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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
NASA NTRS2013

Large-Scale Liquid Hydrogen Tank Rapid Chill and Fill Testing for the Advanced Shuttle Upper Stage Concept

Cryogenic upper stages in the Space Shuttle program were prohibited primarily due to a safety risk of a 'return to launch site' abort. An upper stage concept addressed this concern by proposing that the stage be launched empty and filled using shuttle external tank residuals after the atmospheric pressure could no longer sustain an explosion. However, only about 5 minutes was allowed for tank fill. Liquid hydrogen testing was conducted within a near-ambient environment using the multipurpose hydrogen test bed 638.5 ft3 (18m3) cylindrical tank with a spray bar mounted longitudinally inside. Although the tank was filled within 5 minutes, chilldown of the tank structure was incomplete, and excessive tank pressures occurred upon vent valve closure. Elevated tank wall temperatures below the liquid level were clearly characteristic of film boiling. The test results have substantial implications for on-orbit cryogen transfer since the formation of a vapor film would be much less inhibited due to the reduced gravity. However, the heavy tank walls could become an asset in normal gravity testing for on-orbit transfer, i.e., if film boiling in a nonflight weight tank can be inhibited in normal gravity, then analytical modeling anchored with the data could be applied to reduced gravity environments with increased confidence.

Flachbart, R. H.↗
NASA NTRS1999

Hybrid Thermal Control Testing of a Cryogenic Propellant Tank

This report presents the experimental results of a hybrid thermal control system, one that integrates a passive system (multi-layer insulation) with an active system (a mechanical cyrocooler) applied to cryogenic propellant storage. These experiments were performed on a 1.39 m diameter spherical propellant tank filled with LH2 while installed in an evacuated chamber. The tank heat transfer to the cryocooler was accomplished with a condenser installed in the ullage of the tank and mated to the second stage of the cooler, and by conduction, through copper leaves mated to the first stage of the cooler. The first hybrid system test was performed with both the condenser and the leaves, a configuration that had excess capacity to remove the heat entering the tank; the second test was performed with only the condenser, with a capacity closely matched to the tank heating rate. In both of these tests, the goal of zero boil-off was achieved.

Plachta, David W.↗
NASA NTRS2003

Thermal-Mechanical Cyclic Test of a Composite Cryogenic Tank for Reusable Launch Vehicles

This viewgraph presentation provides an overview of thermal-mechanical cyclic tests conducted on a composite cryogenic tank designed for reusable launch vehicles. Topics covered include: a structural analysis of the composite cryogenic tank, a description of Marshall Space Flight Center's Cryogenic Structure Test Facility, cyclic test plans and accomplishments, burst test and analysis and post-testing evaluation.

Messinger, Ross↗
NASA NTRS2019

NASA’s Space Launch System: First Mission Hardware Nears Completion

The Space Launch System (SLS) Program (Fig. 1) completed several significant production milestones in 2018 for its first mission and is poised for greater accomplishments in 2019. With manufacturing and hardware installation complete, Boeing completed the core stage forward join and shipped the liquid hydrogen tank structural test article to Marshall Space Flight Center for testing. The core stage aft join and LOX tank STA are expected to be completed in 2019 on the way to final stage integration. The four EM-1 engines are poised for stage integration in 2019. The Launch Vehicle Stage Adapter completed outfitting at Marshall and will be shipped to Kennedy Space Center in 2019. All solid rocket motor segments for the EM-1 boosters are cast, inspected and ready for shipment to KSC. The Program continues to work toward first launch of the nation’s new super heavy lift deep space capability in fiscal 2020. SLS is designed, engineered and tested to launch the most challenging exploration missions, minimizing risk and providing the greatest opportunity for mission success and scientific discovery. This paper will discuss the technical and programmatic successes and challenges of the past year and look ahead to plans for 2019.

Honeycutt, John↗
NASA NTRS2019

NASA’s Space Launch System: Exploration Mission-1 Hardware Nears Completion

The Space Launch System (SLS) Program completed several significant production milestones in 2018 for the launch vehicle’s first mission (Fig. 1) and is poised for greater accomplishments in 2019. With manufacturing and hardware installation finished, Boeing completed the core stage forward join and shipped the liquid hydrogen tank structural test article to Marshall Space Flight Center for testing. The core stage aft join and LOX tank STA are expected to be completed in 2019 on the way to final stage integration. The four EM-1 engines are poised for stage integration in 2019. The Launch Vehicle Stage Adapter completed outfitting at Marshall and will be shipped to Kennedy Space Center in 2019. All solid rocket motor segments for the EM-1 boosters are cast, inspected and ready for shipment to KSC. The upper stage, the Interim Cryogenic Propulsion Stage (ICPS), and the Orion Stage Adapter (OSA), where 13 6U CubeSats will ride to deep space on EM-1, were completed and delivered to Exploration Ground Systems at KSC in 2017 and 2018, respectively. The Program continues to work toward first launch of the nation’s new super heavy lift deep space capability in fiscal 2020. SLS is designed, engineered and tested to launch the most challenging exploration missions, minimizing risk and providing the greatest opportunity for mission success. This paper will discuss the technical and programmatic successes and challenges of the past year and look ahead to plans for 2019.

Honeycutt, John↗
NASA NTRS1973

Development of a fracture control method for composite tanks with load sharing liners

This experimental program was undertaken to establish a fracture control method for composite tanks with load sharing liners. Uniaxial specimens containing surface flaws were loaded to failure (static fractured) and cycled to failure and the results were compared with burst tests and cyclic life tests of composite tanks having surface flaws present in the load sharing metal liners. The liner materials investigated were Inconel X750 STA, 2219-T62 aluminum and cryostretched 301 stainless steel at room temperature and at 78 K (-320 F) in liquid nitrogen. Differences were observed in comparing the uniaxial and tank test results. These differences should be resolved if an adequate fracture control method is to be developed.

Bixler, W. D.↗
NASA NTRS2007

Numerical Modeling of Propellant Boil-Off in a Cryogenic Storage Tank

A numerical model to predict boil-off of stored propellant in large spherical cryogenic tanks has been developed. Accurate prediction of tank boil-off rates for different thermal insulation systems was the goal of this collaboration effort. The Generalized Fluid System Simulation Program, integrating flow analysis and conjugate heat transfer for solving complex fluid system problems, was used to create the model. Calculation of tank boil-off rate requires simultaneous simulation of heat transfer processes among liquid propellant, vapor ullage space, and tank structure. The reference tank for the boil-off model was the 850,000 gallon liquid hydrogen tank at Launch Complex 39B (LC- 39B) at Kennedy Space Center, which is under study for future infrastructure improvements to support the Constellation program. The methodology employed in the numerical model was validated using a sub-scale model and tank. Experimental test data from a 1/15th scale version of the LC-39B tank using both liquid hydrogen and liquid nitrogen were used to anchor the analytical predictions of the sub-scale model. Favorable correlations between sub-scale model and experimental test data have provided confidence in full-scale tank boil-off predictions. These methods are now being used in the preliminary design for other cases including future launch vehicles

Majumdar, A. K.↗
NASA NTRS2007

Portable Microleak-Detection System

The figure schematically depicts a portable microleak-detection system that has been built especially for use in testing hydrogen tanks made of polymer-matrix composite materials. (As used here, microleak signifies a leak that is too small to be detectable by the simple soap-bubble technique.) The system can also be used to test for microleaks in tanks that are made of other materials and that contain gases other than hydrogen. Results of calibration tests have shown that measurement errors are less than 10 percent for leak rates ranging from 0.3 to 200 cm3/min. Like some other microleak-detection systems, this system includes a vacuum pump and associated plumbing for sampling the leaking gas, and a mass spectrometer for analyzing the molecular constituents of the gas. The system includes a flexible vacuum chamber that can be attached to the outer surface of a tank or other object of interest that is to be tested for leakage (hereafter denoted, simply, the test object). The gas used in a test can be the gas or vapor (e.g., hydrogen in the original application) to be contained by the test object. Alternatively, following common practice in leak testing, helium can be used as a test gas. In either case, the mass spectrometer can be used to verify that the gas measured by the system is the test gas rather than a different gas and, hence, that the leak is indeed from the test object.

Rivers, H. Kevin↗
NASA NTRS1993

Thermal-fluid analysis of the fill and drain operations of a cryrogenic fuel tank

The Generic Research Cryogenic Tank was designed to establish techniques for testing and analyzing the behavior of reusable fuel tank structures subjected to cryogenic fuels and aerodynamic heating. The Generic Research Cryogenic Tank tests will consist of filling a pressure vessel to a prescribed fill level, waiting for steady-state conditions, then draining the liquid while heating the external surface to simulate the thermal environment associated with hypersonic flight. Initial tests of the Generic Research Cryogenic Tank will use liquid nitrogen with future tests requiring liquid hydrogen. Two-dimensional finite-difference thermal-fluid models were developed for analyzing the behavior of the Generic Research Cryogenic Tank during fill and drain operations. The development and results of the two-dimensional fill and drain models, using liquid nitrogen, are provided, along with results and discussion on extrapolating the model results to the operation of the full-size Generic Research Cryogenic Tank. These numerical models provided a means to predict the behavior of the Generic Research Cryogenic Tank during testing and to define the requirements for the Generic Research Cryogenic Tank support systems such as vent, drain, pressurization, and instrumentation systems. In addition, the fill model provided insight into the unexpected role of circumferential conduction in cooling the Generic Research Cryogenic Tank pressure vessel during fill operations.

Stephens, Craig A.↗
NASA NTRS1995

Task 4 supporting technology. Densification requirements definition and test objectives. Propellant densification requirements definition

The primary challenge of the X-33 CAN is to build and test a prototype LO2 and LH2 densification ground support equipment (GSE) unit, and perform tank thermodynamic testing within the 15 month phase 1 period. The LO2 and LH2 propellant densification system will be scaled for the IPTD LO2 and LH2 tank configurations. The IPTD tanks were selected for the propellant technology demonstration because of the potential benefits to the phase 1 plan: tanks will be built in time to support thermodynamic testing; minimum cost; minimum schedule risk; future testing at MSFC will build on phase 1 data base; and densification system will be available to support X-33 and RLV engine test at IPTD. The objective of the task 1 effort is to define the preliminary requirements of the propellant densification GSE and tank recirculation system. The key densification system design parameters to be established in Task 1 are: recirculation flow rate; heat exchanger inlet temperature; heat exchanger outlet temperature; maximum heat rejection rate; vent flow rate (GN2 and GH2); densification time; and tank pressure level.

Lak, Tibor↗
NASA NTRS1972

Study of acoustic emission during mechanical tests of large flight weight tank structure

A polyphenylane oxide insulated, flight weight, subscale, aluminum tank was monitored for acoustic emissions during a proof test and during 100 cycles of environmental test simulating space flights. The use of a combination of frequency filtering and appropriate spatial filtering to reduce background noise was found to be sufficient to detect acoustic emission signals of relatively small intensity expected from subcritical crack growth in the structure. Several emission source locations were identified, including the one where a flaw was detected by post-test X-ray inspections. For most source locations, however, post-test inspections did not detect flaws; this was partially attributed to the higher sensitivity of the acoustic emission technique than any other currently available NDT method for detecting flaws.

Nakamura, Y.↗
NASA NTRS1973

Study of acoustic emission during mechanical tests of large flight weight tank structure

A PPO-insulated, flight-weight, subscale, aluminum tank was monitored for acoustic emissions during a proof test and during 100 cycles of environmental test simulating space flights. The use of a combination of frequency filtering and appropriate spatial filtering to reduce background noise was found to be sufficient to detect acoustic emission signals of relatively small intensity expected from subcritical crack growth in the structure. Several emission source locations were identified, including the one where a flaw was detected by post-test x-ray inspections. For most source locations, however, post-test inspections did not detect flaws; this was partially attributed to the higher sensitivity of the acoustic emission technique than any other currently available NDT method for detecting flaws. For these non-verifiable emission sources, a problem still remains in correctly interpreting observed emission signals.

Mccauley, B. O.↗