Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Fluid management”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 253 records · Page 14

Issues of Long-Term Cryogenic Propellant Storage in Microgravity

Modern multi-layer insulation (MLI) allows to sharply reduce the heat leak into cryogenic propellant storage tanks through the tank surface and, as a consequence, significantly extend the storage duration. In this situation the MLI penetrations, such as support struts, feed lines, etc., become one of the most significant challenges of the tanks heat management. This problem is especially acute for liquid hydrogen (LH2) storage, since currently no efficient cryocoolers exist that operate at very low LH2 temperatures (20K). Even small heat leaks under microgravity conditions and over the period of many months give rise to a complex slowly-developing, large-scale spatiotemporal physical phenomena in a multi-phase liquid-vapor mixture. These phenomena are not well-understood nor can be easily controlled. They can be of a potentially hazardous nature for long-term on-orbital cryogenic torage, propellant loading, tank chilldown, engine restart, and other in-space cryogenic fluid management operations. To support the engineering design solutions that would mitigate these effects a detailed physics-based analysis of heat transfer, vapor bubble formation, growth, motion, coalescence and collapse is required in the presence of stirring jets of different configurations and passive cooling devices such as MLI, thermodynamic vent system, and vapor-cooled shield. To develop physics-based models and correlations reliable for microgravity conditions and long-time scales there is a need for new fundamental data to be collected from on-orbit cryogenic storage experiments. Our report discusses some of these physical phenomena and the design requirements and future studies necessary for their mitigation. Special attention is payed to the phenomena occurring near MLI penetrations.

Muratov, C. B.↗

CFD Modeling of Cryogenic Chilldown in a Complex Channel under Normal and Low Gravity Conditions

Future NASA architectures have baselined cryogenic propulsion systems as well as cryogenic fluid management to support lunar missions and ultimately to support future missions to Mars. These missions will require chilling hardware down prior to engine restart as well as chilling lines and tanks prior to transferring and refueling these propulsion elements in orbit. In lieu of expensive tests conducted on-orbit, accurate predictive computational models of these chilldown processes can be used to reduce system and propellant mass as well as mission risk. To gain confidence in these computational models, appropriate anchoring and validation to experimental data in a relevant environment needs to be performed. Recent ground and sub-orbital flight experiments conducted by the Japan Aerospace Exploration Agency (JAXA) investigated chilldown of a complex channel resembling a turbopump bearing cavity at low flow rates. This work presents Computational Fluid Dynamics (CFD) model development of the chilldown experiment employing two-phase flow boiling models available in commercial CFD software STAR-CCM+ using Volume of Fluid (VOF) and the traditional Euler-Euler multiphase flow solvers. Comparisons of the numerical and experimental results under normal and low-gravity conditions are presented. An assessment of solid wall temperatures and phase distribution yielded important insights into multiphase solver choice, dependence on gravity environment, and challenges associated with cryogenic flow boiling prediction and validation.

CFD↗

Restraint of Liquid Jets by Surface Tension in Microgravity Modeled

Tension in Microgravity Modeled Microgravity poses many challenges to the designer of spacecraft tanks. Chief among these are the lack of phase separation and the need to supply vapor-free liquid or liquidfree vapor to the spacecraft processes that require fluid. One of the principal problems of phase separation is the creation of liquid jets. A jet can be created by liquid filling, settling of the fluid to one end of the tank, or even closing a valve to stop the liquid flow. Anyone who has seen a fountain knows that jets occur in normal gravity also. However, in normal gravity, the gravity controls and restricts the jet flow. In microgravity, with gravity largely absent, jets must be contained by surface tension forces. Recent NASA experiments in microgravity (Tank Pressure Control Experiment, TPCE, and Vented Tank Pressure Experiment, VTRE) resulted in a wealth of data about jet behavior in microgravity. VTRE was surprising in that, although it contained a complex geometry of baffles and vanes, the limit on liquid inflow was the emergence of a liquid jet from the top of the vane structure. Clearly understanding the restraint of liquid jets by surface tension is key to managing fluids in low gravity. To model this phenomenon, we need a numerical method that can track the fluid motion and the surface tension forces. The fluid motion is modeled with the Navier-Stokes equation formulated for low-speed incompressible flows. The quantities of velocity and pressure are placed on a staggered grid, with velocity being tracked at cell faces and pressure at cell centers. The free surface is tracked via the introduction of a color function that tracks liquid as 1/2 and gas as -1/2. A phase model developed by Jacqmin is used. This model converts the discrete surface tension force into a barrier function that peaks at the free surface and decays rapidly. Previous attempts at this formulation have been criticized for smearing the interface. However, by sharpening the phase function, double gridding the fluid function, and using a higher order solution for the fluid function, interface smearing is avoided. These equations can be rewritten as two coupled Poisson equations that also include the velocity. The method of solution is as follows: first, the phase equations are solved from this solution, a velocity field is generated, then a successive overrelaxation scheme is used to solve for a pressure field consistent with the velocity solution. After the code was implemented in axisymmetric form and verified by several test cases, the drop tower runs of Aydelott were modeled. The model handed the free-surface deformation quite nicely, even to the point of modeling geyser growth in the regime where the free surface was no longer restrained. A representative run is shown.

Chato, David J.↗

Liquid Hydrogen Tank Chill and No-Vent Fill Prediction using Computational Fluid Dynamics

Cryogenic tank chill and fill is an important cryogenic fluid management technology that supports and enables many of NASA’s long-duration space missions. For no-vent fill, the receiver tank pressure remains below the supply tank pressure during the entire duration of the fill so that the tank does not require venting. This is especially advantageous for tank fill operations in low gravity where the position of the liquid is not always known and venting the tank may cause loss of propellant by venting liquid. In lieu of expensive tests conducted on-orbit, accurate computational models capable of predicting receiver tank pressure during cryogenic propellant tank fill may be used to reduce system and propellant mass as well as mission risk. However, these numerical models must be validated or anchored to test data. This study presents computational fluid dynamics (CFD) models with conjugate heat transfer that are used to predict a liquid hydrogen tank chill and no-vent fill ground test conducted at Lewis Research Center (now Glenn Research Center) in 1991. The specific test case chosen for model validation implemented an upward-facing jet near the bottom of a cylindrical 34-liter tank. CFD predictions are compared to experimental measurements of tank pressure, fill level, and wall temperature. The CFD results show reasonable agreement to the test data but overpredict the pressure collapse near the end of the fill despite the liquid jet penetrating the liquid-vapor interface.

Computational Fluid Dynamics↗

Liquid Hydrogen Tank Chill and No-Vent Fill Prediction using Computational Fluid Dynamics

Cryogenic tank chill and fill is an important cryogenic fluid management (CFM) technology that supports and enables many of NASA’s long-duration space missions. For no-vent fill, the receiver tank pressure remains below the supply tank pressure during the entire duration of the fill so that the tank does not require venting. This is especially advantageous for tank fill operations in low gravity where the position of the liquid is not always known and venting the tank may cause loss of propellant by venting liquid. In lieu of expensive tests conducted on-orbit, accurate computational models capable of predicting receiver tank pressure during cryogenic propellant tank fill may be used to reduce system and propellant mass as well as mission risk. However, these numerical models must be validated or anchored to test data. This study presents a computational fluid dynamics (CFD) model with conjugate heat transfer that is used to predict a liquid hydrogen tank chill and no-vent fill ground test conducted at Lewis Research Center (now Glenn Research Center) in 1991. The specific test case chosen for model validation implemented an upward-facing jet near the bottom of a cylindrical 34 liter tank. CFD predictions are compared to experimental measurements of tank pressure, fill level, fluid temperatures, and wall temperatures. The CFD results show reasonable agreement to the test data but overpredict the pressure collapse near the end of the fill despite the liquid jet penetrating the liquid-vapor interface. Several sensitivity studies are considered due to notable uncertainties in the experiment.

Computational Fluid Dynamics↗

Liquid Hydrogen Tank Chill and No-Vent Fill Prediction Using Computational Fluid Dynamics

Cryogenic tank chill and fill is an important cryogenic fluid management (CFM) technology that supports and enables many of NASA’s long-duration space missions. For no-vent fill, the receiver tank pressure remains below the supply tank pressure during the entire duration of the fill so that the tank does not require venting. This is especially advantageous for tank fill operations in low gravity where the position of the liquid is not always known and venting the tank may cause loss of propellant by venting liquid. In lieu of expensive tests conducted on-orbit, accurate computational models capable of predicting receiver tank pressure during cryogenic propellant tank fill may be used to reduce system and propellant mass as well as mission risk. However, these numerical models must be validated or anchored to test data. This study presents a computational fluid dynamics (CFD) model with conjugate heat transfer that is used to predict a liquid hydrogen tank chill and no-vent fill ground test conducted at Lewis Research Center (now Glenn Research Center) in 1991. The specific test case chosen for model validation implemented an upward-facing jet near the bottom of a cylindrical 34 liter tank. CFD predictions are compared to experimental measurements of tank pressure, fill level, fluid temperatures, and wall temperatures. The CFD results show reasonable agreement to the test data but overpredict the pressure collapse near the end of the fill despite the liquid jet penetrating the liquid-vapor interface. Several sensitivity studies are considered due to notable uncertainties in the experiment.

Computational Fluid Dynamics↗

CU in space: The University of Colorado get away special payload G-285

The University of Colorado's first Get Away Special was conceived by a dozen science and engineering students in the spring of 1984. Since that time, the project has grown to include over 100 undergraduate and graduate students who have 'provided the experimental objectives, design, construction, integration, testing and management of the payload. Faculty and staff of the university and its affiliated laboratories as well as engineers from local industries have provided many useful suggestions at all stages of development. The principal motivation for developing this payload is to provide university students with the opportunity to participate in space science and engineering beginning at the ground level. At the same time, they are contributing their results from new science and technological discoveries to several disciplines. There are four separate experiments integrated into the /'single payload of G-285 which are supported by internal payload !power, thermal environment control, command land data handling [ facilities and structural subsystems. The four experiments contained in this payload are: a single spectrometer performing i two experiments- one to study night time shuttle glow phenomena in the ultraviolet and the other to observe NO2 concentrations over / equatorial latitudes in the day; a fluids management experiment ' using centrifugation for particle/liquid/vapor separation; and an experiment using Phycomyces fungi to study the gravireceptor mechanism theory. The experiments are supported by a microprocessor, data storage devices, power and thermal control subsystems. All these are located within a sealed aluminum container. The container, a refitted sounding rocket casing, has a top and bottom which bolt to the main body of the rocket section. The top section holds a five inch diameter quartz window through which light enters the spectrometer. A rotating mirror assembly and one of two battery boxes are mounted on the outside of the top section below the interface plane of the MDA. A second battery box is attached to the bottom section of the sealed container. All payload items except the battery boxes and mirror assembly are located inside the sealed rocket section to insure containment and to prevent outgassing of materials. The container will be sealed prior to launch and purged with one atmosphere of argon.

Kent Tobiska↗

Helium Pressurization Modeling of the EDU Submerged Diffuser Using Thermal Desktop

NASA is currently working on developing its predictive modeling capabilities to support future missions that require long term storage of cryogenic propellants. Through the Evolvable Cryogenics project, Development and Validation of Analysis Tools (DVAT) task, both CFD and multi-node fluid modeling tools are being validated against to increase the following cryogenic fluid management technologies: Self-Pressurization, Pressure Control, Helium Pressurization, de-stratification, jet mixing, Tank and transfer line chill-down, tank filling and transfer. NASA is using previous and future micro-gravity experiments to validate both types of models. Recent activities include: Validation of the Tank Pressure Control Experiment (TPCE), Hydrogen and Helium pressurization, and Completion of the Zero Boil Off Tank (ZBOT) experiment on ISS. Future activities include validation of the ZBOT experiment with both CFD and multi-node analysis tools, validation of the Cryogenic Demonstration System of the Robotic Refueling Mission (RRM3).

low-gravity fluid modeling↗

CFD Modeling & Validation of Single Bubble Growth During Cavitation in Zero Gravity

Cryogenic Fluid Management (CFM) in zero gravity represents a vital area of research as NASA pursues future long-duration space missions. Success of these missions relies heavily on the ability to store and transfer the cryogenic liquid fuels efficiently and safely. In the Zero Boil-Off Tank (ZBOT-1) Experiment in 2018, unexpected and intense phase change occurred at the screened Liquid Acquisition Device (LAD) during tank pressure control that was later attributed to cavitation. The cavitation ultimately resulted in pump failure. Since cryogen cavitation during storage and transfer of propellants in microgravity has been a source of serious concern for the aerospace community, a series of drop tower experiments with liquid methane were also performed at the University of Bremen to carefully study cavitation from a single bubble nucleus in an engineered micron-sized wall cavity. As the test cell is depressurized during the 10-second drop, cavitation causes bubble growth from the nucleus. Here, in a collaboration between the Case Western Reserve University and University of Bremen, we present a two-phase Computational Fluid Dynamics (CFD) model of bubble growth from a single wall cavity during depressurization in microgravity. Both 2D axisymmetric and 3D parametric simulation case studies are performed to show the evolution of the bubble growth. The model uses a Volume of Fluid (VOF) approach with and without adaptive mesh refinement and adaptive time stepping to capture the growth dynamics using an explicit formulation with algebraic reconstruction of the interface. CFD results show good agreement with corresponding experiment. Based on the velocity, temperature, and volume fraction fields generated by the validation case studies, detailed discussion and analysis of fluid flow and heat transfer during bubble growth process are presented to delineate the intricacies of the cavitation process. Strengths and shortcomings of the present numerical approach in capturing this phenomenon are also highlighted.

Two Phase Flow↗

Liquid Nitrogen Testing of an Integrated Reaction Control System

Integrated Reaction Control Systems (IRCS) are considered an enabling technology for future human exploration of the solar system. An IRCS uses the same fuel and oxidizer as the main propulsion system, allowing for increased performance and simplified cryogenic fluid management operations. The IRCS team at Marshall Spaceflight Center is currently evaluating an IRCS system that uses a combination of electric pumps and pressure-regulation devices to provide a constant flow of conditioned propellant to a thruster bank during operation. In contrast to accumulator and gasifier designs, the recirculation loop design is less massive and can provide large, sustained flowrates to the thruster inlet. In the summer 2021 test series presented herein, the feasibility of this concept was evaluated using liquid nitrogen as a simulant for liquid oxygen. The goals of this test series were to demonstrate the ability of the pump and pressure regulator to maintain adequate thruster inlet conditions during transient operation, and to demonstrate the ability for the system to operate in an “idle mode” that maintains system chill between activations. During test operations, the back-pressure regulator responded more slowly than the opening/closing of valves in the thruster simulant, but it was still able to attenuate the pressure fluctuation at the pump discharge and ensure a stable flowrate through the pump. Similarly, the pump was able to be run far below its nominal operating point and successfully flow sufficient fluid to maintain chill conditions.

RCS↗

Liquid Nitrogen Testing of An Integrated Reaction Control System

Integrated Reaction Control Systems (IRCS) are considered an enabling technology for future human exploration of the solar system. An IRCS uses the same fuel and oxidizer as the main propulsion system, allowing for increased performance and simplified cryogenic fluid management operations. The IRCS team at Marshall Spaceflight Center is currently evaluating an IRCS system that uses a combination of electric pumps and pressure-regulation devices to provide a constant flow of conditioned propellant to a thruster bank during operation. In contrast to accumulator and gasifier designs, the recirculation loop design is less massive and can provide large, sustained flowrates to the thruster inlet. In the summer 2021 test series presented herein, the feasibility of this concept was evaluated using liquid nitrogen as a simulant for liquid oxygen. The goals of this test series were to demonstrate the ability of the pump and pressure regulator to maintain adequate thruster inlet conditions during transient operation, and to demonstrate the ability for the system to operate in an “idle mode” that maintains system chill between activations. During test operations, the back-pressure regulator responded more slowly than the opening/closing of valves in the thruster simulant, but it was still able to attenuate the pressure fluctuation at the pump discharge and ensure a stable flowrate through the pump. Similarly, the pump was able to be run far below its nominal operating point and successfully flow sufficient fluid to maintain chill conditions.

RCS↗

Liquid Nitrogen Testing of an Integrated Reaction Control System

Integrated Reaction Control Systems (IRCS) are considered an enabling technology for future human exploration of the solar system. An IRCS uses the same fuel and oxidizer as the main propulsion system, allowing for increased performance and simplified cryogenic fluid management operations. The IRCS team at Marshall Spaceflight Center is currently evaluating an IRCS system that uses a combination of electric pumps and pressure-regulation devices to provide a constant flow of conditioned propellant to a thruster bank during operation. In contrast to accumulator and gasifier designs, the recirculation loop design is less massive and can provide large, sustained flowrates to the thruster inlet. In the summer 2021 test series presented herein, the feasibility of this concept was evaluated using liquid nitrogen as a simulant for liquid oxygen. The goals of this test series were to demonstrate the ability of the pump and pressure regulator to maintain adequate thruster inlet conditions during transient operation, and to demonstrate the ability for the system to operate in an “idle mode” that maintains system chill between activations. During test operations, the back-pressure regulator responded more slowly than the opening/closing of valves in the thruster simulant, but it was still able to attenuate the pressure fluctuation at the pump discharge and ensure a stable flowrate through the pump. Similarly, the pump was able to be run far below its nominal operating point and successfully flow sufficient fluid to maintain chill conditions.

integrated RCS↗

Liquid Nitrogen Testing of an Integrated Reaction Control System

Integrated Reaction Control Systems (IRCS) are considered an enabling technology for future human exploration of the solar system. An IRCS uses the same fuel and oxidizer as the main propulsion system, allowing for increased performance and simplified cryogenic fluid management operations. The IRCS team at Marshall Spaceflight Center is currently evaluating an IRCS system that uses a combination of electric pumps and pressure-regulation devices to provide a constant flow of conditioned propellant to a thruster bank during operation. In contrast to accumulator and gasifier designs, the recirculation loop design is less massive and can provide large, sustained flowrates to the thruster inlet. In the summer 2021 test series presented herein, the feasibility of this concept was evaluated using liquid nitrogen as a simulant for liquid oxygen. The goals of this test series were to demonstrate the ability of the pump and pressure regulator to maintain adequate thruster inlet conditions during transient operation, and to demonstrate the ability for the system to operate in an “idle mode” that maintains system chill between activations. During test operations, the back-pressure regulator responded more slowly than the opening/closing of valves in the thruster simulant, but it was still able to attenuate the pressure fluctuation at the pump discharge and ensure a stable flowrate through the pump. Similarly, the pump was able to be run far below its nominal operating point and successfully flow sufficient fluid to maintain chill conditions.

integrated RCS↗

Summary of Testing Results for the Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER)

Testing was completed on the Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER) between August 2019 and January 2020. SHIIVER was designed to be a test bed for the scaling of cryogenic fluid management technologies as applied to large upper stages and long duration in-space stages. The baseline SHIIVER design consists of uninsulated structural skirts attached to a propellant tank insulated with polyurethane Spray-On Foam Insulation (SOFI). The initial testing of the SHIIVER hardware was with liquid hydrogen and sought to demonstrate the use of boil-off vapor to intercept heat on a structural skirt, multilayer insulation (MLI) on the tank domes, and the radio frequency mass gauge (RFMG). Testing was completed in four stages: a baseline thermal vacuum test prior to installation of the MLI on the tank domes, a thermal vacuum test after the MLI installation, a reverberant acoustic test, and a subsequent thermal vacuum test to verify that no damage occurred during the reverberant acoustic testing. Each thermal vacuum test with chamber wall at ambient temperature and vacuum level in the 10-6 torr range was conducted continuously between approximately 90% full and 25% full. Test results showed that the vapor cooling reduced the heat load to the tank by approximately 10%, but the boil-off by less than 3% at 50% full, with and without MLI installed on the domes. The MLI installed on the domes reduced the heat load to the tank by approximately 40% at all fill levels, but the boil-off by approximately 25% at 90% full and 45% below 65% full. The RFMG performed well over all fill ranges, and several RF tank modes were used to gauge the mass of fluid in the tank. SHIIVER was then exposed to an acoustic environment of 147 dB OASPL (overall sound pressure level) in a reverberant chamber. The acoustic environment envelopes the upper stage internal acoustic level of several different modern launch vehicles. No structural or thermal performance changes were observed after exposure to the acoustic environment. Final thermal vacuum testing after the acoustic testing showed no degradation to the MLI due to the acoustic environment as measured via system heat loads

SHIIVER↗

Addressing CFM Modeling Gaps for Application into NASA’S Future Cutting Edge Missions

NASA, the US industry, and international partners are crafting frameworks to enable sustaining lunar missions. The ongoing programs, led by the agency, and prominent industry players, encompass plans for the sustained use of cryogenic propellants in lunar landers and in-space propellant refueling depots. NASA’s proactive funding initiatives have fueled the advancement of predictive computational models tailored to enhance the storage and transfer of cryogenic propellant. This paper aims to spotlight the latest advancements in this arena and delve into the collaborative efforts surrounding predictive model development within internal NASA programs as well as current and previous collaborations with industry and international partners. The paper presents an overview of recent advancements in cryogenic fluid management model development, along with their correlation with recent microgravity and large-scale cryogenic ground tests. The tests include key experiments such as the ISS Zero-Boil-Off Tank (ZBOT) series of experiments and the (Robotic Refueling Mission 3) RRM3 test during which liquid methane was stored on-orbit for an extended period of five months. The paper also highlights the anchoring of propellant tank pressurized drain tests involving sloshing that were conducted with liquid methane propellant during the Apollo/Saturn Era. Additionally, the paper discusses model anchoring against more recent sloshing tests carried out with liquid hydrogen propellant. Notable large-scale tests, such as a liquid oxygen propellant transfer test conducted by SpaceX were also used to help correlate a two-phase propellant transfer model using the valuable data measured during the test. The paper further showcases model correlations against a substantial oxygen liquefaction test undertaken by NASA to validate In-Situ-Resource-Utilization (ISRU) technologies that will prove pivotal for a sustained lunar presence.

Low-gravity fluid modeling↗

Spontaneous crack healing in calcite reveals the influence of dynamic strain evolution and surface chemistry

The mechanics of fracture healing in calcite remain poorly constrained yet are fundamental to managing fluid transport in geothermal reservoirs and hydrocarbon systems. Here, we apply microfocused synchrotron Laue X-ray diffraction and infrared spectroscopy to investigate subcritical crack healing in a 1 mm-thick calcite crystal subjected to controlled loading in a double-torsion device. Over a 44-hour period following load removal, we map the evolution of residual strain fields surrounding the crack tip and observe a progressive increase in compressive strain perpendicular to the crack plane accompanied by infrared spectroscopic signatures that reveal enhanced accumulation of water at the healed interface. The correlation between strain evolution and surface chemistry suggests that spontaneous crack healing in calcite is driven by dynamic anelastic relaxation coupled with irreversible fluid-mineral interactions. These findings offer insight into time-dependent crack closure processes in carbonates and highlight the role of chemically-mediated plasticity in subsurface fracture evolution.

materials science↗

Low-G fluid behavior technology summaries

This report presents a summarization and categorization of the pertinent literature associated with low-g fluid behavior technology. Initially a literature search was conducted to obtain pertinent documents for review. Reports determined to be of primary significance are summarized in detail. Each summary, where applicable, consists of; (1) report identification, (2) objective(s) of the work, (3) description of pertinent work performed, (4) major results, and (5) comments of the reviewer (GD/C). Pertinent figures are presented on a single facing page separate from the text. Specific areas covered are; interface configuration, interface stability, natural frequency and damping, liquid reorientation, bubbles and droplets, fluid inflow, fluid outflow, convection, boiling and condensation heat transfer, venting effects, and fluid properties. Reports which were reviewed and not summarized, along with reasons for not summarizing, are also listed. Cryogenic thermal control and fluid management systems technology are presented.

Stark, J. A.↗

A liquid hydrogen experiment as a Shuttle payload

The paper describes the cryogenic fluid management experiment (CFME) as a Shuttle payload. The experiment includes a liquid hydrogen tank containing a fine-mesh screen acquisition device, and a thermal control system consisting of a thermodynamic vent system to intercept heat leak to the hydrogen tank and control tank pressure. Engineering data obtained will be used to establish design criteria for subcritical cryogenic storage and supply tankage.

Eberhardt, R. N.↗