch all the liquid hydrogen for the experiments is contained in the largest tank, which has helium-purged insulation to prevent cryo-pumping of air on the launch pad. The tank is loaded by the hydrogen tanking system used for the Centaur upper stage of the Atlas. After reaching orbit the two smaller tanks become receivers for fluid transfers, and when tanked, become the vessels for performing many of the experiments.

Schuster, John R.↗

A Flexible Multibody Approach to Space Launch System Liftoff Pad Separation with Umbilical Disconnect

A flexible multibody dynamic framework is applied to the Space Launch System (SLS) liftoff Coupled Loads Analysis (CLA), enabling computational efficiencies and systematic inclusion of components and various nonlinearities. The objective of this work is to simulate the SLS liftoff transient pad separation event inclusive of umbilical disconnects. The vehicle stacking preloads and cryogenically induced preloads, due to the fueling of the Core Stage (CS), are integrated via specialized deformed coupling procedure to ensure full capture of the liftoff transient event. The Vehicle Stabilizer System (VSS) hydraulic struts are nonlinear and provide amplitude dependent damping, significantly contributing to the liftoff transient event. Ground Extensible Columns (EC) provide additional stiffness and preloads on the Mobile Launcher (ML), also significantly contributing to the liftoff transient. An advanced Henkel-Mar algorithm, with separation and re-contact, thus tracking the potential post separation re-contact between the booster aft skirt and ML, the umbilicals and vehicle, and ground EC separation. For this system level nonlinear dynamic simulation, the flexible multibody framework provides a systematic approach for the addition of component specific algorithms to enforce nonlinearities. This multibody framework is similar to an object-oriented programming language integrating classes of associated subroutines. As such, the complexities associated with the nonlinear CLA are greatly reduced, facilitating simplified bookkeeping as well as accelerating the execution of the nonlinear time-domain simulations.

Joel W Sills Jr.↗

Progress on the James Webb Space Telescope

I will describe the scientific program anticipated for the James Webb Space Telescope and the progress in its construction. When the JWST was conceived in 1995 it was expected to make its greatest contributions in the study of the first objects to form after the Big Bang, in the evolution of galaxies, and in the formation and evolution of stars and planetary systems. Since then, the age-distance-redshift relation has become clear with the precise measurement of the Hubble constant, the discovery of the accelerating universe, and the remarkable agreement of CMBR calculations with direct measurements of the large-scale structure. So what is left and what has changed? Galaxy formation and growth is still mysterious, star formation is still hidden, the dark matter and dark energy are still unobservable, and the tools at hand may or may not help enough. But the JWST, as a general-purpose observatory, will be available for imaginative use, and is just what Simon White's polemic seems to request. As an example, the JWST should be quite capable of observing transiting exoplanets with remarkable precision, even though there was no requirement to do so, and its coronagraphs will be very good even without a monolithic primary mirror. The JWST mission has now been officially approved by NASA and is in the Federal budget. It is planned for launch in 2014. Flight instruments will begin to arrive at Goddard in mid-2010, and the first flight mirror segments have already passed their first cryogenic tests. The flight detectors have been selected and have remarkable performance; for example, the near IR detectors have dark currents of the order of 10 electrons per pixel per hour.

Mather, John C.↗

Evaluation of a hybrid hydrostatic bearing for cryogenic turbopump application

A hybrid hydrostatic bearing was designed to operate in liquid hydrogen at speeds to 80,000 rpm and radial loads to 440 n (100 lbf). The bearing assembly consisted of a pair of 20-mm angular-contact ball bearings encased in a journal, which was in turn supported by a fluid film of liquid hydrogen. The size and operating conditions of the bearing were selected to be compatible with the operating requirements of an advanced technology turbopump. Several test parameters were varied to characterize the bearing's steady-state operation. The rotation of the tester shaft was varied between 0 and 80,000 rpm. Bearing inlet fluid pressure was varied between 2.07 and 4.48 MPa (300 and 650 psia), while the fluid sump pressure was independently varied between 0.34 and 2.07 MPa (50 and 300 psia). The maximum radial load applied to the bearing was 440 N (110 lbf). Measured hybrid-hydrostatic-bearing stiffness was 1.5 times greater than predicted, while the fluid flow rate through the bearing was 35 to 65 percent less than predicted. Under two-phase fluid conditions, the stiffness was even greater and the flow rate was less. The optimal pressure ratio for the bearing should be between 0.2 and 0.55 depending on the balance desired between bearing efficiency and stiffness. Startup and shutdown cyclic tests were conducted to demonstrate the ability of the hybrid-hydrostatic-bearing assembly to survive at least a 300-firing-duty cycle. For a typical cycle, the shaft was accelerated to 50,000 rpm in 1.8 sec. The bearing operated for 337 start-stop cycles without failure.

Spica, P. W.↗