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Performance, reliability, and mission duration of Apollo RCS positive expulsion propellant tank assemblies
The SRF community has shown that high temperature annealing can improve the flux expulsion of niobium cavities during cooldown. The required temperature will vary between cavities and different batches of material, typically around 800 C and up to 1000 C. However, for niobium with a low residual resistance ratio (RRR), even 1000 C is not enough to improve its poor flux expulsion. The purpose of this study is to observe the grain growth behavior of low RRR niobium coupons subjected to high temperature annealing to identify the mechanism for improving flux expulsion in low RRR cavities. We anneal the low RRR material up to 1200 C to understand the limits of flux expulsion performance. We observe that low RRR material experiences less grain growth than high RRR when annealed at the same temperature. We search for the limitations to grain growth in low RRR material and develop a diagnostic based on grain structure to determine the appropriate recipe for good flux expulsion. The results of this study have the potential to unlock a new understanding on SRF materials and enable the next generation of high Q/high gradient surface treatments.
The fabrication of SRF cavities from sheet materials includes deep-drawing, electron beam welding, chemical and mechanical polishing, high-temperature heat treatment, and material diffusion. The performance of these cavities is frequently limited by magnetic flux trapping giving rise to additional rf loss. In this presentation, we thoroughly examine how recrystallization influences flux expulsion in SRF cavities, using cold-worked niobium sheets from various suppliers. Our findings reveal that cold-worked sheets enhance flux expulsion, especially at lower heat treatment temperatures, by promoting improved recrystallization. In particular, a traditionally fabricated Nb cavity half-cell from an annealed poly-crystalline Nb sheet after an 800 C heat treatment leads to a bi-modal microstructure that ties in with flux trapping and inefficient flux expulsion. This non-uniform microstructure is related to varying strain profiles along the cavity shape. A novel approach to prevent this non-uniform microstructure is presented by fabricating a 1.3 GHz single cell Nb cavities with a cold-worked sheet and subsequent heat treatment leading to better flux expulsion after 800 C/3h
The SRF community has shown that high temperature annealing can improve the flux expulsion of niobium cavities during cooldown. The required temperature will vary between cavities and different batches of material, typically around 800 C and up to 1000 C. However, for niobium with a low residual resistance ratio (RRR), even 1000 C is not enough to improve its poor flux expulsion. The purpose of this study is to observe the grain growth behavior of low RRR niobium coupons subjected to high temperature annealing to identify the mechanism for improving flux expulsion. We observe that low RRR material experiences less grain growth than high RRR when annealed at the same temperature. We search for the limitations to grain growth in low RRR material and develop a diagnostic based on grain structure to determine the appropriate recipe for good flux expulsion. The results of this study have the potential to unlock a new understanding on SRF materials and enable the next generation of high Q/high gradient surface treatments.
The SRF community has shown that high temperature annealing can improve the flux expulsion of niobium cavities during cooldown. The required temperature will vary between cavities and different batches of material, typically around 800 C and up to 1000 C. However, for niobium with a low residual resistance ratio (RRR), even 1000 C is not enough to improve its poor flux expulsion. The purpose of this study is to observe the grain growth behavior of low RRR niobium coupons subjected to high temperature annealing to identify the mechanism for improving flux expulsion. We observe that low RRR material experiences less grain growth than high RRR when annealed at the same temperature. We search for the limitations to grain growth in low RRR material and develop a diagnostic based on grain structure to determine the appropriate recipe for good flux expulsion. The results of this study have the potential to unlock a new understanding on SRF materials and enable the next generation of high Q/high gradient surface treatments.
The SRF community has shown that high temperature annealing can improve the flux expulsion of niobium cavities during cooldown. The required temperature will vary between cavities and different batches of material, typically around 800 C and up to 1000 C. However, for niobium with a low residual resistance ratio (RRR), even 1000 C is not enough to improve its poor flux expulsion. The purpose of this study is to observe the grain growth behavior of low RRR niobium coupons subjected to high temperature annealing to identify the mechanism for improving flux expulsion. We observe that low RRR material experiences less grain growth than high RRR when annealed at the same temperature. We search for the limitations to grain growth in low RRR material and develop a diagnostic based on grain structure to determine the appropriate recipe for good flux expulsion. The results of this study have the potential to unlock a new understanding on SRF materials and enable the next generation of high Q/high gradient surface treatments.
The SRF community has shown that high temperature annealing can improve the flux expulsion of niobium cavities during cooldown. The required temperature will vary between cavities and different batches of material, typically around 800 C and up to 1000 C. However, for niobium with a low residual resistance ratio (RRR), even 1000 C is not enough to improve its poor flux expulsion. The purpose of this study is to observe the grain growth behavior of low RRR niobium coupons subjected to high temperature annealing to identify the mechanism for improving flux expulsion. We observe that low RRR material experiences less grain growth than high RRR when annealed at the same temperature. We search for the limitations to grain growth in low RRR material and develop a diagnostic based on grain structure to determine the appropriate recipe for good flux expulsion. The results of this study have the potential to unlock a new understanding on SRF materials and enable the next generation of high Q/high gradient surface treatments.
There is no consensus on how baryon feedback shapes the underlying matter distribution from either simulations or observations. We confront the uncertain landscape by jointly analyzing new measurements of the gas distribution around groups and clusters—DESI+ACT kinetic Sunyaev–Zel’dovich (kSZ) effect profiles and eROSITA X-ray gas masses—with mean halo masses characterized by galaxy–galaxy lensing. Across a wide range of halo masses ( M 500 = 10 13−14 M ⊙ ) and redshifts (0 < z < 1), we find evidence of more efficient gas expulsion beyond several R 500 than predicted by most state-of-the-art simulations. A like-with-like comparison reveals all kSZ and X-ray observations are inconsistent with the fiducial 1 Gpc 3 hydrodynamical FLAMINGO simulation, which was calibrated to reproduce pre-eROSITA X-ray gas fractions: eROSITA X-ray gas fractions are 2 × lower than the simulation, and the kSZ measurements are combined >8σ discrepant. The FLAMINGO simulation variant with the most gas expulsion, and therefore the most suppression of the matter power spectrum relative to a dark-matter-only simulation, provides a good description of how much gas is expelled and how far it extends; the enhanced gas depletion is achieved by more powerful but less frequent AGN outbursts. Joint kSZ, X-ray, and lensing measurements form a consistent picture of gas expulsion beyond several R 500 , implying a more suppressed matter power spectrum than predicted by most recent simulations. Complementary observables (e.g., thermal Sunyaev–Zel’dovich effect and fast radio bursts) and next-generation simulations are critical to understanding the physical mechanism behind this extreme gas expulsion and mapping its impact on the large-scale matter distribution.
An experiment test series of the slush hydrogen (SLH2) project at the NASA LeRC Plum Brook K-Site Facility was completed. This testing was done as part of the characterization and technology database development on slush hydrogen required for the National Aero-Space Plane (NASP) Program. The primary objective of these experiments was to investigate tank thermodynamic parameters during the pressurized expulsion of slush hydrogen. To accomplish this, maintenance of tank pressure control was investigated during pressurized expulsion of slush hydrogen using gaseous hydrogen and gaseous helium pressurant. In addition, expulsion tests were performed using gaseous helium for initial pressurization, then gaseous hydrogen during expulsion. These tests were conducted with and without mixing of the slush hydrogen. Results from the testing included an evaluation of tank pressure control, pressurant requirements, SLH2 density change, and system mass and energy balances.
An experiment test series of the slush hydrogen (SLH2) project at the NASA LeRC Plum Brook K-Site Facility was completed. This testing was done as part of the characterization and technology database development on slush hydrogen required for the National Aero-Space Plane (NASP) Program. The primary objective of these experiments was to investigate tank thermodynamic parameters during the pressurized expulsion of slush hydrogen. To accomplish this, maintenance of tank pressure control was investigated during pressurized expulsion of slush hydrogen using gaseous hydrogen and gaseous helium pressurant. In addition, expulsion tests were performed using gaseous helium for initial pressurization, then gaseous hydrogen during expulsion. These tests were conducted with and without mixing of the slush hydrogen. Results from the testing included an evaluation of tank pressure control, pressurant requirements, SLH2 density change, and system mass and energy balances.
Experimental results are presented for pressurization and expulsion of a flightweight 4.89 cu m liquid hydrogen storage tank under normal gravity conditions. Pressurization and expulsion times were parametrically varied to study the effects of longer transfer times expected in future space flight applications. It was found that the increase in pressurant consumption with increased operational time is significant at shorter pressurization or expulsion durations and diminishes as the duration lengthens. Gas-to-wall heat transfer in the ullage was the dominant mode of energy exchange, with more than 50 percent of the pressurant energy being lost to tank wall heating in expulsions and the long duration pressurizations. Advanced data analysis will require a multidimensional approach combined with improved measurement capabilities of liquid-vapor interfacial transport phenomena.
Experimental results are presented for pressurization and expulsion of a flight-weight 4.89 cu m liquid hydrogen storage tank under normal gravity conditions. Pressurization and expulsion times are parametrically varied to study the effects of longer transfer times expected in future space flight applications. It is found that the increase in pressurant consumption with increased operational time is significant at shorter pressurization or expulsion durations and diminishes as the duration lengthens. Gas-to-wall heat transfer in the ullage is the dominant mode of energy exchange, with more than 50 percent of the pressurant energy being lost to tank wall heating in expulsions and the long duration pressurizations. Advanced data analysis will require a multidimensional approach combined with improved measurement capabilities of liquid-vapor interfacial transport phenomena.
The SRF community has shown that high temperature annealing can improve the flux expulsion of niobium cavities during cooldown. The required temperature will vary between cavities and different batches of material, typically around 800 C and up to 1000 C. However, for niobium with a low residual resistance ratio (RRR), even 1000 C is not enough to improve its poor flux expulsion. The purpose of this study is to observe the grain growth behavior of low RRR niobium coupons subjected to high temperature annealing to identify the mechanism for improving flux expulsion. We observe that low RRR material experiences less grain growth than high RRR when annealed at the same temperature. We search for the limitations to grain growth in low RRR material and develop a diagnostic based on grain structure to determine the appropriate recipe for good flux expulsion. The results of this study have the potential to unlock a new understanding on SRF materials and enable the next generation of high Q/high gradient surface treatments.
The trapped residual magnetic flux during the cool-down due to the incomplete Meissner state is a significant source of radio frequency losses in superconducting radio frequency cavities. Here, in this study, we clearly correlate the niobium microstructure in elliptical cavity geometry and flux expulsion behavior. In particular, a traditionally fabricated Nb cavity half-cell from an annealed poly-crystalline Nb sheet after an 800 °C heat treatment leads to a bi-modal microstructure that ties in with flux trapping and inefficient flux expulsion. This non-uniform microstructure is related to varying strain profiles along the cavity shape. A novel approach to prevent this non-uniform microstructure is presented by fabricating a 1.3 GHz single cell Nb cavity with a cold-worked sheet and subsequent heat treatment leading to better flux expulsion after 800 °C/3 h. Microstructural evolution by electron backscattered diffraction-orientation imaging microscopy on cavity cutouts, and flux pinning behavior by dc-magnetization on coupon samples confirms a reduction in flux pinning centers with increased heat treatment temperature. The heat treatment temperature-dependent mechanical properties and thermal conductivity are reported. The significant impact of cold work in this study demonstrates clear evidence for the importance of the microstructure required for high-performance superconducting cavities with reduced losses caused by magnetic flux trapping.
High-cycle life ring-reinforced hemispherical type positive expulsion diaphragm performance was demonstrated by room temperature fluid expulsion tests of 13" diameter, 8 mil thick stainless steel configurations. A maximum of eleven (11) leak-free, fluid expulsions were achieved by a 25 deg cone angle diaphragm hoop-reinforced with .110-inch cross-sectional diameter wires. This represents a 70% improvement in diaphragm reversal cycle life compared to results previously obtained. The reversal tests confirmed analytic predictions for diaphragm cycle life increases due to increasing values of diaphragm cone angle, radius to thickness ratio and material strain to necking capacity. Practical fabrication techniques were demonstrated for forming close-tolerance, thin corrugated shells and for obtaining closely controlled reinforcing ring stiffness required to maximize diaphragm cycle life. A non-destructive inspection technique for monitoring large local shell bending strains was developed.
Four Arde conospheroid metallic diaphragms were tested at NASA to evaluate their capability for use in the orbit adjust propulsion subsystem (OAPS) of the Atmosphere Explorer spacecraft (AE's C, D, and E). The diaphragms will be used for positive propellant expulsion and spacecraft center of mass (c.m.) control. A leak-free cycle life capability of nine reversals was demonstrated. The diaphragms rolled smoothly from ring to ring in a predictable manner on the first reversal. Varying amounts of diaphragm cocking and ring skipping were observed on subsequent reversals. The diaphragm pressure differential did not exceed 10 psid during any reversal. Cycle life capability, reversal mode, and pressure differential were not affected by sudden reversals, environmental tests, or 18,000 partial reversals. An expulsion efficiency of approximately 97 percent was demonstrated. The results of these tests show that metallic diaphragms can be used as an effective means of positive fuel expulsion; however, to achieve spacecraft c.m. control, the diaphragm must not be reversed prior to flight.
Four Arde conospheroid metallic diaphragms were tested to evaluate their capability for use in the orbit adjust propulsion subsystem (OAPS) of the Explorer spacecraft. The diaphragms will be used for positive propellant expulsion and spacecraft center of mass control. A leak-free cycle life capability of nine reversals was demonstrated. The diaphragms rolled smoothly from ring to ring in a predictable manner on the first reversal. Varying amounts of diaphragm cocking and ring skipping were observed on subsequent reversals. The diaphragm pressure differential did not exceed 7 N/sq cm during any reversal. Cycle life capability, reversal mode, and pressure differential were not affected by sudden reversals, environmental tests, or 18,000 partial reversals. An expulsion efficiency of approximately 97 percent was demonstrated. The results of these tests show that metallic diaphragms can be used as an effective means of positive fuel expulsion; however, to achieve spacecraft center of mass control, the diaphragm must not be reversed prior to flight.
A 13 psi pressure perturbation occurred at approximately 68 seconds on the right Redesigned Solid Rocket Motor (RSRM) during the STS-54 space shuttle mission. While pressure perturbations are a normal characteristic of RSRM operation, the magnitude of the STS-54 perturbation and the resulting thrust imbalance between the left and right motors was outside of flight experience. A joint Marshall Space Flight Center (MSFC) and Thiokol Corporation (RSRM manufacturer) team soon narrowed the probable cause to a temporary nozzle restriction due to slag expulsion. In support of the team, Rockwell Aerospace performed fluid finite element simulations and vehicle flight dynamic correlations to investigate possible slag expulsion mechanisms responsible for pressure perturbations. Results of the simulations and analyses provided evidence that the combination of flight induced accelerations acting on accumulated slag and nozzle vectoring were the most probable cause of RSRM slag expulsion.