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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Dynamic Bellows for a Pulse Tube Cryocooler Application

Electrified aircraft propulsion systems will require powertrain components that are both lightweight and highly efficient. NASA’s 1.4 MW High Efficiency Megawatt Motor (HEMM) has been designed to run at 6800 RPM with >98% efficiency and 16 kW/kg, achieving low losses by incorporating a cryocooler within its rotor shaft to cool superconducting DC windings. A pulse-tube cryocooler typically contains an oscillating piston that drives acoustic waves; however, leakage around the piston reduces the efficiency of the cryocooler. A metal bellows was designed to replace the piston to allow for little to no leakage. The requirements for this bellows were extreme in terms of displacement amplitude, oscillating pressure amplitude, temperature, and frequency. It was determined that an off-the-shelf edge-welded bellows would not work for this application, so a custom bellows was designed to include full convolutions welded only on their outer diameters where the stress is lower. Several high-fatigue-strength materials were considered, including 17-4PH H900 and Aermet 100. The final bellows design includes 74 convolutions with a variable inner diameter that helps distribute and reduce the dynamic stress throughout the length rather than concentrating the high stress in one location. To test the concept, a short 10-convolution bellows with constant inner diameter was designed for testing. One short bellows test article was fabricated with the outer diameter weld, and one by 3D printing. Both will be fatigue-tested with the goal of achieving 10^7 cycles.

Bellows↗
NASA NTRS1972

Development of welded metal bellows having minimum effective diameter change

A program of analysis, design, and fabrication was conducted to develop welded metal bellows having a minimum change in effective diameter for cryogenic turbomachinery face seal applications. Linear analysis of the principle types of bellows provided identification of concepts capable of meeting basic operation requirements. For the 6-inch (.152 m) mean diameter, 1.5-inch free length bellows studied, nonlinear analysis showed that opposed and nested toroidal bellows plates stiffened by means of alternating stiffener rings were capable of maintaining constant effective diameter within 0.3% and 0.1% respectively under the operating conditions of interest. Changes in effective diameter were due principally to bellows axial deflection with pressure differential having a lesser influence. Fabrication problems associated with joining the thin bellows plates to the relatively heavy stiffener rings were encountered and precluded assembly and testing of a bellows core. Fabrication problems are summarized and recommended fabrication methods for future effort are presented.

Henschel, J. K.↗
NASA NTRS2012

Mars Science Laboratory Rover Integrated Pump Assembly Bellows Jamming Failure

The Mars Science Laboratory rover and spacecraft utilize two mechanically pumped fluid loops for heat transfer to and from the internal electronics assemblies and the Radioisotope Thermo-Electric Generator (RTG). The heat transfer fluid is Freon R-11 (CFC-11) which has a large coefficient of thermal expansion. The Freon within the heat transfer system must have a volume for safe expansion of the fluid as the system temperature rises. The device used for this function is a gas-over-liquid accumulator. The accumulator uses a metal bellows to separate the fluid and gas sections. During expansion and contraction of the fluid in the system, the bellows extends and retracts to provide the needed volume change. During final testing of a spare unit, the bellows would not extend the full distance required to provide the needed expansion volume. Increasing the fluid pressure did not loosen the jammed bellows either. No amount of stroking the bellows back and forth would get it to pass the jamming point. This type of failure, if it occurred during flight, would result in significant overpressure of the heat transfer system leading to a burst failure at some point in the system piping. A loss of the Freon fluid would soon result in a loss of the mission. The determination of the source of the jamming of the bellows was quite elusive, leading to an extensive series of tests and analyses. The testing and analyses did indicate the root cause of the failure, qualitatively. The results did not provide a set of dimensional limits for the existing hardware design that would guarantee proper operation of the accumulator. In the end, a new design was developed that relied on good engineering judgment combined with the test results to select a reliable enough solution that still met other physical constraints of the hardware, the schedule, and the rover system.

bellows↗
NASA NTRS1978

Vibration effects of the space shuttle main engine high pressure oxidizer turbopump bellows

A welded metal bellows was subjected to a series of vibration tests in a 400 psi oxygen environment to evaluate the effects of the bellows convolutes rubbing on the damper ring in the high pressure oxidizer turbopump of the space shuttle main engine. The bellows was subjected to approximately 2 million cycles at 0.007 in. double amplitude displacement during this series of tests, at a frequency of 400 Hz. Intrumentation of the test specimen revealed no significant heat buildup caused by the rubbing of the bellows convolutes on the damper ring. A final destruct test was made to determine if a fire would result if the bellows ruptured in the 400 psi oxygen environment, thus exposing a fresh metal surface. The vibration input was changed to 0.8 in. double amplitude displacement at 20 Hz to intentionally rupture the bellows. Failure occurred after 2.5 sec; no fire or heat buildup was encountered.

Harp, J. A.↗
NASA NTRS1990

Pressurized bellows flat contact heat exchanger interface

Disclosed is an interdigitated plate-type heat exchanger interface. The interface includes a modular interconnect to thermally connect a pair or pairs of plate-type heat exchangers to a second single or multiple plate-type heat exchanger. The modular interconnect comprises a series of parallel, plate-type heat exchangers arranged in pairs to form a slot therebetween. The plate-type heat exchangers of the second heat exchanger insert into the slots of the modular interconnect. Bellows are provided between the pairs of fins of the modular interconnect so that when the bellows are pressurized, they drive the plate-type heat exchangers of the modular interconnect toward one another, thus closing upon the second heat exchanger plates. Each end of the bellows has a part thereof a thin, membrane diaphragm which readily conforms to the contours of the heat exchanger plates of the modular interconnect when the bellows is pressurized. This ensures an even distribution of pressure on the heat exchangers of the modular interconnect thus creating substantially planar contact between the two heat exchangers. The effect of the interface of the present invention is to provide a dry connection between two heat exchangers whereby the rate of heat transfer can be varied by varying the pressure within the bellows.

Voss, Fred E.↗
NASA NTRS2022

Detecting Flow-Induced Vibration in Bellows

The NESC performed testing to determine if high-speed video techniques can be used to predict the onset of flow-induced vibrations (FIV) in bellows. A comprehensive test matrix was established to determine if Motion Magnification (MM) and Digital Image Correlation (DIC) can be used to determine the onset of FIV in straight and gimbaled bellows. Several of the tests were intended to determine if MM and DIC can establish the resonant frequencies of the bellows with no a priori knowledge. The results of the MM and DIC were compared with data from strain gages and microphones. Although the testing was limited to one single-ply unshielded bellows, this effort provided the proof-of-concept that MM and DIC are feasible methods for determining the onset of FIV in bellows.

Flow-induced vibration↗
NASA NTRS1971

Development of a metallic bellows expulsion device for fluorine service

A complete expulsion device was designed, fabricated, and tested in accordance with requirements specified by NASA to demonstrate the feasibility of using metallic bellows to expel liquid fluorine. Difficulties were experienced in obtaining leaktight welds at the bellows end terminals, but eventually three assemblies were successfully fabricted and cycle tested, one in LN2, two in LF2. The bellows performed well, except that they failed prematurely in LF2, apparently the result of small initiator cracks in the seam welds of the bellows.

Fearn, R. F.↗
NASA NTRS1989

Pressure-volume properties of metallic bellows

Metallic bellows are commonly used as segments of propellant feedlines for rocket-propelled vehicles to accommodate temperature-induced length variations, manufacturing tolerances, and gimbaling of the engines. These bellows sections deform radially and change volume when internal pressure varies, and the magnitude of such deformation is much higher than that for the straight, cylindrical segments of the line. The greater flexibility, or lesser stiffness, of the bellows, decreases the frequency of acoustic oscillations in the line. These acoustic oscillations are a major factor in the so-called POGO phenomena which have plagued most of the larger liquid rocket-propelled vehicles for many years. A method is developed to calculate the change in volume of a bellows due to a change in internal pressure. Results of an experiment are also presented along with a test-analysis comparison. The computer code is included.

Kiefling, Larry↗
NASA NTRS1966

Fluid damping reduces bellows seal fatigue failures

Service life of a bellows-type seal in the presence of mechanical vibration is increased by a system of interconnected bellows with intervening cavities filled with a fluid which damps the amplitude of periodic deflection of the sealing bellows. Different damping fluids are used according to environmental conditions.

Source record↗
NASA NTRS1966

Bellows joint absorbs torsional deflections in duct system

Long, thin-walled bellows compressed into a short length absorbs the same amount of torsional deflection as the same tube in full length condition and saves in cost, complexity and space. This bellows has lower torsional spring rate to absorb the bulk of the duct assembly tortional deflections, leaving the other bellows free to absorb axial and angular deflections.

Daniels, C. M.↗
NASA NTRS1970

Design and development criteria for metal bellows

Experimental research describes fluid flow and the fluid-elastic mechanism causing bellows flow excitation, and aids in design of conventional bellows liner which suppresses flow-induced vibrations. Analytical models facilitate prediction of flow excitation occurrence and estimation of severity of bellows vibrations.

Gerlach, C. R.↗
NASA NTRS1972

Analytical failure determination of flow-induced fatigue in bellows

Fatigue failure of bellows when subjected to passage of fluids at high speeds is discussed. It is assumed that flow through bellows generates sound in fluid and vibration caused by sound waves is principal contributor to failure. Effects of sound waves on bellows structure are analyzed.

Cron, R. G.↗
NASA NTRS1984

Bellows With Longitudinal Beams

Bellows assembled using two longitudinal side seams allow seam joints to be placed in axial directions of bellows. Design of particular importance in difficult situations where frequent assembly or repair required or in limited-access areas not desirable to disassemble total unit to replace one-piece bellows.

Garvin, W.↗
NASA NTRS1993

Clamshell Thermal-Expansion Bellows

Improved bellows serves as thermal-expansion joint in vacuum-jacketed cyrogenic piping system. Made of Hastelloy C-22 and fabricated in field by welding two clam-shell-like half bellows. No protective paint or maintenance needed. Design modified to fit most thin-wall bellows.

Fesmire, J.↗
NASA NTRS1994

Opposed Bellows Would Expel Contents Of Tank

Proposed storage tank contains two pairs of opposed bellows used to expel its contents. Storage and expulsion volumes of tank same as those of older version of tank equipped with single bellows. Four bellows offer greater stability. Applications include automobile cooling systems and gasoline-powered tools like chain saws and leaf blowers.

Whitaker, Willie↗
NASA NTRS1965

Metal bellows custom-fabricated from tubing

Mandrel assembly mounted in a lathe chuck is used with a forming wheel to roll-form bellows from standard sheet metal tubing. Spacers and mandrels of various sizes custom-fabricate bellows of any desired dimensions.

Source record↗