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At least 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

PDRD Project 19039 - All metal vacuum scroll pump development for tritium

Currently the United States relies on a single source, foreign company, Eumeca (formerly Normetex) for the supply of an all metal vacuum scroll pump to process tritium. This “one of a kind”, all metal, vacuum scroll pump utilizes no “wetted”, polymeric materials that degrade prematurely when exposed to tritium. U.S. based vacuum scroll pump suppliers typically utilize a polymer, Teflon®, as a tip seal material at the edge of the scroll impellers for proper pump function. Teflon® is known to degrade within a relatively short time frame (approximately 1 year) when continually exposed to tritium gas. This degradation results in “flaking” of the Teflon® material which results in particulate contamination of the process gas stream. While filtration of the particulate is possible, doing so requires additional maintenance which is costly in a glovebox environment. In addition, filtration can degrade pumping system performance as particulate collects in the filter media over time. To date, all of the well established U.S and European based vacuum scroll pump manufacturers have been uninterested in developing an all metal vacuum scroll pump that does not use a polymeric scroll tip seal. This position is taken as the vacuum scroll pump manufacturers do not see a large enough market to make it profitable for them to develop and market an all metal vacuum scroll pump. In the mid 2000s, one company, Air Squared, Inc., a small Original Equipment Manufacturer (OEM) specializing in design and fabrication of custom scroll vacuum pumps and compressors, was willing to pursue the effort. The first design effort incorporated Vespel® as a polymeric tip seal material. Results of this effort led to realizing the affect that the Met-Bel MB-601 metal bellows pump has on performance when used as a backing pump for an all metal vacuum scroll pump without a scroll tip seal. As a result, Air Squared subsequently designed an all metal vacuum scroll pump without a tip seal material for evaluation. Although the initial, all metal version of the Air Squared pump was found deficient in regard to scroll impeller stiffness, which resulted in scroll contact, general design and pump performance was verified to be adequate. SRS PDRD Project 19039 was launched in 2019 as a 3rd attempt with Air Squared, Inc. in regard to development of an all metal vacuum scroll pump for consideration as an equivalent to the Eumeca/ Normetex pump. The effort specified 300 series stainless steel for the scroll impellers, all metal sealing, and design to meet tritium throughput and ultimate vacuum requirements. In addition, a 60 psig design pressure rating requirement was specified for the pump containment boundary. The 3rd generation Air Squared pump has been designed, fabricated, and has received preliminary testing. Preliminary testing has indicated proper leak tightness and pump performance. However, work continues regarding development of a pumping chamber containment bellows that can be subjected to 66 psig without damage to the bellows. Work will continue in 2020 and 2021 to pursue a pumping chamber containment bellows that meets the pressure rating requirement.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1974

Shuttle active thermal control system development testing. Volume 8: Tube anomaly investigation

A modular radiator system projected for use on the space shuttle has been tested. During thermal vacuum testing of the radiator panels leaks developed in the coolant fluid tubes containing the Freon 21 refrigerant. An analysis of thermal vacuum test conditions revealed that the test anomaly consisted of trapped Freon 21 fluid between frozen tube corners colder than the remainder of the panel. The trapped fluid expanded on further warming, causing high pressures to develop in the tubes. The pressure was sufficient to induce tube ruptures. Metallurgical analysis showed that concentric extrusion holes and heat treatment of the aluminum alloy to the -T6 condition would have prevented the ruptures. Thermal analysis indicates that attaching the tube corners to the radiator fin could eliminate the fluid trapping.

Reed, M. W.↗
NASA NTRS2016

Space Suit Portable Life Support System (PLSS) 2.0 Unmanned Vacuum Environment Testing

For the first time in more than 30 years, an advanced space suit Portable Life Support System (PLSS) design was operated inside a vacuum chamber representative of the flight operating environment. The test article, PLSS 2.0, was the second system-level integrated prototype of the advanced PLSS design, following the PLSS 1.0 Breadboard that was developed and tested throughout 2011. Whereas PLSS 1.0 included five technology development components with the balance the system simulated using commercial-off-the-shelf items, PLSS 2.0 featured first generation or later prototypes for all components less instrumentation, tubing and fittings. Developed throughout 2012, PLSS 2.0 was the first attempt to package the system into a flight-like representative volume. PLSS 2.0 testing included an extensive functional evaluation known as Pre-Installation Acceptance (PIA) testing, Human-in-the-Loop testing in which the PLSS 2.0 prototype was integrated via umbilicals to a manned prototype space suit for 19 two-hour simulated EVAs, and unmanned vacuum environment testing. Unmanned vacuum environment testing took place from 1/9/15-7/9/15 with PLSS 2.0 located inside a vacuum chamber. Test sequences included performance mapping of several components, carbon dioxide removal evaluations at simulated intravehicular activity (IVA) conditions, a regulator pressure schedule assessment, and culminated with 25 simulated extravehicular activities (EVAs). During the unmanned vacuum environment test series, PLSS 2.0 accumulated 378 hours of integrated testing including 291 hours of operation in a vacuum environment and 199 hours of simulated EVA time. The PLSS prototype performed nominally throughout the test series, with two notable exceptions including a pump failure and a Spacesuit Water Membrane Evaporator (SWME) leak, for which post-test failure investigations were performed. In addition to generating an extensive database of PLSS 2.0 performance data, achievements included requirements and operational concepts verification, as well as demonstration of vehicular interfaces, consumables sizing and recharge, and water quality control.

Watts, Carly↗
NASA NTRS1993

Interpretation of discrepancies in mass spectroscopy data obtained from different experimental configurations

Many helium mass spectrometer leak detectors at KSC employ sampling systems that feature hand held sniffer probes. Authors of general leakage-testing literature recommend sniffer probes for leak location but not for quantitative leakage measurement. Their use in the latter application at KSC involves assumptions that may be subtle. The purpose of the research effort reported herein was to establish the significance of indicated leak rates displayed by sniffer-probe equipped leak detectors and to determine whether the use of alternative hardware or testing procedures may reduce the uncertainty of leakage measurements made with them. The report classifies probe-type sampling systems for helium leak detectors according to their internal plumbing (direct or branched), presents a basic analysis of the fluid dynamics in the sampling system in the branched-conduit case, describes the usual test method for measuring the internal supply-to-sample flowrate ratio (a.k.a permeation ratio), and describes a concept for a sponge-tipped probe whose external supply-to-sample flowrate ratio promises to be lower than that of a simple-ended probe. One conclusion is that the main source of uncertainty in the use of probe-type sampling systems for leakage measurement is uncertainty in the external supply-to-sample flowrate ratio. In contrast, the present method for measuring the internal supply-to-sample flowrate ratio is quantitative and satisfactory. The implication is that probes of lower external supply-to-sample flowrate ratio must be developed before this uncertainty may be reduced significantly.

Russell, John M.↗
NASA NTRS2003

Test Data Analysis of a Spray Bar Zero-Gravity Liquid Hydrogen Vent System for Upper Stages

To support development of a zero-gravity pressure control capability for liquid hydrogen (LH2), a series of thermodynamic venting system (TVS) tests was conducted in 1996 and 1998 using the Marshall Space Flight Center (MSFC) multipurpose hydrogen test bed (MHTB). These tests were performed with ambient heat leaks =20 and 50 W for tank fill levels of 90%, 50%, and 25%. TVS performance testing revealed that the spray bar was highly effective in providing tank pressure control within a 7-kPa band (131-138 Wa), and complete destratification of the liquid and the ullage was achieved with all test conditions. Seven of the MHTB tests were correlated with the TVS performance analytical model. The tests were selected to encompass the range of tank fill levels, ambient heat leaks, operational modes, and ullage pressurants. The TVS model predicted ullage pressure and temperature and bulk liquid saturation pressure and temperature obtained from the TVS model were compared with the test data. During extended self-pressurization periods, following tank lockup, the model predicted faster pressure rise rates than were measured. However, once the system entered the cyclic mixing/venting operational mode, the modeled and measured data were quite similar.

Hedayat, A.↗
DOE OSTI2021

Fabrication and Preliminary Demonstration of Microwave Resonant Cavity Transducer Performance

We are investigating a microwave cavity-based transducer for in-core high-temperature fluid flow sensing in molten salt cooled reactors (MSCR) and sodium fast reactors (SFR). This sensor is a hollow metallic cylindrical cavity, which can be fabricated from stainless steel, and as such is expected to be resilient to radiation, high temperature and corrosive environment of MSCR and SFR. The principle of sensing consists of making one wall of the cylindrical cavity flexible enough so that dynamic pressure, which is proportional to fluid velocity, will cause membrane deflection. Membrane deflection causes cavity volume change, which leads to a shift in the resonant frequency. We have developed an initial design for proof-of-principle testing of the flow sensor performance in microwave K-band. A cylindrical resonator prototype was fabricated from brass for initial tests in water. The cavity size is matched to the flange of a standard WR-42 waveguide. Microwave field is coupled into the resonant cavity through a subwavelength-size aperture. A test article was developed, consisting of a piping Tee with bulkhead WR-42 microwave waveguide installed in leak-proof design. In the test article, the cylindrical cavity is positioned in the center of the pipe. A microwave waveguide circulator was installed in the setup to suppress microwave reflections at the cavity entrance. Preliminary spectral characterization of cavity spectral response was performed with microwave VNA. Applying mechanical pressure to cavity membrane showed a measurable shift in the microwave resonant frequency. We also investigate mechanical integrity of the flowmeter’s membrane through computer simulations. By calculating the stress on the plate due to deflection and, comparing the stress to the material ultimate tensile strength and yield strength, it can be estimated if the plate will fail. The stress on the plate was calculated with an analytic closed form solution model, and with COMSOL Structural Mechanics Module which does not involve any approximations. Both the analytic model and COMSOL model showed that maximum stresses on the plate, which are at the radial boundary of the plate, are three orders of magnitude smaller than the yield strength and ultimate tensile strength. This indicates that the sensor is at a low risk of mechanical failure.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS1972

Evaluation of tantalum 316 stainless steel transition joints

Tubular transition joints providing a metallurgically bonded connection between tantalum and 316 stainless steel pipe sections were comparatively evaluated for durability under thermal cycling conditions approximating the operation of a SNAP-8 mercury boiler. Both coextruded and vacuum brazed transition joints of 50mm (2 inch) diameter were tested by thermal cycling 100 times between 730 C and 120 C(1350 F and 250 F) in a high vacuum environment. The twelve evaluated transition joints survived the full test sequence without developing leaks, although liquid penetrant bond line indications eventually developed in all specimens. The brazed transition joints exhibited the best dimensional stability and bond line durability.

Stoner, D. R.↗
NASA NTRS1978

Thermal-leak analyzer for vacuum-jacketed lines

Technique involves coating suspected area with water-soluble black paint that gives even, infrared emission. Painted area is warmed with heat gun; an infrared scanner is used to detect cooled spot on jacket exterior. Introduction of atmospheric pressure into jacket intensifies leak jet and improves test sensitivity.

Heisman, R. M.↗
NASA NTRS1987

Development of the helium signature test for orbiter main propulsion system revalidation between flights

This paper presents the development of a test technique for revalidation of the Space Shuttle Orbiter Main Propulsion System during ground turnaround operations between flights of the Space Transportation System (STS). The Main Propulsion System consists of the three Space Shuttle Main Engines (SSME's) and the Main Propulsion System (MPS) connecting the SSME's to the orbiter/ground and orbiter/External Tank (ET) interfaces. The Helium Signature Test (HST) performs an end-to-end leak check of the MPS/SSME subsystems that serves as a final validation of those systems for reuse. The test was initially developed during the ground processing flow prior to the STS-6 launch of orbiter Challenger. The test was developed to fulfill a requirement for an overall subsystem leak check as a result of experience gained during the STS-6 Challenger Flight Readiness Firing (FRF) series, during which leaks were encountered in the SSME's that were not detected by routine fluid joint leak checks. The HST technique is described in detail, including orbiter and test equipment configuration, and compared to other leak detection methods used to revalidate MPS/SSME systems for reuse. The HST data base accumulated since STS-6 is summarized and future test applications are described.

Bilardo, Vincent J., Jr.↗
NASA NTRS2015

Wrapped Multilayer Insulation

New NASA vehicles, such as Earth Departure Stage (EDS), Orion, landers, and orbiting fuel depots, need improved cryogenic propellant transfer and storage for long-duration missions. Current cryogen feed line multilayer insulation (MLI) performance is 10 times worse per area than tank MLI insulation. During each launch, cryogenic piping loses approximately 150,000 gallons (equivalent to $300,000) in boil-off during transfer, chill down, and ground hold. Quest Product Development Corp., teaming with Ball Aerospace, developed an innovative advanced insulation system, Wrapped MLI (wMLI), to provide improved thermal insulation for cryogenic feed lines. wMLI is high-performance multilayer insulation designed for cryogenic piping. It uses Quest's innovative discrete-spacer technology to control layer spacing/ density and reduce heat leak. The Phase I project successfully designed, built, and tested a wMLI prototype with a measured heat leak 3.6X lower than spiral-wrapped conventional MLI widely used for piping insulation. A wMLI prototype had a heat leak of 7.3 W/m2, or 27 percent of the heat leak of conventional MLI (26.7 W/m2). The Phase II project is further developing wMLI technology with custom, molded polymer spacers and advancing the product toward commercialization via a rigorous testing program, including developing advanced vacuuminsulated pipe for ground support equipment.

Dye, Scott A.↗
NASA NTRS2015

Wrapped Multilayer Insulation

New NASA vehicles, such as Earth Departure Stage (EDS), Orion, landers, and orbiting fuel depots, need improved cryogenic propellant transfer and storage for long-duration missions. Current cryogen feed line multilayer insulation (MLI) performance is 10 times worse per area than tank MLI insulation. During each launch, cryogenic piping loses approximately 150,000 gallons (equivalent to $300,000) in boil-off during transfer, chill down, and ground hold. Quest Product Development Corp., teaming with Ball Aerospace, developed an innovative advanced insulation system, Wrapped MLI (wMLI), to provide improved thermal insulation for cryogenic feed lines. wMLI is high-performance multilayer insulation designed for cryogenic piping. It uses Quest's innovative discrete-spacer technology to control layer spacing/ density and reduce heat leak. The Phase I project successfully designed, built, and tested a wMLI prototype with a measured heat leak 3.6X lower than spiral-wrapped conventional MLI widely used for piping insulation. A wMLI prototype had a heat leak of 7.3 W/sq m, or 27 percent of the heat leak of conventional MLI (26.7 W/sq m). The Phase II project is further developing wMLI technology with custom, molded polymer spacers and advancing the product toward commercialization via a rigorous testing program, including developing advanced vacuuminsulated pipe for ground support equipment.

Dye, Scott A.↗
NASA NTRS2013

Leak Mitigation in Mechanically Pumped Fluid Loops for Long Duration Space Missions

Mechanically pumped fluid loops (MPFLs) are increasingly considered for spacecraft thermal control. A concern for long duration space missions is the leak of fluid leading to performance degradation or potential loop failure. An understanding of leak rate through analysis, as well as destructive and non-destructive testing, provides a verifiable means to quantify leak rates. The system can be appropriately designed to maintain safe operating pressures and temperatures throughout the mission. Two MPFLs on the Mars Science Laboratory Spacecraft, launched November 26, 2011, maintain the temperature of sensitive electronics and science instruments within a -40 deg C to 50 deg C range during launch, cruise, and Mars surface operations. With over 100 meters of complex tubing, fittings, joints, flex lines, and pumps, the system must maintain a minimum pressure through all phases of the mission to provide appropriate performance. This paper describes the process of design, qualification, test, verification, and validation of the components and assemblies employed to minimize risks associated with excessive fluid leaks from pumped fluid loop systems.

thermal controls↗
NASA NTRS1989

SSME Propellant Path Leak Detection

The complicated high-pressure cycle of the space shuttle main engine (SSME) propellant path provides many opportunities for external propellant path leaks while the engine is running. This mode of engine failure may be detected and analyzed with sufficient speed to save critical engine test hardware from destruction. The leaks indicate hardware failures which will damage or destroy an engine if undetected; therefore, detection of both cryogenic and hot gas leaks is the objective of this investigation. The primary objective of this phase of the investigation is the experimental validation of techniques for detecting and analyzing propellant path external leaks which have a high probability of occurring on the SSME. The selection of candidate detection methods requires a good analytic model for leak plumes which would develop from external leaks and an understanding of radiation transfer through the leak plume. One advanced propellant path leak detection technique is obtained by using state-of-the-art technology infrared (IR) thermal imaging systems combined with computer, digital image processing, and expert systems for the engine protection. The feasibility of IR leak plume detection is evaluated on subscale simulated laboratory plumes to determine sensitivity, signal to noise, and general suitability for the application.

Roger Crawford↗
NASA NTRS1996

New instrumentation technologies for testing the bonding of sensors to solid materials

This report presents the results of a comprehensive research and development project that was conducted over a three-year period to develop new technologies for testing the attachment of sensors to solid materials for the following NASA applications: (1) testing the performance of composites that are used for the lining of solid rocket motor nozzles, (2) testing the bonding of surface-mounted platinum resistance thermometers that are used on fuel and oxidizer lines of the space shuttle to detect valve leaks by monitoring temperature, (3) testing the attachment of strain gages that are used in testing the performance of space shuttle main engines, and (4) testing the thermocouples that are used for determining the performance of blast tube liner material in solid rocket boosters.

Hashemian, H. M.↗
NASA NTRS2007

Cryogenic Pressure Control Modeling for Ellipsoidal Space Tanks

A computational fluid dynamics (CFD) model is developed to simulate pressure control of an ellipsoidal-shaped liquid hydrogen tank under external heating in normal gravity. Pressure control is provided by an axial jet thermodynamic vent system (TVS) centered within the vessel that injects cooler liquid into the tank, mixing the contents and reducing tank pressure. The two-phase cryogenic tank model considers liquid hydrogen in its own vapor with liquid density varying with temperature only and a fully compressible ullage. The axisymmetric model is developed using a custom version of the commercially available FLOW-31) software. Quantitative model validation is ,provided by engineering checkout tests performed at Marshall Space Flight Center in 1999 in support of the Solar Thermal Upper Stage_ Technology Demonstrator (STUSTD) program. The engineering checkout tests provide cryogenic tank self-pressurization test data at various heat leaks and tank fill levels. The predicted self-pressurization rates, ullage and liquid temperatures at discrete locations within the STUSTD tank are in good agreement with test data. The work presented here advances current CFD modeling capabilities for cryogenic pressure control and helps develop a low cost CFD-based design process for space hardware.

Lopez, Alfredo↗
NASA NTRS2003

Leak Location and Classification in the Space Shuttle Main Engine Nozzle by Infrared Testing

The Space Shuttle Main Engine (SSME) is composed of cooling tubes brazed to the inside of a conical structural jacket. Because of the geometry there are regions that can't be inspected for leaks using the bubble solution and low-pressure method. The temperature change due escaping gas is detectable on the surface of the nozzle under the correct conditions. The methods and results presented in this summary address the thermographic identification of leaks in the Space Shuttle Main Engine nozzles. A highly sensitive digital infrared camera is used to record the minute temperature change associated with a leak source, such as a crack or pinhole, hidden within the nozzle wall by observing the inner "hot wall" surface as the nozzle is pressurized. These images are enhanced by digitally subtracting a thermal reference image taken before pressurization, greatly diminishing background noise. The method provides a nonintrusive way of localizing the tube that is leaking and the exact leak source position to within a very small axial distance. Many of the factors that influence the inspectability of the nozzle are addressed; including pressure rate, peak pressure, gas type, ambient temperature and surface preparation.

Russell, Samuel S.↗
NASA NTRS1992

Li/BCX (thionyl chloride) battery for the NASA AN/PRC-112 survival radio

As part of the NASA contingency planning related to aborting a launch after liftoff, an emergency radio is required for use by the crew when they return to Earth at some unplanned location. The power source for the radio must be able to satisfy the performance requirements for the radio's mission as well as be compatible with in-cabin storage in the space shuttle. The radio needs a base load power of about 1 W with capability to handle power spikes greater then 6.5 W. A slightly enlarged battery pack using the Li/BCX chemistry in C-size cells was developed that meets these power levels and extends the operational life of the radio by over a factor of four compared to its operation using a Li/SO2 cell battery pack. In addition, the cells meet the requirements for the Li/BCX cells used for extra-vehicular activities by the crew of the shuttle. One of the major qualifying tests is the ability of the cells to withstand exposure to high temperature (149 C) without leaking. Electrical performance and thermal abuse test data will be presented for the cells.

Ebel, Steven J.↗
NASA NTRS2006

Evaluation of Dry, Rough Vacuum Pumps

This document provides information on the testing and evaluation of thirteen dry rough vacuum pumps of various designs and from various manufacturers. Several types of rough vacuum pumps were evaluated, including scroll, roots, and diaphragm pumps. Tests included long term testing, speed curve generation, voltage variance, vibrations emissions and susceptibility, electromagnetic interference emissions and susceptibility, static leak rate, exhaust restriction, response/recovery time tests, and a contamination analysis for scroll pumps. Parameters were found for operation with helium, which often is not provided from the manufacturer

Hunter, Brian↗