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Comparison of Cryogenic Flow Boiling in Liquid Nitrogen and Liquid Hydrogen Chilldown Experiments

This paper presents a comparison between experimental results from recent liquid hydrogen (LH 2 ) transfer line chilldown experiments at high Reynolds (Re) numbers versus liquid nitrogen (LN 2 ) experiments conducted at low Re numbers. Parasitic heat leak, inner wall temperatures, inner wall heat fluxes, and heat transfer coefficients are computed to compare between the two systems. Analysis of temperature traces and flow visualization indicates that the chilldown process evolves much more rapidly at higher Re numbers due to a quick transition from vapor flow to annular liquid flow and near immediate liquid contact along the pipe walls. The lower kinematic viscosity and surface tension of LH 2 , along with reduced parasitic heat leak and higher Re numbers relative to the LN 2 experiments, causes chilldown to proceed almost immediately into the nucleate boiling regime, in comparison to low Re flows where >75% of the chilldown is spent in vapor film boiling.

Cryogenic Heat Transfer Coefficient

Test Data Analysis of the Thermodynamic Vent System-Augmented Top Spray Injector Liquid Nitrogen Transfer Experiments

Traditionally, a cryogenic tank must be pre-chilled to some “target” temperature before the main vent valve can be closed to attempt a non-vented fill (NVF) of cryogenic liquid propellant. This methodology is particularly attractive for performing in-space transfer of cryogens due to the unknown location of the liquid/vapor interface in microgravity and the high likelihood of venting liquid if the vent valve is opened during transfer. This paper presents in-depth test data analysis of a Thermodynamic Vent System (TVS) augmented injector used for cryogenic tank chilldown and fill experiments of a thin-walled Titanium tank. Eight tests were conducted using liquid nitrogen across a range of inlet conditions and boundary conditions, and three different chilldown/fill methods. For four of the tests, the injector sprays liquid into the tank as normal, but also uses a TVS heat exchanger to cool the metallic injector itself as well as the main incoming liquid stream. Results show that using the TVS augmented injector simplifies transfer operation via enhanced condensation at the injector surface at the cost of sacrificing only a small amount of propellant.

Thermodynamic Vent System

Rewet Temperature Correlations for Liquid-Nitrogen Boiling Pipe Flows Across Varying Flow Conditions and Orientations

In many convective liquid-vapor phase change heat transfer engineering applications, cryogenic fluids are widely used in industrial processes, spacecraft and cryosurgery systems, and so on. For example, cryogens are usually used as liquid fuels such as liquid hydrogen and oxygen in the rocket industry, liquid nitrogen (LN2) and helium are frequently used to cool superconducting magnetic device for medical applications. In these systems, proper transport, handling, and storage of cryogenic fluids are of extreme importance. Among all the cryogenic transport processes performed in room temperatures, quenching, also termed chilldown, is a unavoidable initial, transient phase-change heat transfer process that brings the system down to the cryogenic condition. The Leidenfrost temperature or rewet temperature that signals the end of film boiling is practically considered the completion point of a quenching process. Therefore, rewet temperature has been considered the most important parameter for the engineering design of cryogenic thermal management systems. As most of the previous correlations for predicting the Leidenfrost temperature and the rewet temperature have been basically developed for water, they are shown to disagree with recent liquid nitrogen pipe chilldown experiments in upward and downward flow directions over a wide range of flow rates, pressures, and degrees of inlet subcooling. In addition to a complete review of the literature, two new correlations are presented in this work, one based on bubble growth and another based on the theoretical maximum limit of superheat. Each correlation performs well over the entire data set.

liquid nitrogen

Experimental Effervescence and Freezing Point Depression Measurements of Nitrogen in Liquid Methane-Ethane Mixtures

NASA is designing an unmanned submarine to explore the depths of the hydrocarbon-rich seas on Saturn’s moon Titan. Data from Cassini indicates that the Titan north polar environment sustains stable seas of variable concentrations of ethane, methane, and nitrogen, with a surface temperature near 93 K. The submarine must operate autonomously, study atmosphere/sea exchange, interact with the seabed, hover at the surface or any depth within the sea, and be capable of tolerating variable hydrocarbon compositions. Currently, the main thermal design concern is the effect of effervescence on submarine operation, which affects the ballast system, science instruments, and propellers. Twelve effervescence measurements on various liquid methane-ethane compositions with dissolved gaseous nitrogen are thus presented from 1.5 bar to 4.5 bar at temperatures from 92 K to 96 K to simulate the conditions of the seas. After conducting effervescence measurements, two freezing point depression measurements were conducted. The freezing liquid line was depressed more than 15 K below the triple point temperatures of pure ethane (90.4 K) and pure methane (90.7 K). Experimental effervescence measurements will be used to compare directly with effervescence modeling to determine if changes are required in the design of the thermal management system as well as the propellers.

Freezing Point Depression

Decoupling Surface Topography from Gravitational Acceleration in Cryogenic Pool Boiling

Boiling heat transfer is governed by a complex interplay between surface conditions and gravitational acceleration. To isolate the sole effects of gravity, we investigated the pool boiling characteristics of liquid nitrogen on atomically smooth silicon dioxide (SiO 2 ) surfaces under terrestrial (1-g) and reduced gravity (0±0.02 g) conditions achieved via parabolic flight. Our results quantify a drastic reduction in the critical heat flux (CHF) in reduced gravity, decreasing from 16.15 W/cm 2 at 1-g to 5−6 W/cm 2 at μ-g due to the suppression of buoyancy. Conversely, we observed a distinct increase in the heat transfer coefficient (HTC) in the reduced gravity condition prior to CHF. By utilizing a surface with a maximum peak-to-valley height of ≈36.7 nm and low contact angle hysteresis (<10°), we confirm this HTC enhancement is an intrinsic response to the gravitational environment, decoupled from surface-defect-induced nucleation. These findings demonstrate that the influence of surface topography is significantly more prominent in reduced gravity than in terrestrial conditions, providing a critical baseline for rationalizing the design of cryogenic thermal management systems in space and quantum applications.

Liquid nitrogen

Numerical Predictions of the Flow and Heat Transfer Characteristics in the Film Boiling Regime During Tube Quenching

Cryogenic fluid management plays a major role in refueling of spacecrafts while in space for NASA’s future human space exploration missions. Due to the low boiling points of cryogens, storage, transport and handling of these fluids becomes difficult and may result in inefficient operation of the space propulsion systems. For refueling applications in space, the cryogenic fluids have to be transported across different locations and hence, the transfer of cryogenic fluids through pipes become critical. The cryogenic chill-down process is characterized by different regimes of flow boiling, viz., film boiling, transition boiling and nucleate boiling. The prediction of these regimes in a single CFD framework available in the literature is challenging and the present work attempts to address this challenge by initially modeling the film boiling regime accurately and to incorporate an user-defined function for transition and nucleate boiling at a later stage. Hence, the aim of the present work is to numerically model and validate the film boiling regime of the chilldown curve for liquid nitrogen experiments available in the literature. The validations are carried out at different inlet mass fluxes to have a robust simulation methodology. A dispersed mixture model is used to predict the vapor-liquid interface dynamics with the phase change phenomena modeled using the Lee model.

line chilldown

Cryogenic Spray Quenching of A Simulated Propellant Storage Tank Wall With Heat Transfer Enhancement By A Thin-Film Coating and Flow Pulsing in Microgravity

Human space exploration to the Moon, Mars, and possibly asteroids is NASA’s biggest challenge for the new millennium. One of the critical elements to this mission is the effective, sufficient, and reliable supply of cryogenic propellant fluids. Future lower-earth-orbiting (LEO) propellant fuel depots and human-carrying orbital transfer spacecraft flying to the moon and Mars will have to utilize the high thrust and high efficiency of liquid cryogenic chemical propulsion or nuclear thermal propulsion. Efficient in-space tank-to-tank propellant transfer (propellant fuel depot to orbital transfer spacecraft) of cryogenic propellants is an enabling technology for the planned Crewed Mars Surface Mission. The transfer of cryogenic propellants in space, however, has yet to be accomplished, solely due to the unavailability of cryogenic quenching heat transfer data during chilldown (quenching) and filling of the propellant receiver tank in reduced gravity and microgravity as liquid propellant cannot be stored in a required liquid state until the tank is quenched down to the liquid temperature. Therefore, highly energy efficient thermal-fluid management breakthrough concepts to conserve and minimize the cryogen consumption during propellant transfer have become the focus of research and engineering development, especially for the deep-space mission to Mars. In this paper, we introduce such concepts and demonstrate their feasibility for cryogenic storage tank chilldown in parabolic flights under a simulated space microgravity condition. In order to maximize the storage tank chilldown efficiency for the least amount of cryogen consumption, the technology adopted included cryogenic spray cooling, Teflon thin-film coating of the simulated tank surface, and spray flow pulsing. The completed flight experiments successfully demonstrated that spray cooling is the most efficient cooling method for the tank chilldown in microgravity. In microgravity, Teflon coating alone can improve the efficiency up to 72% and the efficiency can be improved up to 59% by flow pulsing alone. However, Teflon coating together with flow pulsing was found to substantially enhance the chilldown efficiency in microgravity for up to 113%.

spray

Cryogenic Flow Boiling in Microgravity: Effects of Reduced Gravity on Two-Phase Fluid Physics and Heat Transfer

With the growing interest in space exploration, cryogenic technologies involving two-phase flow and heat transfer are in high demand to successfully procure advanced space applications such as fuel depots and nuclear thermal propulsion (NTP) systems for deep space missions. However, the unique and extreme thermal properties of cryogenic fluids introduce distinct flow boiling fluid physics and energy transport phenomena, which differ significantly from those observed with conventional fluids. Understanding the unique two-phase physics in cryogenic flow boiling remains an ongoing challenge. Furthermore, the lack of readily available microgravity cryogenic steady-state heat transfer data hinders the assessment of gravitational effects on cryogenic flow boiling. This study aims to elucidate the gravitational effects on two-phase fluid physics and heat transfer by conducting the first-ever experimental measurement of cryogenic flow boiling performance using a steady-state heated method in a reduced gravity environment. Parabolic flight experiments were performed to acquire both heat transfer measurements and high-speed video of interfacial behaviors, under varying gravity levels (microgravity, hypergravity, Lunar gravity, and Martian gravity). The experiments involved flow boiling of liquid nitrogen (LN 2 ) with a near-saturated inlet along a circular heated tube of dimensions 8.5-mm inner diameter and 680-mm heated length. The operating parameters varied are mass velocity of 398.3 - 1342.8 kg/m2s, inlet quality of -0.08 to -0.01, and inlet pressure of 413.68 - 689.48 kPa. Captured microgravity flow patterns range from bubbly to annular, all having vapor structures that are larger than those under higher gravity levels. Under microgravity, absence of buoyancy yields symmetrical vapor structures without flow stratification, laying a physical foundation for the distinct two-phase heat transfer trends during LN 2 flow boiling in microgravity. Transient data collected during the flight parabolas exhibited decreasing heated wall temperature as the aircraft transitioned from hypergravity to microgravity phases. The temperature variation indicated an enhancement in flow boiling heat transfer with decreasing gravity levels and a reduction with increasing gravity levels. The effect of reduced gravity on cryogenic flow boiling heat transfer coefficient (HTC) is discussed based on steady state heat transfer analysis. Seminal HTC correlations are evaluated against the measured microgravity HTC data, of which one is identified for superior accuracy in predicting microgravity data. Finally, a new HTC correlation is proposed to improve accuracy of microgravity predictions, yet there still exists room for further improvement with future terrestrial flow boiling experiments at different flow orientations relative to Earth gravity.

Microgravity

Cryogenic Mixed Mode I – Mode II Fracture Toughness of Various Polymer Composite Materials

The present study investigates the mixed mode interlaminar fracture toughness of six polymer matrix composite materials at both room temperature and cryogenic liquid nitrogen temperature. The single leg bending test employed gives a mix of Mode I (opening) and Mode II (in-plane shearing) cracking. The tested thermoplastic-matrix composites were shown to have total mixed mode toughnesses 3.1–4.3 times higher than those of representative thermoset resin composites.

Carbon fiber

Artemis I Orion ESM Propulsion System Engine Performance

NASA's Orion spacecraft transports humans and cargo into cislunar space for the Artemis program. The European Service Module (ESM), supplied by ESA and its European industry partners, provides Orion with power and in-space propulsion. The Orion-ESM propulsion system is a bipropellant hypergolic propulsion system using monomethyl hydrazine (MMH) and nitrogen tetroxide (MON-3). Primary translational propulsion is provided by the Orbital Maneuvering System Engine(OMS-E), with backup translational propulsion provided by eight Auxiliary thrusters (AUX). Attitude control and small translational maneuvers are provided by twenty four Reaction Control System (RCS) engines. The 2022 Artemis I mission was the first integrated flight test of the Orion-ESM spacecraft and its propulsion system. The OMS-E used on Artemis I was a refurbished Space Shuttle OMS-E that previously flew on nineteen missions ranging from STS-41G in 1984 to STS-112 in 2002. The Auxiliary engines are modified Aerojet Rocketdyne R4D-11 engines produced specifically for the Orion program. The RCS engines are Ariane Group engines originally used for the Automated Transfer Vehicle (ATV) program. This paper will discuss the unique operational requirements for each engine on Orion and the development and qualification effort sat both the engine and system-level that were completed to enable a successful Artemis I mission. Next the paper will evaluate the in-flight performance of the engines during the Artemis I mission showing nominal performance as expected. Additionally, comparisons to models will be presented showing very good correlation. Finally, the paper will address the plan for the engines on future Orion missions and the evolution of the system operation.

Liquid Propulsion Systems

Artemis I Orion ESM Propulsion System Engine Performance

NASA's Orion spacecraft transports humans and cargo into cislunar space for the Artemis program. The European Service Module (ESM), supplied by ESA and its European industry partners, provides Orion with power and in-space propulsion. The Orion-ESM propulsion system is a bipropellant hypergolic propulsion system using monomethyl hydrazine (MMH) and nitrogen tetroxide (MON-3). Primary translational propulsion is provided by the Orbital Maneuvering System Engine(OMS-E), with backup translational propulsion provided by eight Auxiliary thrusters (AUX). Attitude control and small translational maneuvers are provided by twenty four Reaction Control System (RCS) engines. The 2022 Artemis I mission was the first integrated flight test of the Orion-ESM spacecraft and its propulsion system. The OMS-E used on Artemis I was a refurbished Space Shuttle OMS-E that previously flew on nineteen missions ranging from STS-41G in 1984 to STS-112 in 2002. The Auxiliary engines are modified Aerojet Rocketdyne R4D-11 engines produced specifically for the Orion program. The RCS engines are Ariane Group engines originally used for the Automated Transfer Vehicle (ATV) program. This paper will discuss the unique operational requirements for each engine on Orion and the development and qualification effort sat both the engine and system-level that were completed to enable a successful Artemis I mission. Next the paper will evaluate the in-flight performance of the engines during the Artemis I mission showing nominal performance as expected. Additionally, comparisons to models will be presented showing very good correlation. Finally, the paper will address the plan for the engines on future Orion missions and the evolution of the system operation.

Reuse

Thermal Performance of Common Bulk-Fill Cryogenic Insulation Materials in Helium and Hydrogen Background Gases

Maritime shipping of vast quantities of liquid hydrogen (LH 2 ) will be necessary to facilitate a global hydrogen ecosystem; with some studies estimating volumes up to 172,000 m 3 for individual tanker ships, and requiring stationary storage tanks at terminals of 50,000 m 3 to 100,000 m 3 —ten to fifteen times larger than the current largest tank, located at launch pad B at NASA Kennedy Space Center (KSC). Such a radical scale-up will push the boundary of traditional, vacuum-insulated tank designs. Hence, a potential need exists for non-vacuum solutions, which necessitates exploring the thermal performance of insulation materials in non-condensable background gasses at LH 2 temperatures, namely helium and hydrogen. Testing of two bulk-fill insulation materials common to large LH 2 storage tanks, perlite and glass bubbles, in helium and hydrogen was recently conducted by the Cryogenics Test Laboratory at KSC using the Cryostat-100 liquid nitrogen boiloff calorimeter per the ASTM C1774 standard methodology. Effective thermal conductivity (k e ) and heat flux (q) results for each insulation/gas combination are presented across the full vacuum range, as well as thermal profiles through the insulation thickness between 78 K and 293 K.

A M Swanger

On the isotopic signature of recent solar-wind nitrogen

One of the most intriguing discoveries yielded by the Apollo samples was evidence pointing towards a significant long-term change in the composition of the sun. Such a change, of the size inferred from the lunar sample data, is inconsistent with present theories of solar evolution. Consequently, there is much interest in exploring this phenomenon as closely as possible, to determine exactly what compositional changes have taken place and whether those changes really did take place in the sun, or whether the cause lies elsewhere. The reason why we can use the moon to analyze the elements in the sun is that the sun emits a stream of ions, known as the solar wind, whose composition, on average, is believed to be the same as that in the surface regions of the sun. When the solar-wind ions hit the surface of the moon, many of them penetrate a short distance into the dust grains lying on the lunar surface. Thus, after a grain has sat on the lunar surface for a while, it has a rim of material that is partly lunar and partly solar in composition. For most chemical elements, the difference between lunar and solar composition is so sufficiently small that the solar elements cannot be detected, but for a handful of elements that are missing from the moon, their solar 'signature' can be observed in samples of lunar soil brought back by the astronauts. Among those elements is nitrogen, the most common element in the air we breathe, but very rare indeed on the moon. Our analytical techniques are not sophisticated enough yet to enable us to analyze individual lunar soil grains for nitrogen, much less to zero in on just the nitrogen in the surface of such a grain. Consequently we are forced to analyze samples consisting of many different grains, each of which could have experienced its own individual history. This makes it difficult to identify the nitrogen implanted in grain surfaces, and also to define the age of a sample.

Kim, Y.

Heat Transfer Enhancement in Cryogenic Quenching Process

This paper reports a heat transfer advancement in the cryogenic quenching process. An experiment was performed to evaluate the enhancement of quenching heat transfer by the use of metal tubes with low thermal conductivity coating layers. Four coating thicknesses with various coolant mass flow rates of liquid nitrogen were investigated. The results indicated that the tube inner surface coating greatly enhanced the quenching efficiency. The quenching efficiency was found to increase with increasing number of coating layers, and the efficiency also increased with decreasing mass flow rates. In general, the efficiencies cover a range between 40.6% and 80%. Comparing to the bare surface case, the percentage increase in the quenching efficiency was the minimum at 4.2% for a single coated layer at the highest flow rate and the maximum of 109.1% for four coated layers at the lowest flow rate. The coated tubes could save up to 53% in the amount of cryogen consumption.

two-phase flow

Polymer Composite Material Testing for a Cryotank Application

Composite cryotanks will play a key role in enabling the next generation of efficient aircraft. Carbon fiber reinforced polymer (CFRP) composites have the benefits of reduced weight and potentially higher structural strength compared to traditional metallic fuel tanks. A material screening study was conducted to inform material selection for liquid hydrogen (LH2) fuel storage. Three composite materials were considered because of their aerospace grade toughness, strength, and existing data to compare against. These materials were a thermoplastic low-melt polyaryletherketone (LM-PAEK)/carbon fiber (CF), thermoset/CF, and hybrid thermoset/thermoplastic polyurethane (TPU) veil/CF composite. Mechanical screening tests included tension, compression, in-plane shear (IPS), and tensile-tensile fatigue (TTF). Each material was tested at both a baseline (no liquid nitrogen/LN2 cycling) and 100 LN2-cycled conditions to determine the knockdown factor, if any, of each material when exposed to environmental loading effects in a cryotank. Results show minimal effects of the LN2-cycling compared against baseline values. The three materials behaved similarly in tension; however, the thermoplastic/CF had the highest IPS toughness. The hybrid thermoset/TPU/CF composite had the lowest IPS strength, compressive strength, and toughness. LN2-cycling had minimal effects on tensile-tensile fatigue performance of the thermoplastic/CF material. Mechanical data was captured to guide material down selection for future commercially viable hydrogen aircraft design. In its current state, there does not exist a consolidated, publicly available database for CFRP composite material performance data at cryogenic temperatures. The next step in this work is to test the thermoplastic and thermoset CFRP composites, as well as the neat resins, at LH2 relevant temperature (20 K) to capture this crucial material property data. These results are essential to inform cryotank design and modeling efforts. The process to start this next round of testing has begun. Planned mechanical tests include toughness (single-edge notched beam), tension (unidirectional and quasi-isotropic), thermal expansion, and thermal conductivity. Some tests will also be conducted at an intermediate temperature of 111 K relevant to liquid natural gas (LNG), another attractive fuel choice. The ultimate goal is to manufacture a sub-scale cryotank part that can pass relevant burst, fatigue, permeation, and thermal cycling tests. This work is a part of NASA’s Commercially viable Hydrogen Aircraft for Robust Growth in Efficiency (CHARGE) Project under the larger NASA Subsonic Vehicle Technologies and Tools (SVTT) Project.

composites

CFD Modeling of Bi-Directional PMD inside Cryogenic Propellant Tanks Onboard Parabolic Flights

Future cryogenic propulsion systems will require efficient methods with which to transfer cryogenic propellants from a depot storage tank to a customer receiver tank to minimize cost and maximize reusability. The Reduced Gravity Cryogenic Transfer project is currently developing advanced cryogenic fluid management technology and developing and validating new numerical models for three phases of transfer: line chilldown, tank chilldown, and tank fill. Additionally, multiple liquid nitrogen (LN 2 ) parabolic flight transfer rigs are being designed by universities and NASA to investigate the gravitational sensitivities that exist in these three technologies. In order to maximize the collection of low-g data during flights, it is required to extract as much (LN 2 as possible from the supply tank, despite variable gravity levels. The purpose of this paper is to present computational fluid dynamics (CFD) volume of fluid simulations of (LN 2 behavior in the supply tank onboard parabolic flights to validate the optimal design of a bi-directional propellant management device (PMD) using the commercial software FLOW-3D. A parametric study is conducted on the effects of gravity level, fill level, pore size, open area, thickness, and type of baffle on PMD performance. Based on results, the PMD as designed exceeds the targeted expulsion efficiency.

Jason Hartwig

Europa Propulsion Valve Seat Material Testing

The Europa mission and spacecraft design presented unique challenges for selection of valve seat materials that met the fluid compatibility requirements, and combined fluid compatibility and high radiation exposure level requirements. The Europa spacecraft pressurization system valves will be exposed to fully saturated propellant vapor for the duration of the mission. The effects of Nitrogen Tetroxide (NTO) and Monomethylhydrazine (MMH) propellant vapors on heritage valve seat materials, such as Vespel SP-1 and Polychlorotrifluoroethylene (PCTFE), were evaluated to determine if an alternate material is required. In liquid system applications, Teflon is the only available compatible valve seat material. Radiation exposure data for Teflon in an air or vacuum environment has been previously documented. Radiation exposure data for Teflon in an oxidizer environment such as NTO, was not available, and it was unknown whether the effects would be similar to those on air-exposed samples. Material testing was conducted by Marshall Space Flight Center (MSFC) and White Sands Test Facility (WSTF) to determine the effects of propellant vapor on heritage seat materials for pressurization valve applications, and the effects of combined radiation and NTO propellant exposure on Teflon. The results indicated that changes in heritage pressurization valve seat materials' properties rendered them unsuitable for the Europa application. The combined radiation and NTO exposure testing of Teflon produced results equivalent to combined radiation and air exposure results.

Brad M Addona

Screen Channel Liquid Acquisition Device Outflow Tests in Liquid Hydrogen

This paper presents experimental design and test results of the recently concluded 1-g inverted vertical outflow testing of two 325x2300 full scale liquid acquisition device (LAD) channels in liquid hydrogen (LH 2 ). One of the channels had a perforated plate and internal cooling from a thermodynamic vent system (TVS) to enhance performance. The LADs were mounted in a tank to simulate 1-g outflow over a wide range of LH 2 temperatures (20.3 – 24.2 K), pressures (100 – 350 kPa), and flow rates (0.010 – 0.055 kg/s). Results indicate that the breakdown point is dominated by liquid temperature, with a second order dependence on mass flow rate through the LAD. The best performance is always achieved in the coldest liquid states for both channels, consistent with bubble point theory. Higher flow rates cause the standard channel to break down relatively earlier than the TVS cooled channel. Both the internal TVS heat exchanger and subcooling the liquid in the propellant tank are shown to significantly improve LAD performance.

Fuel Depot