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NASA NTRS2016

Successful Completion of the JWST OGSE2 Cryogenic Test at JSC Chamber-A While Managing Numerous Challenges

The James Webb Space Telescope (JWST) Optical Telescope Element (OTE) assembly is the largest optically stable infrared-optimized telescope currently being manufactured and assembled, and scheduled for launch in 2018. The JWST OTE, including the primary mirrors, secondary mirror, and the Aft Optics Subsystems (AOS) are designed to be passively cooled and operate at near 45 degrees Kelvin. Due to the size of its large sunshield in relation to existing test facilities, JWST cannot be optically or thermally tested as a complete observatory-level system at flight temperatures. As a result, the telescope portion along with its instrument complement will be tested as a single unit very late in the program, and on the program schedule critical path. To mitigate schedule risks, a set of 'pathfinder' cryogenic tests will be performed to reduce program risks by demonstrating the optical testing capabilities of the facility, characterizing telescope thermal performance, and allowing project personnel to learn valuable testing lessons off-line. This paper describes the 'pathfinder' cryogenic test program, focusing on the recently completed second test in the series called the Optical Ground Support Equipment 2 (OGSE2) test. The JWST OGSE2 was successfully completed within the allocated project schedule while faced with numerous conflicting thermal requirements during cool-down to the final cryogenic operational temperatures, and during warm-up after the cryo-stable optical tests. The challenges include developing a pre-test cool-down and warm-up profiles without a reliable method to predict the thermal behaviors in a rarified helium environment, and managing the test article hardware safety driven by the project Limits and Constraints (L&C's). Furthermore, OGSE2 test included the time critical Aft Optics Subsystem (AOS), a part of the flight Optical Telescope Element that would need to be placed back in the overall telescope assembly integrations. The OGSE2 test requirements included the strict adherence of the project contamination controls due to the presence of the contamination sensitive flight optical elements. The test operations required close coordination of numerous personnel while they being exposed and trained for the 'final' combined OTE and instrument cryo-test in 2017. This paper will also encompass the OGSE2 thermal data look-back review.

JWST OGSE2 Cryogenic Test↗

NASA NTRS2017

Cryogenic Testing of the Thermal Vacuum Chamber and Ground Support Equipment for the James Webb Space Telescope in Chamber A at Johnson Space Center

The James Webb Space Telescope (JWST) is the largest cryogenic instrument telescope to be developed for space flight. The telescope will be passively cooled to 50 K and the instrument package will be at 40 K with the mid-infrared instrument at 6 K. The final cryogenic test of the Optical Telescope Element (OTE) and Integrated Science Instrument Module (ISIM) as an assembly (OTE + ISIM OTIS) will be performed in the largest 15 K chamber in the world, Chamber A at Johnson Space Center. The planned duration of this test will be 100 days in the middle of 2017. Needless to say, this ultimate test of OTIS, the cryogenic portion of JWST will be crucial in verifying the end-to-end performance of JWST. A repeat of this test would not only be expensive, but would delay the launch schedule (currently October 2018). Therefore a series of checkouts and verifications of the chamber and ground support equipment were planned and carried out between 2012 and 2016. This paper will provide a top-level summary of those tests, trades in coming up with the test plan, as well as some details of individual issues that were encountered and resolved in the course of testing.

thermal vacuum chamber↗

NASA NTRS2017

Research and Development History of Glass Bubbles Bulk-Fill Thermal Insulation Systems for Large-Scale Cryogenic Liquid Hydrogen Storage Tanks

Based on the published literature record, this document provides an overview of the research and development of glass bubbles bulk-fill thermal insulation systems for cryogenic equipment in general and, in particular, for large-scale cryogenic liquid hydrogen (LH2) storage spheres. Glass bubbles (also known as hollow glass microspheres) are used in place of perlite powder which began use in double-wall cryogenic tanks in the 1930s. Included in this overview is a historical summary, a development timeline, a selected publications list, and the key technical points from those publications.

Cryogenic storage tanks↗

NASA NTRS2016

Cryogenic Selective Surfaces

There are many challenges involved in deep-space exploration, but several of these can be mitigated, or even solved, by the development of a coating that can reject most of the Sun's energy and yet still provide some far-infrared heat emission. Such a coating would allow non-heat-generating objects in space to reach cryogenic temperatures without using an active cooling system. This would be a benefit to deep-space sensors that require low temperatures, such as the James Webb Telescope focal plane array. It would also allow the use of superconductors in deep space, which could lead to magnetic energy storage rings, lossless power delivery, or perhaps a large-volume magnetic shield against galactic cosmic radiation. But perhaps the most significant enablement achieved from such a coating would be the long-term storage in deep space of cryogenic liquids, such as liquid oxygen (LOX).In this report, we review the state of the art in low-temperature coatings and calculate the lowest temperatures each of these can achieve, demonstrating that cryogenic temperatures cannot be reached in deep space in this fashion. We then propose a new coating that does allow coated objects in deep space to achieve the very low temperatures required to store liquid oxygen or nitrogen. These new coatings consist of a moderately thick scattering layer (typically 5 mm) composed of a material transparent to most of the solar spectrum. This layer acts as a scatterer to the Sun's light, performing the same process as titanium dioxide in white paint in the visible. Under that layer, we place a metallic reflector, e.g. silver, to reflect long-wave radiation that is not well scattered. The result is a coating we call "Solar White," in that it scatters most of the solar spectrum just as white paint does for the visible. Our modeling of these coatings has shown that temperatures as low as 50 K can be reached for a coated object fully exposed to sunlight at 1 AU from the Sun and far from the Earth.In the second half of the report we explore a mission application of this coating in order to show that it allows LOX to be carried on a mission to Mars. Heat can reach a LOX tank in five ways: direct radiation from the Sun, scattered or reflected radiation from the Sun off of spacecraft components, radiation from nearby planets or the Moon, radiation from the infrared emission of other parts of the spacecraft, and conduction along support struts and flow lines. We discuss these and sum their total contribution when using a Solar White coating to demonstrate an architecture that allows the transportation of LOX to Mars. After this, other applications of Solar White are listed.

Cryogenic Materials↗

NASA NTRS2014

Influential Factors for Liquid Acquisition Device Screen Selection for Cryogenic Propulsion Systems

This paper presents the influential factors which govern screen selection for liquid acquisition devices (LADs) operating in microgravity conditions for future in-space cryogenic propulsion engines and cryogenic propellant depots. Space flight requirements, which include mass flow rate, acceleration level and direction, and thermal environment, dictate screen selection for a particular mission. The five influential factors include bubble point pressure, flow-through-screen pressure drop, wicking rate, screen compliance, and material compatibility. Governing equations and analytical models for these parameters are developed from first principles. A comprehensive survey of the historical data on coarser LAD meshes over four decades of work is conducted, and liquid hydrogen data for finer Dutch Twill meshes (325 x 2300, 450 x 2750, 510 x 3600) from recently concluded experiments is also presented to validate analytical models. Each of these parameters is measurable from ground based tests, making it facile to predict flight system performance. Therefore analytical models in this paper will be valuable for future LAD designs for both cryogenic and storable propulsion systems. Additionally, analysis will be given on the impact of the factors on liquid hydrogen systems.

Fuel Depot↗

NASA NTRS2016

Cryogenic Low Noise MMIC Amplifiers for U-Band (40-60 GHz)

In this work, we describe monolithic millimeter-wave integrated circuit (MMIC) Low Noise Amplifier (LNA) and mixer designs for U-Band, also known as the WR19 waveguide band (40-60 GHz). The LNAs were fabricated in NGC’s 35 nm InP HEMT MMIC process. The MMICs were packaged in WR19 waveguide housings and tested for noise, both at room temperature and cryogenically. We present the results, including a comparison to the state-of-the-art, and discuss applications for amplifiers in this frequency range. To date, these are the first cryogenic 35 nm InP MMIC results covering the 40-60 GHz range. We achieved a noise temperature less than 30 K over the 40-60 GHz range, when the amplifiers were cryogenically cooled. These results are comparable with other results in the literature, and we believe are the lowest reported for MMICs in the 50-60 GHz range.

MMIC↗

NASA NTRSDate not supplied

A Cryogenically-Cooled MW Inverter for Electric Aircraft Propulsion

Power electronic converter will be a key enabler for future electrified aircraft propulsion system. In aircraft applications, superconducting technologies such as superconducting motors and generators along with supporting power systems will grow in importance. Utilizing cryogenic cooling for power converter potentially can significantly improve the inverter system efficiency and specific power. This paper presents the cooling, hardware,and testing of a cryogenically-cooled MW inverter developed for electrified aircraft propulsion system. The 1 MVA full load testing with cryogenic cooling is demonstrated. The developed inverter system achieves 18 kVA/kg specific power and 99% efficiency, which provides a promising solution to achieve high power density and efficiency for future electrified aircraft propulsion system.

cryogenically-cooled inverter↗

NASA NTRSDate not supplied

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↗

NASA NTRSDate not supplied

Autogenous Pressurization of a Cryogenic Tank Using Computational Fluid Dynamics

Well-validated simulation tools can be used to predict long-term storage and transfer of cryogenic propellants, which are essential to NASA’s mission plan to return to the Moon and continue to Mars. Autogenous pressurization of propellant tanks is used to supply rocket engine turbopumps with pressurized liquid fuel and oxidizer, preventing cavitation. Additionally, autogenous pressurization can be used to pressurize propellant tanks to support on-orbit propellant transfer. In lieu of expensive tests conducted on-orbit, accurate predictive computational models of these processes can be used to reduce system and propellant mass as well as mission risk. Using simulation tools also reduces the cost of analyzing and developing this technology. This study presents a multiphase computational fluid dynamics model capable of simulating autogenous pressurization of a large cryogenic tank using the commercial code STAR-CCM+. Experimental data from a full-scale tank pressurization test under terrestrial gravity is compared to simulation results using transient error metrics. Comparisons show good agreement and give confidence in using these and other validated simulation tools to develop cryogenic pressurization systems.

Cryogenics↗

NASA NTRSDate not supplied

Autogenous Pressurization of a Cryogenic Tank using Computational Fluid Dynamics

cryogenics↗

NASA NTRS2021

Design, Calibration, and Application of A Cryogenic Low-Background Infrared Radiometer for Spectral Irradiance and Radiance Measurements From 4- to 20-μm Wavelength

We have constructed, calibrated, and tested a cryogenic low-background infrared (IR) radiometer for both spectral radiance and irradiance measurements over the 4- to 20-μm wavelength range. The primary purpose of the Missile Defense Transfer Radiometer (MDXR) is to measure absolute irradiance or radiance from cryogenic IR test chamber sources using a photoconductive Si:As blocked-impurity band (BIB) detector and a set of spectral filters. The MDXR also includes an absolute cryogenic radiometer (ACR) and a Fourier-transform spectrometer (FTS). For irradiance measurements, the ACR is used to provide the primary power scale for the BIB detector in conjunction with spectral filters, whereas the FTS/BIB configuration derives its scale from an internal blackbody source. The two measurement scales show agreement for the irradiance of highly collimated (<1 mrad) IR beams from 10 -13 to 10 -8 W / μm / cm 2 within the combined relative uncertainties of 2.6% (coverage factor k = 1.) We have also calibrated the radiometer for radiance measurements using a large cavity fluid bath blackbody that overfills the spatial and angular extent of the radiometer entrance pupil. The radiometric calibration uncertainty analysis of the radiometer and its maintenance and stability are discussed.

radiometry↗

NASA NTRSDate not supplied

Molecular Accumulation during JWST’s Optical Telescope Cryogenic Thermal Vacuum Testing

Maintaining molecular cleanliness during the JWST’s Optical Telescope/Instrument Module (OTIS) Cryogenic Thermal Vacuum (TV) test campaign was critical to the success of its optical mission on orbit. In the thermal vacuum tests leading up to the final cryogenic test to validate the OTIS flight hardware, NASA Johnson Space Center’s (JSC’s) TV Chamber A was fully characterized for molecular contamination. It was found to contain common volatile condensable materials (VCM), including hydrocarbons, plasticizers, and silicones, all of which absorb in JWST’s infrared wavelength region. Due to the risks involved, cleaning molecular contamination from the OTIS mirrors was not an option and heating the Primary Mirror (PM) segments would have also been a risky and expensive endeavor. As a result, a monitoring process was developed and implemented during four different Pathfinder or risk reduction tests that were scheduled to occur prior to the flight hardware test. The goal was to quantify and assess the risk of molecular contamination depositing on the PM resulting from relatively warm chamber shrouds “leading” colder PM mirrors during warmup, by a margin of 10-50 Kelvin (K). This was accomplished using Cryogenic Quartz Crystal Microbalances (CQCMs), held at temperatures slightly cooler than the segments to signal the onset of contamination events. Per the JWST Contamination Control Plan (CCP)1, the total Primary Mirror molecular allocation requirement was 50 angstroms. In all tests, the results showed an average accumulated molecular contamination of <10 angstroms.

molecular, contamination, thermal vacuum, cryogeni↗

NASA NTRSDate not supplied

Analysis of Cryogenic Propellant Liquefaction Rates in Cooled Constant-Wall-TemperatureTanks

NASA has been focused on developing technology that would allow the production of cryogenic propellants on the Lunar and Martian surfaces. Utilizing Lunar/Martian resources, the produced gaseous propellants must first be liquefied and stored prior to use on the Moon or Mars ascent vehicle. Liquefaction of cryogenic propellants is a necessary technical development to enable NASA’s future spaceflight goals. This paper presents an overview of a proposed model for a propellant liquefaction system, and the effect of tank wall temperature and the ullage pressure control band on cryogenic propellant liquefaction rates. The propellant system was assumed to be a receiver of a gas from an In-Situ Resource Utilization (ISRU) harvester and condensed the gas by cooling the tank walls. First, the heat transfer principles pertinent to condensation are summarized, followed by an overview of the model which performed the analysis, including a summary of the Fortran algorithm implementation. The sensitivity of the condensation rate relative to varying tank wall temperatures is also discussed.

cryogenics↗

NASA NTRSDate not supplied

Analysis of Cryogenic Propellant Liquefaction Rates in Cooled Constant-Wall-Temperature Tanks

NASA has been focused on developing technology that would allow the production of cryogenic propellants on the Lunar and Martian surfaces. Utilizing Lunar/Martian resources, the produced gaseous propellants must first be liquefied and stored prior to use on the Moon or Mars ascent vehicle. Liquefaction of cryogenic propellant is a necessary technical development to enable NASA’s future spaceflight goals. This paper presents an overview of the effect of spacecraft propellant system parameters on cryogenic propellant liquefaction rates. The propellant system was assumed to be a receiver of a gas from an In-Situ Resource Utilization (ISRU) harvester and condensed the gas by cooling the tank walls. First, the general thermodynamic principles pertinent to condensation are summarized, followed by an overview of the model which performed the analysis, including a summary of the Fortran implementation. Comparisons between the model results and test data are discussed, as well as sensitivity of the condensation rate to various parameters.

cryogenics↗

NASA NTRS2023

Analysis of Cryogenic Propellant Liquefaction Rates in Cooled Constant-Wall-TemperatureTanks

NASA has been focused on developing technology that would allow the production of cryogenic propellants on the Lunar and Martian surfaces. Utilizing Lunar/Martian resources, the produced gaseous propellants must first be liquefied and stored prior to use on the Moon or Mars ascent vehicle. Liquefaction of cryogenic propellant is a necessary technical development to enable NASA’s future spaceflight goals. This paper presents an overview of the effect of spacecraft propellant system parameters on cryogenic propellant liquefaction rates. The propellant system was assumed to be a receiver of a gas from an In-Situ Resource Utilization (ISRU) harvester and condensed the gas by cooling the tank walls. First, the general thermodynamic principles pertinent to condensation are summarized, followed by an overview of the model which performed the analysis, including a summary of the Fortran implementation. Comparisons between the model results and test data are discussed, as well as sensitivity of the condensation rate to various parameters.

cryogenics↗

NASA NTRSDate not supplied

Single and Multi-Node Modeling of Direct, Submerged, and Self-Pressurization of A Cryogenic Propellant Tank Using Nodal Tools

The pressurization of cryogenic propellant tanks will always be an important process so long as cryogenic liquids are being considered as fuel sources or used for other in-space applications. Pressure control of the tank ullage is necessary for managing propellant flowrates to an engine or a receiver tank, and modeling of the process is used to predict the pressurant requirements and the amount of propellant boiloff. Direct ullage pressurization is the more traditional approach to tank pressurization, as the physics are straight-forward, and ample test (flight) data have been collected and analyzed over the past several decades. Submerged injection pressurization is an alternate method for tank pressurization and has been shown to reduce pressurant requirements, subcool the propellant, and reduce the risk of ullage collapse. Additionally, the pressurant gas entering the ullage is usually much colder when using the submerged pressurization approach, resulting in reduced propellant boiloff. These benefits are at the expense of vaporizing a small percentage of the propellent. Both tank pressurization methods are viable options for current and future space missions, and it is important to have the capability of analyzing the tank ullage conditions for both approaches. Our previous work has demonstrated the development of a Generalized Fluid System Simulation Program (GFSSP) model, which contains a thermodynamic equilibrium heat and mass transfer subroutine capable of effectively analyzing both direct and submerged pressurization systems [1-2]. This subroutine has most recently been enhanced to include the non-equilibrium effect of pressurant dissolution into the propellant. To date the ullage has always been represented as a single node, and although the simulated single-node temperatures have good comparison with the volume-averaged ullage temperatures computed from test data, the physics of the thermal stratification in the ullage were never captured, and adjustment factors in the model were required. The purpose of this paper is to introduce the development of a multi-node ullage model using GFSSP and to discuss the improvements of the simulated ullage temperature distribution and its resulting effects on ullage heat transfer processes. Test data from the Cryogenic Propellant Storage and Transfer Engineering Developmental Unit (CPST EDU) was used for model validation. For additional comparison, a Thermal Desktop (TD) model was also developed to analyze the CPST EDU direct ullage pressurization tests using both a single node and multi-node approach. The model includes the direct pressurant line, vent line, fill/drain line, and a TD FloCAD Compartment. The TD FloCAD Compartment is employed to represent the liquid and ullage as single volumes inside the tank, to include a liquid/vapor interface, and to generate network level objects such as lumps (analogous to nodes in GFSSP), paths, and ties between the fluid and thermal elements. An established heat load on the model tank was leveraged from a pre-existing higher-fidelity model correlated to CPST EDU test data.

pressurization↗

NASA NTRS2023

Validation of Universal Cryogenic Flow Boiling Correlations in Thermal Desktop for Liquid Helium

Understanding two-phase cryogenic propellant behavior is key to enabling technologies for future spaceflight missions. Developing accurate models of two-phase flow phenomena, particularly flow boiling in the heating configuration is relevant to the propellant transfer process both in microgravity and on other planetary surfaces. Currently there is a need for more accurate, direct cryogenic data anchored models for various boiling phenomena. Recently, universal correlations for cryogens flowing in heated tubes have been developed for a wide variety of fluids, thermodynamic conditions, and various regimes across the boiling curve, and have been patched to provide a smooth, continuous predictive curve. This paper demonstrates how these correlations have been ported into Thermal Desktop to improve predictive performance. To test the validity of the new correlations, Thermal Desktop is validated against a historical dataset of flow boiling experiments in the heating configuration using liquid helium. Based on results, the new correlations show a substantial improvement over the original built-in flow boiling correlations in Thermal Desktop in predicting the wall temperature as a function of preponderant parameters for this quantum fluid.

cryogenic propellant transfer↗

NASA NTRSDate not supplied

Validation of Universal Cryogenic Flow Boiling Correlations in Thermal Desktop for Liquid Helium

Understanding two-phase cryogenic propellant behavior is key to enabling technologies for future spaceflight missions. Developing accurate models of two-phase flow phenomena, particularly in the current work, flow boiling in the heating configuration, is relevant to the propellant transfer process both in 1-g and microgravity. Currently there is a need for more accurate, direct cryogenic data anchored models for various boiling phenomena. Recently, universal correlations for cryogens flowing in heated tubes have been developed for a wide variety of fluids, thermodynamic conditions, and various regimes across the boiling curve, and have been patched to provide a smooth, continuous predictive curve. This paper describes implementation and validation of these correlations into Thermal Desktop to improve predictive performance, with a focus on liquid helium. Results from Thermal Desktop using both the built-in and new correlations are validated against a historical dataset of flow boiling experiments in the heating configuration using liquid helium. Based on results, the new correlations show a substantial improvement over the original built-in flow boiling correlations in Thermal Desktop in predicting the wall temperature as a function of preponderant parameters for this quantum fluid at temperatures greater than the lambda temperature, T λ = 2.17K.

cryogenic propellant transfer↗