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Performance, reliability, and mission duration of Apollo RCS positive expulsion propellant tank assemblies
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.
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.
This paper presents a two-phase computational fluid dynamics (CFD) model for simulating autogenous pressurization and expulsion in a cryogenic liquid hydrogen storage tank, utilizing a volume-of-fluid (VOF) approach combined with the kinetics-based Schrage equation to accurately capture the phase boundary and interfacial heat, mass, and momentum transfer between liquid and vapor phases. The model is validated against experimental data from NASA's K-site tank facility, specifically experimental case 225, which involved pressurization and controlled expulsion of liquid hydrogen. Various turbulence models are evaluated to assess their influence on model accuracy. The CFD simulations successfully replicate key thermodynamic behaviors observed during the experiments, including pressure evolution, temperature profiles, and phase-change dynamics at the vapor-liquid interface. The predicted tank pressures, temperatures, and pressurant requirements agree with experimental data, with pressurant mass predictions within 16\% of observed values. This study highlights the importance of selecting appropriate turbulence models to accurately simulate complex flow and heat transfer phenomena during tank pressurization and expulsion. By enhancing the accuracy and reliability of CFD models for liquid hydrogen under cryogenic conditions, this research contributes to developing efficient cryogenic propellant management strategies for future space missions.
This paper presents a two-phase computational fluid dynamics (CFD) model for simulating autogenous pressurization and expulsion in a cryogenic liquid hydrogen storage tank, utilizing a volume-of-fluid (VOF) approach combined with the kinetics-based Schrage equation to accurately capture the phase boundary and interfacial heat, mass, and momentum transfer between vapor and liquid phases. The model is validated against experimental data from NASA's K-site tank facility, specifically experimental case 225, which involved autogenous pressurization and controlled expulsion of liquid hydrogen. Various turbulence models are evaluated to assess their influence on model accuracy. The CFD simulations successfully replicate key thermodynamic behaviors observed during the experiments, including pressure evolution, temperature profiles, and phase-change dynamics at the vapor-liquid interface. The predicted tank pressures and temperatures agree well with experimental data, whereas the pressurant mass predictions are within 16% of observed values. This study emphasizes the importance of selecting appropriate turbulence models to accurately simulate the complex flow and heat transfer phenomena during tank autogenous pressurization and expulsion. By improving the accuracy and reliability of CFD models for these processes, this research contributes to developing efficient cryogenic propellant management strategies for future space missions.
Volatile liquid positive expulsion system with metallic expulsion diaphragms
Expulsion bladders and materials for cryogenic liquids in tests involving 70 to 126 expulsion cycles
Thermal conditioning systems for satisfying engine net positive suction pressure (NPSP) requirements, and propellant expulsion systems for achieving propellant dump during a return-to-launch site (RTLS) abort were studied for LH2/LO2 and LCH4/LO2 upper stage propellant combinations. A state-of-the-art thermal conditioning system employing helium injection beneath the liquid surface shows the lowest weight penalty for LO2 and LCH4. A technology system incorporating a thermal subcooler (heat exchanger) for engine NPSP results in the lowest weight penalty for the LH2 tank. A preliminary design of two state-of-the-art and two new technology systems indicates a weight penalty difference too small to warrant development of a LH2 thermal subcooler. Analysis results showed that the LH2/LO2 propellant expulsion system is optimized for maximum dump line diameters, whereas the LCH4/LO2 system is optimized for minimum dump line diameter (LCH4) and maximum dump line diameter (LO2). The primary uncertainty is the accurate determination of two-phase flow rates through the dump system; experimentation is not recommended because this uncertainty is not considered significant.
Slush hydrogen is currently being considered as a fuel for the National AeroSpace Plane (NASP) because it offers the potential for decreased vehicle size and weight. However, no large scale data was available on the production, transfer, and tank pressure control characteristics required to use the fuel for the NASP. Therefore, experiments were conducted at NASA-Lewis K-Site Facility to improve the slush hydrogen data base. Slush hydrogen was produced using the evaporative cooling, or freeze-thaw, technique in batches for approx. 800 gallons. This slush hydrogen was pressure transferred to a 5 ft diameter spherical test tank following production, and flow characteristics were measured during this transfer process. The slush hydrogen in the test tank was pressurized and expelled using a pressurized expulsion technique to obtain information on tank pressure control for the NASP. Results from the production, transfer, pressurization, and pressurized expulsion tests are described.
Slush hydrogen is currently being considered as a fuel for the National Aero-Space Plane (NASP) because it offers the potential for decreased vehicle size and weight. However, no large-scale data was available on the production, transfer, and tank pressure control characteristics required to use the fuel for the NASP. Therefore, experiments were conducted at the NASA Lewis Research Center K-Site Facility to improve the slush hydrogen database. Slush hydrogen was produced using the evaporative cooling, or freeze-thaw, technique in batches of about 800 gallons. This slush hydrogen was pressure transferred to a 5 ft diameter spherical test tank following production, and flow characteristics were measured during this transfer process. The slush hydrogen in the test tank was pressurized and expelled using a pressurized expulsion technique to obtain information on tank pressure control for the NASP. Results from the production, transfer, pressurization, and pressurized expulsion tests are described.
During the Shuttle launches, the solid rocket motors (SRM) occasionally experience pressure perturbations (8-13 psi) between 65-75 s into the motor burn time. The magnitudes of these perturbations are very small in comparison with the operating motor chamber pressure, which is over 600 psi during this time frame. These SRM pressure perturbations are believed to he caused primarily by the expulsion of slag (aluminum oxide). Two SRM static tests, TEM-11 and FSM-4, were instrumented extensively for the study of the phenomena associated with pressure perturbations. The test instrumentation used included nonintrusive optical and infrared diagnostics of the plume, such as high-speed photography, radiometers, and thermal image cameras. Results from all of these nonintrusive observations provide substantial circumstantial evidence to support the scenario that the pressure perturbation event in the Shuttle SRM is caused primarily by the expulsion of molten slag. In the static motor tests, the slag was also expelled preferentially near the bottom of the nozzle because of slag accumulation at the bottom of the aft end of the horizontally oriented motor.
Tests have been conducted to determine the starting characteristics of a 50,000-pound-thrust rocket engine with the conditions of a quantity of fuel lying dormant in the simulated main thrust chamber. Ignition was provided by a smaller rocket firing rearwardly along the center line. Both alcohol-water and anhydrous ammonia were used as the residual fuel. The igniter successfully expelled the maximum amount of residual fuel (3 1/2 gal) in 2.9 seconds when the igniter.was equipped with a sonic discharge nozzle operating at propellant flow rates of 3 pounds per second. Lesser amounts of residual fuel required correspondingly lower expulsion times. When the igniter was equipped with a supersonic exhaust nozzle operating at a flow of 4 pounds per second, a slightly less effective expulsion rate was encountered.