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At least 343 records · Page 19

All sources NASA NTRS DOE OSTI

NASA NTRS1981

Development and validation of cryogenic foam insulation for LH2 subsonic transports

Fourteen foam insulation specimens were tested. Some were plain foam while others contained flame retardants, chopped fiberglass reinforcement and/or vapor barriers. The thermal performance of the insulation was determined by measuring the rate at which LH2 boiled from an aluminum tank insulated with the test material. The test specimens were approximately 50 mm (2 in.) thick. They were structurally scaled so that the test cycle would duplicate the maximum thermal stresses predicted for the thicker insulation of an aircraft liquid hydrogen fuel tank during a typical subsonic flight. The simulated flight cycle of approximately 10 minutes duration heated the other insulation surface to 316 K (110 F) and cooled it to 226 K (20 F) while the inner insulation surface remained at liquid hydrogen temperature of 20 K (-423 F). Two urethane foam insulations exceeded the initial life goal of 2400 simulated flight cycles and sustained 4400 cycles with only minor damage. The addition of fiberglass reinforcement of flame retardant materials to an insulation degraded thermal performance and/or the life of the foam material. Installation of vapor barriers enhanced the structural integrity of the material but did not improve thermal performance. All of the foams tested were available materials; none were developed specifically for LH2 service.

Anthony, F. M.↗

NASA NTRS1987

Development of tailorable advanced blanket insulation for advanced space transportation systems

Two items of Tailorable Advanced Blanket Insulation (TABI) for Advanced Space Transportation Systems were produced. The first consisted of flat panels made from integrally woven, 3-D fluted core having parallel fabric faces and connecting ribs of Nicalon silicon carbide yarns. The triangular cross section of the flutes were filled with mandrels of processed Q-Fiber Felt. Forty panels were prepared with only minimal problems, mostly resulting from the unavailability of insulation with the proper density. Rigidizing the fluted fabric prior to inserting the insulation reduced the production time. The procedures for producing the fabric, insulation mandrels, and TABI panels are described. The second item was an effort to determine the feasibility of producing contoured TABI shapes from gores cut from flat, insulated fluted core panels. Two gores of integrally woven fluted core and single ply fabric (ICAS) were insulated and joined into a large spherical shape employing a tadpole insulator at the mating edges. The fluted core segment of each ICAS consisted of an Astroquartz face fabric and Nicalon face and rib fabrics, while the single ply fabric segment was Nicalon. Further development will be required. The success of fabricating this assembly indicates that this concept may be feasible for certain types of space insulation requirements. The procedures developed for weaving the ICAS, joining the gores, and coating certain areas of the fabrics are presented.

Calamito, Dominic P.↗

NASA NTRS1995

Insulation Requirements of High-Voltage Power Systems in Future Spacecraft

The scope, size, and capability of the nation's space-based activities are limited by the level of electrical power available. Long-term projections show that there will be an increasing demand for electrical power in future spacecraft programs. The level of power that can be generated, conditioned, transmitted, and used will have to be considerably increased to satisfy these needs, and increased power levels will require that transmission voltages also be increased to minimize weight and resistive losses. At these projected voltages, power systems will not operate satisfactorily without the proper electrical insulation. Open or encapsulated power supplies are currently used to keep the volume and weight of space power systems low and to protect them from natural and induced environmental hazards. Circuits with open packaging are free to attain the pressure of the outer environment, whereas encapsulated circuits are imbedded in insulating materials, which are usually solids, but could be liquids or gases. Up to now, solid insulation has usually been chosen for space power systems. If the use of solid insulation is continued, when voltages increase, the amount of insulation for encapsulation also will have to increase. This increased insulation will increase weight and reduce system reliability. Therefore, non-solid insulation media must be examined to satisfy future spacecraft power and voltage demands. In this report, we assess the suitability of liquid, space vacuum, and gas insulation for space power systems.

Qureshi, A. Haq↗

NASA NTRS1999

An Instrument for Real-Time Measurement of Solid Rocket Motor Insulation Erosion

An instrument (eroding potentionmeter) has been designed to measure real-time case wall and inhibitor insulation char depth within a rocket motor during firing. Thus measurement can be close to the real-time recession of the insulation surface. The eroding potentionmeter consists of two small (3 mils 9in diameter) twisted resistive wires that are polyimide insulated. The wire pair form an electrical circuit and will recede with the erosion of the rocket motor internal insulation. A constant current applied along the wires will detect the resistance change via a voltage drop across the wires as the wire pair recedes with the decomposition fo the insulation. The eroding potentionmeter, as presently designed, can be an effective tool for real time measurement of internal insulation recession of a solid rocket motor. This tool will provide a way to accurately measure inhibitor performance or to measure flight effects of insulation erosion on a flight test. The eroding potentiometer has been verified on a plasma torch test and two static tests of a small solid rocket motor. There are some irregularities in the measured date, but the data remains useful in determining the real-time performance of internal insulation during a motor firing.

McWhorter, B. B.↗

NASA NTRS2000

Use of Several Thermal Analysis Techniques to Study the Cracking of an Nitrile Butadiene Rubber (NBR) Insulator on the Booster Separation Motor (BSM) of the Space Shuttle

Two different vendor rubber formulations have been used to produce the silica-filled NBR insulators for the BSM used on both of the Solid Rocket Boosters (SRBs) of the Space Shuttle. A number of lots of the BSM insulator in 1998-99 exhibited surface cracks and/or crazing. Each insulator is bonded to the BSM aluminum aft closure with an epoxy adhesive. Induced insulator stresses from adhesive cure are likely greatest where the insulator/adhesive contour is the greatest, thus showing increased insulator surface cracking in this area. Thermal analysis testing by Dynamic Mechanical Analyzer (DMA) and Thermomechanical Analysis (TMA) was performed on one each of the two vendor BSM insulators previously bonded that exhibited the surface cracking. The TMA data from the film/fiber technique yielded the most meaningful results, with thin insulator surface samples containing cracks having roughly the same modulus (stiffness) as thin insulator bulk samples just underneath.

Wingard, Charles D.↗

NASA NTRS2002

Optimal Design of Functionally Graded Metallic Foam Insulations

The focus of our work has been on developing an insight into the physics that govern the optimum design of thermal insulation for use in thermal protection systems of launch vehicle. Of particular interest was to obtain optimality criteria for designing foam insulations that have density (or porosity) distributions through the thickness for optimum thermal performance. We investigate the optimum design of functionally graded thermal insulation for steady state heat transfer through the foam. We showed that the heat transfer in the foam has competing modes, of radiation and conduction. The problem assumed a fixed inside temperature of 400 K and varied the aerodynamic surface heating on the outside surface from 0.2 to 1.0 MW/sq m. The thermal insulation develops a high temperature gradient through the thickness. Investigation of the model developed for heat conduction in foams showed that at high temperatures (as on outside wall) intracellular radiation dominates the heat transfer in the foam. Minimizing radiation requires reducing the pore size, which increases the density of the foam. At low temperatures (as on the inside wall), intracellular conduction (of the metal and air) dominates the heat transfer. Minimizing conduction requires increasing the pore size. This indicated that for every temperature there was an optimum value of density that minimized the heat transfer coefficient. Two optimization studies were performed. One was to minimize the heat transmitted though a fixed thickness insulation by varying density profiles. The second was to obtain the minimum mass insulation for specified thickness. Analytical optimality criteria were derived for the cases considered. The optimality condition for minimum heat transfer required that at each temperature we find the density that minimizes the heat transfer coefficient. Once a relationship between the optimum heat transfer coefficient and the temperature was found, the design problem reduced to the solution of a simple nonlinear differential equation. Preliminary results of this work were presented at the American Society of Composites meeting, and the final version was submitted for publication in the AIAA Journal. In addition to minimizing the transmitted heat, we investigated the optimum design for minimum weight given an acceptable level of heat transmission through the insulation. The optimality criterion developed was different from that obtained for minimizing beat transfer coefficient. For minimum mass design, we had to find for a given temperature the optimum density, which minimized the logarithmic derivative of the insulation thermal conductivity with respect to its density. The logarithmic derivative is defined as the ratio of relative change in the dependent response (thermal conductivity) to the relative change in the independent variable (density). The results have been documented as a conference paper that will be presented at the upcoming AIAA.

Haftka, Raphael T.↗

NASA NTRS2001

A Study of the Electrostatic Interaction Between Insulators and Martian/Lunar Soil Simulants

Using our previous experience with the Mars Environmental Compatibility Assessment (MECA) electrometer, we have designed a new type of aerodynamic electrometer. The goal of the research was to measure the buildup of electrostatic surface charge on a stationary cylindrical insulator after windborne granular particles have collided with the insulator surface in a simulated dust storm. The experiments are performed inside a vacuum chamber. This allows the atmospheric composition and pressure to be controlled in order to simulate the atmospheric conditions near the equator on the Martian surface. An impeller fan was used to propel the dust particles at a cylindrically shaped insulator under low vacuum conditions. We tested the new electrometer in a 10 mbar CO2 atmosphere by exposing two types of cylindrical insulators, Teflon (1.9 cm diameter) and Fiberglass (2.5 cm diameter), to a variety of windborne granular particulate materials. The granular materials tested were JSC Mars-1 simulant, which is a mixture of coarse and fine (<5microns diameter) particle sizes, and some of the major mineral constituents of the Martian soil. The minerals included Ottawa sand (SiO2), iron oxide (Fe2O3), aluminum oxide (Al2O3) and magnesium oxide (MgO). We also constructed a MECA-like electrometer that contained an insulator capped planar electrode for measuring the amount of electrostatic charge produced by rubbing an insulator surface over Martian and lunar soil simulants. The results of this study indicate that it is possible to detect triboelectric charging of insulator surfaces by windborne Martian soil simulant, and by individual mineral constituents of the soil simulant. We have also found that Teflon and Fiberglass insulator surfaces respond in different ways by developing opposite polarity surface charge, which decays at different rates after the particle impacts cease.

Mantovani, James G.↗

NASA NTRS2002

A Multilayered Thin Film Insulator for Harsh Environments

The status of work to develop a reliable high temperature dielectric thin film for use with thin film sensors is presented. The use of thin films to electrically insulate thin film sensors on engine components minimizes the intrusiveness of the sensor and allows a more accurate measurement of the environment. A variety of insulating films were investigated for preventing electrical shorting caused by insulator failure between the sensor and the component. By alternating layers of sputtered high temperature ceramics, a sequence of insulating layers was devised that prevents pinholes from forming completely through the insulator and maintains high electrical resistivity at high temperatures. The major technical challenge remaining is to optimize the fabrication of the insulator with respect to composition to achieve a reliable high temperature insulating film. Data from the testing of various potentially insulating thin film systems is presented and their application to thin film sensors is also discussed.

Wrbanek, John D.↗

NASA NTRS2002

Investigating the Use of Ultrasonic Guided Waves for Aging Wire Insulation Assessment

Aging wiring has become a critical issue to DoD, NASA, FAA, and Industry. The problem is that insulation on environmentally aged wire becomes brittle and cracks. This exposes the underlying conductive wire to the potential for short circuits and fire. The difficulty is that techniques to monitor aging wire problems focus on applying electrical sensing techniques that are not very sensitive to the wire insulation. Thus, the development of methods to quantify and monitor aging wire insulation is highly warranted. Measurement of wire insulation stiffness by ultrasonic guided waves is being examined. Initial laboratory tests were performed on a simple model consisting of a solid cylinder and then a solid cylinder with a polymer coating. Experimental measurements showed that the lowest order axisymmetric mode may be sensitive to stiffness changes in the wire insulation. To test this theory, mil-spec wire samples MIL-W-81381, MIL-W-22759/34, and MIL-W-22759/87 (typically found in aircraft) were heat-damaged in an oven, in a range of heating conditions. The samples were 12, 16, and 20 gauge and the heat-damage introduced material changes in the wire-insulation that made the originally flexible insulation brittle and darker in color. Axisymmetric mode phase velocity increased for the samples that were exposed to heat for longer duration. For example, the phase velocity in the 20-gauge MIL-W-22759/34 wire changed from a baseline value of 2790m/s to 3280m/s and 3530m/s for one-hour exposures to 3490C and 3990C, respectively. Although the heat-damage conditions are not the same as environmental aging, we believe that with further development and refinements, the ultrasonic guided waves can be used to inspect wire-insulation for detrimental environmental aging conditions.

Anastasi, Robert F.↗

NASA NTRS2010

Basalt fiber and nanoclay compositions, articles incorporating the same, and methods of insulating a rocket motor with the same

An insulation composition that comprises at least one nitrile butadiene rubber, basalt fibers, and nanoclay is disclosed. Further disclosed is an insulation composition that comprises polybenzimidazole fibers, basalt fibers, and nanoclay. The basalt fibers may be present in the insulation compositions in a range of from approximately 1% by weight to approximately 6% by weight of the total weight of the insulation composition. The nanoclay may be present in the insulation compositions in a range of from approximately 5% by weight to approximately 10% by weight of the total weight of the insulation composition. Rocket motors including the insulation compositions and methods of insulating a rocket motor are also disclosed.

Gajiwala, Himansu M.↗

NASA NTRS2000

Advanced Space Suit Insulation Feasibility Study

For planetary applications, the space suit insulation has unique requirements because it must perform in a dynamic mode to protect humans in the harsh dust, pressure and temperature environments. Since the presence of a gaseous planetary atmosphere adds significant thermal conductance to the suit insulation, the current multi-layer flexible insulation designed for vacuum applications is not suitable in reduced pressure planetary environments such as that of Mars. Therefore a feasibility study has been conducted at NASA to identify the most promising insulation concepts that can be developed to provide an acceptable suit insulation. Insulation concepts surveyed include foams, microspheres, microfibers, and vacuum jackets. The feasibility study includes a literature survey of potential concepts, an evaluation of test results for initial insulation concepts, and a development philosophy to be pursued as a result of the initial testing and conceptual surveys. The recommended focus is on microfibers due to the versatility of fiber structure configurations, the wide choice of fiber materials available, the maturity of the fiber processing industry, and past experience with fibers in insulation applications

Trevino, Luis A.↗

NASA NTRS2011

Rocket motors incorporating basalt fiber and nanoclay compositions and methods of insulating a rocket motor with the same

Gajiwala, Himansu M.↗

NASA NTRS2012

Mass Efficiency Considerations for Thermally Insulated Structural Skin of an Aerospace Vehicle

An approximate equation was derived to predict the mass of insulation required to limit the maximum temperature reached by an insulated structure subjected to a transient heating pulse. In the course of the derivation two figures of merit were identified. One figure of merit correlates to the effectiveness of the heat capacity of the underlying structural material in reducing the amount of required insulation. The second figure of merit provides an indicator of the mass efficiency of the insulator material. An iterative, one dimensional finite element analysis was used to size the external insulation required to protect the structure at a single location on the Space Shuttle Orbiter and a reusable launch vehicle. Required insulation masses were calculated for a range of different materials for both structure and insulator. The required insulation masses calculated using the approximate equation were shown to typically agree with finite element results within 10 to 20 percent over the range of parameters studied. Finite element results closely followed the trends indicated by both figures of merit.

Blosser, Max L.↗

NASA NTRS2013

Polymer-Reinforced, Non-Brittle, Lightweight Cryogenic Insulation

The primary application for cryogenic insulating foams will be fuel tank applications for fueling systems. It is crucial for this insulation to be incorporated into systems that survive vacuum and terrestrial environments. It is hypothesized that by forming an open-cell silica-reinforced polymer structure, the foam structures will exhibit the necessary strength to maintain shape. This will, in turn, maintain the insulating capabilities of the foam insulation. Besides mechanical stability in the form of crush resistance, it is important for these insulating materials to exhibit water penetration resistance. Hydrocarbon-terminated foam surfaces were implemented to impart hydrophobic functionality that apparently limits moisture penetration through the foam. During the freezing process, water accumulates on the surfaces of the foams. However, when hydrocarbon-terminated surfaces are present, water apparently beads and forms crystals, leading to less apparent accumulation. The object of this work is to develop inexpensive structural cryogenic insulation foam that has increased impact resistance for launch and ground-based cryogenic systems. Two parallel approaches will be pursued: a silica-polymer co-foaming technique and a post foam coating technique. Insulation characteristics, flexibility, and water uptake can be fine-tuned through the manipulation of the polyurethane foam scaffold. Silicate coatings for polyurethane foams and aerogel-impregnated polyurethane foams have been developed and tested. A highly porous aerogel-like material may be fabricated using a co-foam and coated foam techniques, and can insulate at liquid temperatures using the composite foam

Hess, David M.↗

NASA NTRS2024

Thermal Modeling and Testing of High-Temperature Refractory Ceramic Insulation Felts

Heat transfer in high-temperature, high-porosity, flexible refractory ceramic fibrous insulation felts is investigated. Heat transfer in these insulation materials consists of combined gas conduction, solid conduction, and radiation modes, with the precise theoretical modeling of the latter two modes being formidable. A semi-empirical model that requires inverse methods and steady-state thermal test data to infer some of the required model parameters is further developed in this study, and applied to five insulation materials for temperatures between 300 K and 1900 K. The steady-state thermal test setup at NASA Langley Research Center with recent modifications to increase its testing capability to 1900 K is discussed. Design considerations to ensure one-dimensional heat transfer in the test setup are described. Test data and corresponding thermal models for alumina and zirconia-based fibrous insulation felts are presented. Furthermore, test data and thermal models on two fibrous insulation samples containing additives to further suppress either radiation or gas conduction modes of heat transfer are presented. Previously published alumina-based insulation data are also re-processed using the updated modeling methodology. The significance of various heat transfer modes in typical insulation samples is discussed and used to provide general guidance on optimum insulation layups.

Kamran Daryabeigi↗

DOE OSTI2015

Final Technical Report: Electromagnetic Pump Insulation Materials Development and Testing (PLM-DOC-0005-2465) Report # DOEGEHB00613

Final Technical Report: Electromagnetic Pump Insulation Materials Development and Testing (Report # DOEGEHB00613) summarizes the information gathered from the analysis of the 160 m3/min EM Pump insulation that was tested in 2000-2002 and additional evaluations of new resilient, engineered insulation system evaluated and tested at both GRC and ANL. This report provides information on Tasks 1 and 2 of the entire project. This report also provides information in three broad areas: Historical and current data; Conclusions based on test data; and Insulation specifications for use in EM Pumps. The research for Task 2 builds upon Task 1: Update EM Pump Databank, which is summarized within this report. Where research for Task 3 and 4 Next-Generation EM Pump Analysis Tools identified parameters or analysis model that benefits Task 2 research, those items are noted within this report. The important design variables for the manufacture and operation of an EM Pump that the insulation research can evaluate are: space constraints; voltage capability of insulation system; maximum flux density through iron; flow rate and outlet pressure; efficiency and manufacturability. The development summary of the Electromagnetic Pump Insulation Materials Development and Testing was completed to include: Historical and current data; Conclusions based on test data; and Insulation specifications for use in EM Pumps.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Evacuated Spheres for Closed-Cell Vacuum Insulation

Insulation materials with a thermal resistance per inch higher than 6h∙ft 2 ∙°F/Btu∙in or R6/in (42m∙K/W) are needed for building envelope retrofits in which solutions with slim profiles are required because of minimal available space or because real estate has a premium cost. These insulation materials will also be of benefit to prefabricated construction given that slim designs either reduce shipping costs or increase the floor space provided to the customer. Vacuum insulation panels (VIPs) are the current state-of-the-art insulation material with a resistance of about R35/in (243m∙K/W); however, their use in buildings is hindered by the fact that damages to their protective film decrease their performance to ≤R8/in (56m∙K/W). Given the lack of robust, highly-insulating materials, we are exploring methods to develop evacuated spheres that can act as a closed-cell vacuum insulation. The evacuated spheres could be assembled into boards that could attain ~R14/in (97m∙K/W). Advantages that evacuated spheres will offer over VIPs are that they will likely be more suitable for construction because punctures will only cause localized damage, and that the boards could be cut into customized shapes. We are currently investigating two processes to evacuate spheres to produce polymeric vacuum insulation spheres (PVISs) and coated and evacuated insulation spheres (CEISs). PVISs involve the extrusion of economical polymers, blowing agents, and gas barriers. CEISs use naturally-occurring or synthesized hollow particles with porous shells that are evacuated and coated with a gas impermeable thin film. Both manufacturing processes aim for very large throughputs to ensure cost-effectiveness and adoption by the construction industry. This paper discusses the manufacturing techniques that we are exploring and our progress to date.

Hun, Diana E.↗

DOE OSTI2022

The effect of barrier films and exposure on the aging of vacuum insulation panels with fumed silica cores

Vacuum insulation panels have very low thermal conductivities compared to conventional insulation materials. The reduction of the core pressure significantly lowers gas phase conduction and overall thermal conductivity. As a consequence, increases in gas pressure can significantly increase thermal conductivity of the VIP. In addition, the thermal conductivity of the core is sensitive to moisture content. For vacuum insulation panels with fumed silica cores, work shows that the measured thermal conductivity increases by 0.5 x 10-3 W/mK per mass percent increase in water content [1]. This is significant since the thermal conductivity of vacuum insulation panels with fumed silica cores is in the range of 0.004 W/mK. This work investigates the long-term behavior of vacuum insulation panels comprised of fumed silica cores with polymer (ethylene vinyl alcohol) and metalized (aluminized) barrier films exposed to different exposure conditions: ambient conditions; exterior conditions in a mixed humid climate; and 24oC and 80 percent relative humidity. Results show that the increase in thermal conductivity is more pronounced for vacuum insulation panels made using polymer barrier films compared to the same panel protected by a metalized film. The increase is more pronounced when exposed to high relative humidity, 80 percent. After almost two years exposure, the decrease in thermal conductivity for vacuum insulation panels protected by a metalized barrier films are between 4 and 11 percent depending on exposure condition. The smallest decrease is for ambient conditions where the largest decrease is for exposure to 80 percent relative humidity. Similar behavior was observed for panels protected using polymer films, except the decrease in thermal conductivity was significantly higher, between approximately 20 and 60 percent, in the same order as for panels protected by metalized films. Measurements are ongoing with an attempt to develop a better relationship between these types of tests and vacuum insulation panel service life.

Aldykiewicz Jr, Antonio↗