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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

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NASA NTRS1975

Study of cryogenic propellant systems for loading the space shuttle. Part 2: Hydrogen systems

Computer simulation studies of liquid hydrogen fill and vent systems for the space shuttle are studied. The computer programs calculate maximum and minimum permissible flow rates during cooldown as limited by thermal stress considerations, fill line cooldown time, pressure drop, flow rates, vapor content, vent line pressure drop and vent line discharge temperature. The input data for these programs are selected through graphic displays which schematically depict the part of the system being analyzed. The computed output is also displayed in the form of printed messages and graphs. Digital readouts of graph coordinates may also be obtained. Procedures are given for operation of the graphic display unit and the associated minicomputer and timesharing computer.

Steward, W. G.↗

NASA NTRS1985

Long-life high performance fuel cell program

A multihundred kilowatt Regenerative Fuel Cell for use in a space station is envisioned. Three 0.508 sq ft (471.9 cm) active area multicell stacks were assembled and endurance tested. The long term performance stability of the platinum on carbon catalyst configuration suitability of the lightweight graphite electrolyte reservoir plate, the stability of the free standing butyl bonded potassium titanate matrix structure, and the long life potential of a hybrid polysulfone cell edge frame construction were demonstrated. A 18,000 hour demonstration test of multicell stack to a continuous cyclical load profile was conducted. A total of 12,000 cycles was completed, confirming the ability of the alkaline fuel cell to operate to a load profile simulating Regenerative Fuel Cell operation. An orbiter production hydrogen recirculation pump employed in support of the cyclical load profile test completed 13,000 hours of maintenance free operation. Laboratory endurance tests demonstrated the suitability of the butyl bonded potassium matrix, perforated nickel foil electrode substrates, and carbon ribbed substrate anode for use in the alkaline fuel cell. Corrosion testing of materials at 250 F (121.1 C) in 42% wgt. potassium identified ceria, zirconia, strontium titanate, strontium zirconate and lithium cobaltate as candidate matrix materials.

Martin, R. E.↗

NASA NTRS1990

Modeling a constant power load for nickel-hydrogen battery testing using SPICE

The effort to design and model a constant power load for the HST (Hubble Space Telescope) nickel-hydrogen battery tests is described. The constant power load was designed for three different simulations on the batteries: life cycling, reconditioning, and capacity testing. A dc-dc boost converter was designed to act as this constant power load. A boost converter design was chosen because of the low test battery voltage (4 to 6 VDC) generated and the relatively high power requirement of 60 to 70 W. The SPICE model was shown to consistently predict variations in the actual circuit as various designs were attempted. It is concluded that the confidence established in the SPICE model of the constant power load ensures its extensive utilization in future efforts to improve performance in the actual load circuit.

Bearden, Douglas B.↗

NASA NTRS2000

Marshall Space Flight Center High Speed Turbopump Bearing Test Rig

The Marshall Space Flight Center has a unique test rig that is used to test and develop rolling element bearings used in high-speed cryogenic turbopumps. The tester is unique in that it uses liquid hydrogen as the coolant for the bearings. This test rig can simulate speeds and loads experienced in the Space Shuttle Main Engine turbopumps. With internal modifications, the tester can be used for evaluating fluid film, hydrostatic, and foil bearing designs. At the present time, the test rig is configured to run two ball bearings or a ball and roller bearing, both with a hydrostatic bearing. The rig is being used to evaluate the lifetimes of hybrid bearings with silicon nitride rolling elements and steel races.

Gibson, Howard↗

NASA NTRS2004

Measuring Permeability of Composite Cryotank Laminants

This paper describes a test method developed to identify whether certain materials and material systems are suitable candidates for large pressurized reusable cryogenic tanks intended for use in current and future manned launch systems. It provides a quick way to screen numerous candidate materials for permeability under anticipated loading environments consistent with flight conditions, as well as addressing reusability issues. cryogenic tank, where the major design issue was hydrogen permeability. It was successfully used to evaluate samples subjected to biaxial loading while maintaining test temperatures near liquid hydrogen. After each sample was thermally preconditioned, a cyclic pressure load was applied to simulate the in-plane strain. First permeability was measured while a sample was under load. Then the sample was unloaded and allowed to return to ambient temperature. The test was repeated to simulate reusability, in order to evaluate its effects on material permeability.

Oliver, Stanley T.↗

NASA NTRS2020

Analysis of a 100-W Regenerative Fuel Cell Demonstration

A 100-W regenerative fuel cell (RFC) demonstration was successfully completed at the NASA Glenn Research Center on December 11, 2014. This effort was funded by Advanced Space Power Systems milestone and represented the first demonstration of passive laboratory-scale stacks arranged as an RFC, consisting of a non-flow-through fuel cell and a static-feed electrolyzer. Once developed, these stacks present the potential to minimize system mass, volume, and parasitic power in comparison to existing terrestrial electrochemical systems and nonnuclear power generation options. Testing involved the fuel cell powering a simulated load then recycling fuel cell product water by subsequently electrolyzing it to regenerate hydrogen and oxygen gases for fuel cell operations. A total of five cycles were completed over a 2-week period, yielding cell voltage data for stack performance and quality measures for regenerated reactants. Overall, round-trip efficiency was calculated to be 47.4 percent. Gas crossover was observed in electrolyzer gas products, as residual gas analysis showed 1.1 percent hydrogen in oxygen and 0.4 percent oxygen in hydrogen. Fuel cell product water was determined to be more acidic and conductive and have a higher fluoride content when compared to deionized water.

fuel cell↗

NASA NTRS1999

Lightweight Battery Charge Regulator Used to Track Solar Array Peak Power

A battery charge regulator based on the series-connected boost regulator (SCBR) technology has been developed for high-voltage spacecraft applications. The SCBR regulates the solar array power during insolation to prevent battery overcharge or undercharge conditions. It can also be used to provide regulated battery output voltage to spacecraft loads if necessary. This technology uses industry-standard dc-dc converters and a unique interconnection to provide size, weight, efficiency, fault tolerance, and modularity benefits over existing systems. The high-voltage SCBR shown in the photograph has demonstrated power densities of over 1000 watts per kilogram (W/kg). Using four 150-W dc-dc converter modules, it can process 2500 W of power at 120 Vdc with a minimum input voltage of 90 Vdc. Efficiency of the SCBR was 94 to 98 percent over the entire operational range. Internally, the unit is made of two separate SCBR s, each with its own analog control circuitry, to demonstrate the modularity of the technology. The analog controllers regulate the output current and incorporate the output voltage limit with active current sharing between the two units. They also include voltage and current telemetry, on/off control, and baseplate temperature sensors. For peak power tracking, the SCBR was connected to a LabView-based data acquisition system for telemetry and control. A digital control algorithm for tracking the peak power point of a solar array was developed using the principle of matching the source impedance with the load impedance for maximum energy transfer. The algorithm was successfully demonstrated in a simulated spacecraft electrical system at the Boeing PhantomWorks High Voltage Test Facility in Seattle, Washington. The system consists of a 42-string, high-voltage solar array simulator, a 77-cell, 80-ampere-hour (A-hr) nickel-hydrogen battery, and a constant power-load module. The SCBR and the LabView control algorithm successfully tracked the solar array peak power point through various load transients, including sunlight discharge transients when the total load exceeded the maximum solar array output power.

Soeder, James F.↗

NASA NTRS1996

Development of a Pressure Box to Evaluate Reusable-Launch-Vehicle Cryogenic-Tank Panels

A cryogenic pressure-box test machine has been designed and is being developed to test full-scale reusable launch vehicle cryogenic-tank panels. This machine is equipped with an internal pressurization system, a cryogenic cooling system, and a heating system to simulate the mechanical and thermal loading conditions that are representative of a reusable launch vehicle mission profile. The cryogenic cooling system uses liquid helium and liquid nitrogen to simulate liquid hydrogen and liquid oxygen tank internal temperatures. A quartz lamp heating system is used for heating the external surface of the test panels to simulate cryogenic-tank external surface temperatures during re-entry of the launch vehicle. The pressurization system uses gaseous helium and is designed to be controlled independently of the cooling system. The tensile loads in the axial direction of the test panel are simulated by means of hydraulic actuators and a load control system. The hoop loads in the test panel are reacted by load-calibrated turnbuckles attached to the skin and frame elements of the test panel. The load distribution in the skin and frames can be adjusted to correspond to the tank structure by using these turnbuckles. The seal between the test panel and the cryogenic pressure box is made from a reinforced Teflon material which can withstand pressures greater than 52 psig at cryogenic temperatures. Analytical results and tests on prototype test components indicate that most of the cryogenic-tank loading conditions that occur in flight can be simulated in the cryogenic pressure-box test machine.

Ambur, Damodar R.↗

NASA NTRS1996

Development of a Pressure Box to Evaluate Reusable-Launch-Vehicle Cryogenic-Tank Panels

A cryogenic pressure-box test machine has been designed and is being developed to test full-scale reusable-launch-vehicle cryogenic-tank panels. This machine is equipped with an internal pressurization system, a cryogenic cooling system, and a heating system to simulate the mechanical and thermal loading conditions that are representative of a reusable-launch-vehicle mission profile. The cryogenic cooling system uses liquid helium and liquid nitrogen to simulate liquid hydrogen and liquid oxygen tank internal temperatures. A quartz lamp heating system is used for heating the external surface of the test panels to simulate cryogenic-tank external surface temperatures during re-entry of the launch vehicle. The pressurization system uses gaseous helium and is designed to be controlled independently of the cooling system. The tensile loads in the axial direction of the test panel are simulated by means of hydraulic actuators and a load control system. The hoop loads in the test panel are reacted by load-calibrated turnbuckles attached to the skin and frame elements of the test panel. The load distribution in the skin and frames can be adjusted to correspond to the tank structure by using these turnbuckles. The seal between the test panel and the cryogenic pressure box is made from a reinforced Teflon material which can withstand pressures greater than 52 psig at cryogenic temperatures. Analytical results and tests on prototype test components indicate that most of the cryogenic-tank loading conditions that occur in flight can be simulated in the cryogenic pressure-box test machine.

Ambur, Damodar R.↗

NASA NTRS1971

Advances in cryogenic foam insulations.

Description of a discretely oriented thread-reinforced polyurethane foam thermal insulation system for liquid hydrogen fuel tanks. The 3-D foam and glass liner composite is designed to be adhesively bonded to the inside surface of the tank wall and to be in direct contact with liquid hydrogen. All elements of this insulation composite are capable of sustaining the loads and environmental conditions imposed by testing under simulated Space Shuttle vehicle requirements at temperatures between -423 and +350 F.

Lemons, C. R.↗

NASA NTRS2002

Pulse Detonation Engine Test Bed Developed

A detonation is a supersonic combustion wave. A Pulse Detonation Engine (PDE) repetitively creates a series of detonation waves to take advantage of rapid burning and high peak pressures to efficiently produce thrust. NASA Glenn Research Center's Combustion Branch has developed a PDE test bed that can reproduce the operating conditions that might be encountered in an actual engine. It allows the rapid and cost-efficient evaluation of the technical issues and technologies associated with these engines. The test bed is modular in design. It consists of various length sections of both 2- and 2.6- in. internal-diameter combustor tubes. These tubes can be bolted together to create a variety of combustor configurations. A series of bosses allow instrumentation to be inserted on the tubes. Dynamic pressure sensors and heat flux gauges have been used to characterize the performance of the test bed. The PDE test bed is designed to utilize an existing calorimeter (for heat load measurement) and windowed (for optical access) combustor sections. It uses hydrogen as the fuel, and oxygen and nitrogen are mixed to simulate air. An electronic controller is used to open the hydrogen and air valves (or a continuous flow of air is used) and to fire the spark at the appropriate times. Scheduled tests on the test bed include an evaluation of the pumping ability of the train of detonation waves for use in an ejector and an evaluation of the pollutants formed in a PDE combustor. Glenn's Combustion Branch uses the National Combustor Code (NCC) to perform numerical analyses of PDE's as well as to evaluate alternative detonative combustion devices. Pulse Detonation Engine testbed.

Breisacher, Kevin J.↗

NASA NTRSDate not supplied

Control System Development for A Zero Boil-Off Hydrogen Storage Demonstration With Two-Stage Active Cooling

A NASA team is designing and building a test article to demonstrate the long duration storage of liquid hydrogen via active cooling (cryocoolers) while implementing a two-stage cooling approach. This activity is one of a large portfolio of NASA’s Space Technology Mission Directorate funded activities which focuses on the technology maturation needed for long duration storage of cryogenic liquid in-space. The current state-of-the-art for liquid hydrogen storage on-orbit is on the order of hours while NASA’s planned missions require storage for months, or even years. To enable such a long duration, Zero Boil-Off conditions must be achieved which requires passive technologies to minimize environmental heat loads, but also active cooling to intercept and reject the remaining heat to deep space. The implementation of active cooling results in a significant amount of dry mass added to the vehicle. Utilizing a Two-Stage Cooling approach, analysis and testing to date indicates the Zero Boil-Off of liquid hydrogen can be achieved with less mass and electrical power relative to a single-stage cooling approach where only one cryocooler is used. This activity will demonstrate the fully integrated suite of technologies needed to enable the Two-Stage Cooling approach which includes Multi-Layer Insulation blankets, Low Conductivity Structures, a Tube-On-Tank Heat Exchanger, Tube-On-Shield Heat Exchanger and a Two-Stage Cryogenerator (both 90 Kelvin and 20 Kelvin) with each stage having an independently controlled circulation loop. The bulk of the heat load is intercepted by the 90 Kelvin loop via a thin foil heat exchanger internal to the insulation blankets (also known as a Broad Area Cooling Shield), with the remainder removed at cryofluid temperature (20 Kelvin) by tubes directly welded to the outer tank surface. In this paper, we examine the challenges of controlling the system, and describe the development of control algorithms and software for future testing with liquid hydrogen. The interactions between the cryofans which control circulation loop mass flow rates, electrical heaters which vary the cryocooler lift to simulate the operation of variable-lift flight units, tank heaters which can vary the overall heat load, and the effects of changes in circulation loop pressure as temperatures change, can be complex and must be well understood to maintain steady-state propellant conditions and achieve Zero Boil-Off. Parallel PID loops and watchdog programs implemented on the user interface system will help bring the systems to steady state operation and keep them at selected operating points within acceptable error, while avoiding runaway feedback loops.

cryogenics↗

NASA NTRS2000

Propellant Densification Ground Testing Conducted for Launch Vehicles

The NASA Glenn Research Center at Lewis Field has taken the lead in the development of practical densified cryogenic propellants for launch vehicle applications. The technology of subcooling cryogenic propellants below their normal boiling point to produce a denser fluid is one of the key process technologies necessary to meet the challenge of single-stage-to-orbit and reusable launch vehicles. Densified propellants are critical to lowering launch costs because they enable more propellant to be packed into a given unit volume, thus improving the performance by reducing the overall size and weight of the launch vehicle. This two-pronged research and test program has evolved into (1) conducting tank loading tests using densified liquid hydrogen and (2) developing two large-scale propellant densification systems that will be performance tested next year at Glenn. The propellant-loading test program was undertaken at Glenn in coordination with Lockheed Martin Michoud Space Systems. In this testing, the liquid hydrogen recirculation and densification process was simulated, and the thermal stratification of the densified propellant was recorded throughout the tank. The test article was a flight-weight tank constructed from composite materials similar to those to be used on the X-33 launch vehicle. The tank geometry as designed by Lockheed Martin had two cylindrical lobes with a center septum. Liquid hydrogen flow rate, pressure data, and temperature data plotted over time were collected while the subscale tank was filled with 27 R (15 K) densified liquid hydrogen propellant. This testing has validated mathematical models and demonstrated the readiness of densified propellant technology for near-term use. It marks the first time that such a process has been carried out with a multiple-lobe, flight-similar tank. Glenn researchers have also been working on providing a process and critical test data for the continuous production of densified liquid hydrogen (LH2) and densified liquid oxygen (LO2). Each densification production process uses a high-efficiency, subatmospheric boiling bath heat exchanger to cool the working fluid. A near triple-point hydrogen boiling bath is used to condition and subcool hydrogen to 27 R (15 K), and a nitrogen boiling bath is used to cool the liquid oxygen to 120 R (66.7 K). Multistage centrifugal compressors operating at cryogenic inlet conditions maintain the heat exchanger bath vapor pressure below 1 atm. The LO2 propellant densification unit shown in the photograph has a 30 lb/sec capacity, whereas the LH2 unit was designed to process 8 lb/sec of propellant. Each densification unit will be transported to Glenn's South Forty area after all fabrication work is completed sometime late next year. There the LO2 and LH2 densifier performance tests will be conducted with another larger Lockheed Martin tank designated the Structural Test Article (STA). This liquid oxygen tank is a full-scale, flight-weight, prototype aluminum tank designed for the X-33. It has a capacity of 20,000 gallons of LO2. The tank loading and recirculation testing planned for next year with STA will provide the data necessary for full-scale development of propellant densification technology.

Tomsik, Thomas M.↗

NASA NTRS1988

Thermostructural analysis of simulated cowl lips

Three dimensional finite element analyses using MSC/NASTRAN and MARC are performed to predict the thermal and structural response of various cooling schemes under high heat loads. Steady state heat transfer analyses and elastic stress analyses are performed using MSC/NASTRAN. Elastic/plastic analyses are done using MARC. To help verify these analyses experimentally, a hydrogen-oxygen rocket engine was modified to use the exhaust stream as a high enthalpy, high heat flux source to evaluate various actively cooled, simulated cowl lip (leading edges) segments as well as flat structural segments. Cross flow and parallel flow cooling configurations were tested and analyzed using cooling fluids of water and gaseous hydrogen. In addition, various material types, including high conductivity copper, nickel, and a copper and graphite metal matrix composite were tested and compared.

Melis, Matthew E.↗

NASA NTRSDate not supplied

Results of Use of Heat Flux Sensors on Liquid Hydrogen Tanks

Heat flux sensors were used to characterize the performance of insulation on the Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER), a large-scale test article designed to simulate upper stage cryogenic propellant tank thermal performance in simulated space environments. Usually, the insulation heat loads are derived from calculations removing all other heat sources and attributing the residual heat load to the insulation system. Testing for SHIIVER included the tank being just insulated with spray-on-foam insulation as well as covering the domes with multilayer insulation while leaving the barrel section insulated with spray-on-foam. Heat flux sensors were located at multiple locations on both domes as well as on the barrel section of the tank. Results from the SHIIVER testing using the heat flux sensors are compared to other calculated heat inputs for both liquid nitrogen and liquid hydrogen testing as a function of tank fill level. Further investigation into the transient nature of the SHIIVER testing including the heat flux sensors provided insight into heat flow patterns that may not have been otherwise seen using temperature sensors and calculated insulation heat loads. While the demonstrated uncertainties in the absolute values in the heat flux sensors are high, the values and the trends match well with other calculation methods. The results of SHIIVER allow for the use of heat flux sensors for measurements of insulation performance and dynamic system thermal response for future applications.

Cryogenic Fluid Management↗

NASA NTRSDate not supplied

Results of Use of Heat Flux Sensors on Liquid Hydrogen Tanks

ABSTRACT: Heat flux sensors were used to characterize the performance of insulation on the Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER), a large-scale test article designed to simulate upper stage cryogenic propellant tank thermal performance in simulated space environments. Usually, the insulation heat loads are derived from calculations removing all other heat sources and attributing the residual heat load to the insulation system. Testing for SHIIVER included the tank being just insulated with spray-on-foam insulation as well as covering the domes with multilayer insulation while leaving the barrel section insulated with spray-on-foam. Heat flux sensors were located at multiple locations on both domes as well as on the barrel section of the tank. Results from the SHIIVER testing using the heat flux sensors are compared to other calculated heat inputs for both liquid nitrogen and liquid hydrogen testing as a function of tank fill level. Further investigation into the transient nature of the SHIIVER testing including the heat flux sensors provided insight into heat flow patterns that may not have been otherwise seen using temperature sensors and calculated insulation heat loads. While the demonstrated uncertainties in the absolute values in the heat flux sensors are high, the values and the trends match well with other calculation methods. The results of SHIIVER allow for the use of heat flux sensors for measurements of insulation performance and dynamic system thermal response for future applications.

Cryogenic Fluid Management↗

NASA NTRS1994

Non-isolated 30 kW class arcjet PCU

A 30 kW class arcjet Power Conditioning Unit, PCU, was built and tested during this Phase 2 SBIR contract. The PCU is an improved version of two previously developed PCU's. All of these units are 3-phase, 20 kHz buck regulators with current mode feed back to modulate the duty cycle to control the arcjet current at any selected operating point. The steady state control can assure arcjet stability despite the negative dynamic resistance of the arc discharge. The system also has a circuit to produce a high voltage start pulse to breakdown the gas and initiate the arc. The start pulse is formed by temporarily switching a short current path across the output terminals with a special solid state switching array. The switches then open rapidly, and the energy stored in the output inductors of the buck regulator produces a pulse of approximately 2500 V for approximately 500 nsec. The system was tested and modified until the transition to steady operation occurred after start up with a very small surge current overshoot. The system also can withstand a direct short circuit across the output without damage. The automatic feed back control simply reduces the duty cycle to hold the current at the set point. When the short is removed the full power output is immediately restored. This latest version arcjet PCU is conduction cooled to remove waste heat by conduction to the base plate. This unit is closer to flight a type of design than the previous functional bread boards. Waste heat is small because the PCU has a very high efficiency, 296 percent. The PCU was extensively tested with resistor loads to simulate operation with an arcjet. The unit was tested with ammonia arcjets at the Jet Propulsion Laboratory. Approximately 400 hours of testing were completed, with several starts. Many hours were also demonstrated with resistive loads. Some testing with hydrogen arcjets was also carried out at NASA LeRC. This system concept is now the design base for the ATTD program.

Wong, See-Pok↗

NASA NTRS1992

Thermal-structural test facilities at NASA Dryden

The National Aero-Space Plane (NASP) has renewed interest in hypersonic flight and hot-structures technology development for both the airframe and engine. The NASA Dryden Thermostructures Research Facility is a unique national facility that was designed to conduct thermal-mechanical tests on aircraft and aircraft components by simulating the flight thermal environment in the laboratory. The layout of the facility is presented, which includes descriptions of the high-bay test area, the instrumentation laboratories, the mechanical loading systems, and the state-of-the-art closed-loop thermal control system. The hot-structures test capability of the facility is emphasized by the Mach-3 thermal simulation conducted on the YF-12 airplane. The Liquid-Hydrogen Structural Test Facility, which is presently in the design phase, will provide the capability of thermally testing structures containing hydrogen.

Deangelis, V. Michael↗