Engineering topics
Starr, Stanley
Publications and source records attributed to Starr, Stanley.
Technology Development for Hydrogen Propellant Storage and Transfer at the Kennedy Space Center (KSC)
The National Aeronautics and Space Administration (NASA) is a major user of liquid hydrogen. In particular, NASA's John F. Kennedy (KSC) Space Center has operated facilities for handling and storing very large quantities of liquid hydrogen (LH2) since the early 1960s. Safe operations pose unique challenges and as a result NASA has invested in technology development to improve operational efficiency and safety. This paper reviews recent innovations including methods of leak and fire detection and aspects of large storage tank health and integrity. We also discuss the use of liquid hydrogen in space and issues we are addressing to ensure safe and efficient operations should hydrogen be used as a propellant derived from in-situ volatiles.
Regolith and Environment Science and Oxygen and Lunar Volatile Extraction (RESOLVE): Lunar Advanced Volatile Analysis (LAVA) Capillary Fluid Dynamic Restriction Effects on Gas Chromatography
The Resource Prospector (RP) mission with the Regolith and Environment Science and Oxygen Lunar Volatile Extraction (RESOLVE) payload aims to show the presence of water in lunar regolith, and establish a proving ground for NASAs mission to Mars. One of the analysis is performed by the Lunar Advanced Volatiles Analysis (LAVA) subsystem, which consists of a fluid network that facilitates the transport of volatile samples to a gas chromatograph and mass spectrometer (GC-MS) instrument. The understanding of fluid dynamics directed from the GC to the MS is important due to the influence of flow rates and pressures that affect the accuracy of and prevent the damage to the overall GC-MS instrument. The micro-scale capillary fluid network within the GC alone has various lengths and inner-diameters; therefore, determination of pressure differentials and flow rates are difficult to model computationally, with additional complexity from the vacuum conditions in space and lack of a lunar atmosphere. A series of tests were performed on an experimental set-up of the system where the inner diameters of the GC transfer line connecting to the MS were varied. The effect on chromatography readings were also studied by applying these lines onto a GC instrument. It was found that a smaller inner diameter transfer line resulted in a lower flow rate, as well as a lower pressure differential across the thermal conductivity detector (TCD) unit of the GC and a negligible pressure drop across the mock-up capillary column. The chromatography was affected with longer retention times and broader peak integrations. It was concluded that a 0.050 mm inner diameter line still proved most suitable for the systems flow rate preferences. In addition, it was evident that this small transfer line portrayed some expense to GC signal characteristics and the wait time for steady-state operation.
A System for Measuring the Sway of the Vehicle Assembly Building
A system was developed to measure the sway of the Vehicle Assembly Building (VAB) at Kennedy Space Center. This system was installed in the VAB and gathered more than one total year of data. The building movement was correlated with measurements provided by three wind towers in order to determine the maximum deflection of the building during high-wind events. The VAB owners were in the process of obtaining new platforms for use in assembling very tall rockets when analysis of the VAB showed that a high wind could move the building sufficiently that an upper platform might impact a rocket. The problem arises because safety requires a relatively small gap between the platform and the rocket, while a large enough gap is needed to ensure that stacking tolerances prevent contact between the rocket and the platform. This only leaves an inch or two (approximately 2 to 5 cm) of total clearance, so when the analysis showed that more than a couple of inches of motion could occur in a high wind, there was a potential for damaging the rocket. The KSC Applied Physics Laboratory was asked to install a system in the VAB that could measure the motion of the building in high winds to determine the actual building sway. The motion of the VAB roof under wind load was measured optically, and under analysis, it was determined that a relatively large-aperture optical system would be required to reduce diffraction effects to less than a small fraction of an inch (approximately mm) at a distance of 500 ft (≈150 m). A 10-in. (approximately 250 mm) telescope was placed on the floor of the building, looking at the ceiling. On the ceiling, a flat plate with three white LEDs was mounted in an "L" shape, such that the telescope was essentially looking at three stars. Software was written to track the motion of these three points using an image processing system. This provided a better than 1/10-in. (approximately 2.5-mm) 2D measurement faster than once a second. Data was downloaded once a month for comparison with the wind tower data. The system was fully operational and provided enough data to show that the VAB will only move 1 in. (approximately 2.5 cm) at the ceiling under 70-knot winds. Adjustable platforms are not required.
Recent Projects in the KSC Applied Physics Lab
Topics include: Shuttle heritage; ISRU /RESOLVE: a) Payload for Lunar Lander/Rover on Polar Areas of Moon. b) Avionics/Software. New Technologies for Exploration: a) Radiation Shielding work. b) Cooperative Tractor Beams.
Color-Changing Sensors for Detecting the Presence of Hypergolic Fuels
Hypergolic fuel sensors were designed to incorporate novel chemochromic pigments into substrates for use in various methods of leak detection. There are several embodiments to this invention that would provide specific visual indication of hypergols used during and after transfer. The ability to incorporate these pigments into various polymer matrices provides a unique opportunity to manufacture nearly any type of sensor shape that is required. The vibrant color change from yellow to black instantaneously shows the worker the presence of hypergols in the area.
Measuring Air Leaks into the Vacuum Space of Large Liquid Hydrogen Tanks
Large cryogenic liquid hydrogen tanks are composed of inner and outer shells. The outer shell is exposed to the ambient environment while the inner shell holds the liquid hydrogen. The region between these two shells is evacuated and typically filled with a powderlike insulation to minimize radiative coupling between the two shells. A technique was developed for detecting the presence of an air leak from the outside environment into this evacuated region. These tanks are roughly 70 ft (approx. equal 21 m) in diameter (outer shell) and the inner shell is roughly 62 ft (approx. equal 19 m) in diameter, so the evacuated region is about 4 ft (approx. equal 1 m) wide. A small leak's primary effect is to increase the boil-off of the tank. It was preferable to install a more accurate fill level sensor than to implement a boil-off meter. The fill level sensor would be composed of an accurate pair of pressure transducers that would essentially weigh the remaining liquid hydrogen. This upgrade, allowing boil-off data to be obtained weekly instead of over several months, is ongoing, and will then provide a relatively rapid indication of the presence of a leak.
Measuring Moisture Levels in Graphite Epoxy Composite Sandwich Structures
Graphite epoxy composite (GEC) materials are used in the construction of rocket fairings, nose cones, interstage adapters, and heat shields due to their high strength and light weight. However, they absorb moisture depending on the environmental conditions they are exposed to prior to launch. Too much moisture absorption can become a problem when temperature and pressure changes experienced during launch cause the water to vaporize. The rapid state change of the water can result in structural failure of the material. In addition, heat and moisture combine to weaken GEC structures. Diffusion models that predict the total accumulated moisture content based on the environmental conditions are one accepted method of determining if the material strength has been reduced to an unacceptable level. However, there currently doesn t exist any field measurement technique to estimate the actual moisture content of a composite structure. A multi-layer diffusion model was constructed with Mathematica to predict moisture absorption and desorption from the GEC sandwich structure. This model is used in conjunction with relative humidity/temperature sensors both on the inside and outside of the material to determine the moisture levels in the structure. Because the core materials have much higher diffusivity than the face sheets, a single relative humidity measurement will accurately reflect the moisture levels in the core. When combined with an external relative humidity measurement, the model can be used to determine the moisture levels in the face sheets. Since diffusion is temperaturedependent, the temperature measurements are used to determine the diffusivity of the face sheets for the model computations.
eLaunch Hypersonics: An Advanced Launch System
This presentation describes a new space launch system that NASA can and should develop. This approach can significantly reduce ground processing and launch costs, improve reliability, and broaden the scope of what we do in near earth orbit. The concept (not new) is to launch a re-usable air-breathing hypersonic vehicle from a ground based electric track. This vehicle launches a final rocket stage at high altitude/velocity for the final leg to orbit. The proposal here differs from past studies in that we will launch above Mach 1.5 (above transonic pinch point) which further improves the efficiency of air breathing, horizontal take-off launch systems. The approach described here significantly reduces cost per kilogram to orbit, increases safety and reliability of the boost systems, and reduces ground costs due to horizontal-processing. Finally, this approach provides significant technology transfer benefits for our national infrastructure.
Thermographic Methods of Detecting Insulation Voids in Large Cryogenic Tanks
Four very large (900Kgal) cryogenic liquid hydrogen and oxygen storage tanks at Kennedy Space Center's LC-39 launch pads were constructed in 1965 to support the Apollo/Saturn V Program and continue to support the Space Shuttle Program. These double-walled spherical tanks with powdered insulation in the annular region, have received minimal refurbishment or even inspection over the years. Intrusively inspecting these tanks would mean a significant down time to the program as the cryogenic liquid and the perlite insulation would have to be removed which would be a significant task and long-term schedule disruption. A study of the tanks was performed to determine the extent to which performance and structural information could be revealed without intrusive inspection. Thermal images of the tanks were taken over a variety of environmental conditions to determine the best conditions under which to compare and use thermography as a health monitoring technique as the tanks continue to age. The settling and subsequent compaction of insulation is a serious concern for cryogenic tanks. Comparison of images from the tanks reveals significant variations in the insulation in the annual regions and point to the use of thermography as a way to monitor for insulation migration and possible compaction. These measurements, when combined with mathematical models of historical boil-off data provide key insight to the condition of the vessels. Acceptance testing methods for new tanks, before they are filled with cryogenic commodity (and thereby thermally cycled), are needed and we explore how thermography can be used to accomplish this.
Development of a 3D X-Ray Backscatter Imaging Technique for NDE
Objective of this project is to develop and demonstrate 3D X-ray backscatter NDE techniques to allow the depth and size estimation of defects in aerospace structures.
The Development of NDE TEchniques for Payload Fairings and Other Composite Structures
The Objective of the project is to develop and demonstrate NDE techniques to assist in the fabrication and operational monitoring of expendable vehicle payload fairings and other composite structures.
Legacy and Emergence of Spaceport Technology Development at the Kennedy Space Center
Kennedy Space Center (KSC) has a long and successful legacy in the checkout and launch of missiles and space vehicles. These operations have become significantly more complex, and their evolution has driven the need for many technology developments. Unanticipated events have also underscored the need for a local, highly responsive technology development and testing capability. This evolution is briefly described, as well as the increasing level of technology capability at KSC. The importance of these technologies in achieving past national space goals suggests that the accomplishment of low-cost and reliable access to space will depend critically upon KSC's future success in developing spaceport technologies. This paper concludes with a description KSC's current organizational approach and major thrust areas in technology development. The first phase of our historical review focuses on the development and testing of field- deployable short- and intermediate-range ballistic missiles (1953 to 1958). These vehicles are later pressed into service as space launchers. The second phase involves the development of large space lift vehicles culminating in the Saturn V launches (1959 to 1975). The third phase addresses the development and operations of the partially reusable launch vehicle, Space Shuttle (1976 to 2000). In the current era, KSC is teaming with the U.S. Air Force (AF), industry, academia, and other partners to identify and develop Spaceport and Range Technologies necessary to achieve national space goals of lower-cost and higher-reliability space flight.