Results for “cryogenic engineering” — Page 29

NASA NTRS2001

Cooled Ceramic Matrix Composite Panel Successfully Tested in Rocket Exhaust

Actively cooled ceramic matrix composite (CMC) components are enabling or enhancing for a broad range of hypersonic and reusable launch vehicle propulsion systems. Teaming with other NASA centers, the Air Force, and industry, the Glenn Ceramics Branch has successfully tested multiple cooled CMC panel concepts in high-heat-flux, high-pressure, flowing rocket engine combustion gas environments. Sub-element components survived multiple cycles and the severe thermal gradients imposed by combustion gas temperatures in excess of 5500 F and cryogenic hydrogen or ambient temperature water internal coolants. These demonstrations are critical for the continued development of this class of materials, and the research is expected to continue with additional concepts and increasingly larger and more complex geometries being fabricated and tested in a broad range of engine operating conditions.

Eckel, Andrew J.↗

NASA NTRS1975

Advanced space engine component technology status

Key to the achievement of maximum benefit from the Space Tug transportation system is the availability of a low-cost, high-performance engine system. To define this engine system, studies have been conducted under Air Force and NASA direction, and pertinent hardware technology programs have been initiated. From among the several candidate systems studied, the cryogenic, staged-combustion cycle, high chamber pressure system in conjunction with a large-area-ratio nozzle was selected for component and subsystem demonstration. Main turbopump, high-area-ratio thrust chamber, preburner, and igniter components are being evaluated. A brief description of the engine capabilities, the main liquid hydrogen and liquid oxygen turbopump/preburner, and the main thrust chamber programs are presented; designs and progress in fabrication are shown and test results discussed.

Zachary, A. T.↗

NASA NTRSDate not supplied

The Potential Effects of Radiation-Caused Tank Heating in Nuclear Thermal Propulsion Applications

Nuclear thermal propulsion (NTP) vehicles provide a strong option for crewed missions to Mars. Such designs which use cryogenic hydrogen as the stored propellant can provide ISP in excess of 850 seconds and thrusts capable of accelerations roughly comparable to typical in-space chemical engines thus enabling shorter travel times and wider mission abort windows. Given those capabilities, NTP engines provide a viable option for travel to Mars. Nonetheless, complications arise as the nuclear reactions in the reactor core not only heat the propellant but also emit radiation which affects components across the vehicle. In particular, the radiation which reaches the propellant tanks can heat the stored cryogenic propellant, altering the temperature of the propellant as it leaves the tank headed to the turbopump. Determining whether that tank heating causes significant heating of the outflowing propellant serves as an important question for any NTP vehicle design. Results show that warm propellant can cause buoyancy-driven fluid motion within the tank and ultimately can be drawn into the outflow from the tank, and thus must be accounted for in analysis and design of NTP vehicles.

Kalen E Braman↗

NASA NTRSDate not supplied

The Potential Effects of Radiation-Caused Tank Heating in Nuclear Thermal Propulsion Applications

Nuclear thermal propulsion (NTP) vehicles provide a strong option for crewed missions to Mars. Such designs which use cryogenic hydrogen as the stored propellant can provide ISP in excess of 850 seconds and thrusts capable of accelerations roughly comparable to typical in-space chemical engines thus enabling shorter travel times and wider mission abort windows. Given those capabilities, NTP engines provide a viable option for travel to Mars. Nonetheless, complications arise as the nuclear reactions in the reactor core not only heat the propellant but also emit radiation which affects components across the vehicle. In particular, the radiation which reaches the propellant tanks can heat the stored cryogenic propellant, altering the temperature of the propellant as it leaves the tank headed to the turbopump. Determining whether that tank heating causes significant heating of the outflowing propellant serves as an important question for any NTP vehicle design. Results show that warm propellant can cause buoyancy-driven fluid motion within the tank and ultimately can be drawn into the outflow from the tank, and thus must be accounted for in analysis and design of NTP vehicles.

Kalen Braman↗

NASA NTRS1985

Effect of low temperature on fatigue and fracture properties of Ti-5Al-2.5Sn(ELI) for use in engine components

Experiments were conducted to evaluate the characteristics of the Ti-5Al-2.5Sn (ELI) alloy used in a fuel pump impeller at cryogenic temperatures. Tension, fracture toughness, and fatigue crack propagation data were collected determining the effect of frequency and load ratio on crack propagation. The results revealed that tensile strength increased significantly at 20 K compared to room temperature and fracture toughness was reduced at cryogenic temperatures. The fatigue crack growth rate was not sensitive to experimental conditions and there were only minimal crack orientation effects. Different frequencies produced no effect. At various temperatures and frequencies a load ratio increase resulted in higher crack growth rates. At low stress intensity levels the fatigue rate for both temperatures was the same; however, at high stress intensity levels the crack growth rate at 20 K increased because of the decrease in fracture toughness. The results correlated well with previous data.

Ryder, J. T.↗

NASA NTRS1989

COLD-SAT: An orbital cryogenic hydrogen technology experiment

The COLD-SAT spacecraft will perform subcritical liquid hydrogen storage and transfer experiments under low-gravity conditions to provide engineering data for future space transportation missions. Consisting of an experiment module mated to a spacecraft bus, COLD-SAT will be placed in an initial 460 km circular orbit by an Atlas I commercial launch vehicle. After deployment, the three-axis-controlled spacecraft bus will provide electric power, experiment control and data management, communications, and attitude control along with propulsive acceleration levels ranging from 10(-6) to 10(-4)g. These accelerations are an important aspect of some of the experiments, as it is desired to know the effects that low gravity levels might have on the heat and mass transfer processes involved. The experiment module will contain the three liquid hydrogen tanks, valves, pressurization equipment, and instrumentation. At launch all the hydrogen will be in the largest tank, which has helium-purged MLI and is loaded and topped off by the hydrogen tanking system used for the Centaur upper stage of the Atlas. The two smaller tanks will be utilized in orbit for performing some of the experiments. The experiments are grouped into two classes on the basis of their priority, and include six regarded as enabling technology and nine regarded as enhancing technology.

Schuster, J. R.↗

NASA NTRS1989

COLD-SAT - An orbital cryogenic hydrogen technology experiment

The COLD-SAT spacecraft will perform subcritical liquid hydrogen storage and transfer experiments under low-gravity conditions to provide engineering data for future space transportation missions. Consisting of an experiment module mated to a spacecraft bus, COLD-SAT will be placed in an initial 460 km circular orbit by an Atlas I commercial launch vehicle. After deployment, the three-axis-controlled spacecraft bus will provide electric power, experiment control and data management, communications, and attitude control along with propulsive acceleration levels ranging from 10 (-6) to 10(-4) g. These accelerations are an important aspect of some of the experiments, as it is desired to know the effects that low gravity levels might have on the heat and mass transfer processes involved. The experiment module will contain the three liquid hydrogen tanks, valves, pressurization equipment, and instrumentation. At launch all the hydrogen will be in the largest tank, which has helium-purged MLI and is loaded and topped off by the hydrogen tanking system used for the Centaur upper stage of the Atlas. The two smaller tanks will be utilized in orbit for performing some of the experiments. The experiments are grouped into two classes on the basis of their priority, and include six regarded as enabling technology and nine regarded as enhancing technology.

Schuster, J. R.↗

NASA NTRS1996

Cryogenic Brush Seal Test Results

Brush seals are compliant, contact seals that have long-life, low-leakage characteristics desirable for use in rocket engine turbopumps. 50.8-mm (2.0 inch) diameter brush seals with a nominal initial radial interference of 0.127-mm (0.005 inch) were tested in liquid nitrogen at shaft speeds up to 35,000 rpm and differential pressure loads up to 1.21 MPa (175 psi) per brush. The measured leakage rate of a single brush was 2-3 times less than that measured for a 12-tooth, 0.127-mm (0.005 inch) radial clearance labyrinth seal used as a baseline. Stage effects were studied and it was found that two brush seals with a large separation distance leaked less than two brushes tightly packed together. The maximum measured groove depth on the Inconel 718 rotor was 25.4 (mu)m (0.001 inch) after 4.31 hours of shaft rotation. The Haynes-25 bristles wore approximately 25.4-76.2 (mu)m (0.001-0.003 inch) under the same conditions. Three seal runner coatings, chromium carbide, Teflon impregnated chromium, and zirconium oxide, were tested in liquid hydrogen at 35,000 and 65,000 rpm with separate 50.8 mm diameter brush seals made of Haynes-25 bristles and having a nominal initial radial interference of 129 rpm. Two bare Inconel-718 rotors were also tested as a baseline. The test results revealed significant differences between the wear characteristics of the uncoated and coated seal runners. At both speeds the brush seal with the bare Inconel-718 seal runner exhibited significant bristle wear with excessive material transferring to the runner surface. In contrast, the coated seal runners inhibited the transfer and deposit of bristle material. The chromium carbide coating showed only small quantities of bristle material transferring to its surface. The Teflon impregnated chromium coating also inhibited material transfer and provided some lubrication. This coating, however, is self-sacrificing. The Teflon remained present on the low speed runner, but it was completely removed from the high speed brush seal, which was tested considerably longer. The tests of the Teflon coating revealed the importance of using a lubricating and low friction coating for brush seals to reduce bristle and seal runner wear. The zirconium oxide coating exhibited the greatest amount of coating wear, while the brushes incurred only slight wear. Further testing of ceramics is recommended before making a final judgement on the viability of ceramic coatings for brush seals because of the contrast between the results reported by Carlile and the results presented herein. Strictly based on the results presented hereinabove, the chromium carbide and Teflon impregnated chromium coatings were considered preferable to the uncoated Inconel-718 and zirconium oxide coatings because of their good wear resistance and characteristics to inhibit bristle material wear and transfer to the seal runner.

Proctor, Margaret P.↗

NASA NTRS1992

Cryogenic Magnetic Bearing Test Facility (CMBTF)

The Cryogenic Magnetic Bearing Test Facility (CMBTF) was designed and built to evaluate compact, lightweight magnetic bearings for use in the SSME's (space shuttle main engine) liquid oxygen and liquid hydrogen turbopumps. State of the art and tradeoff studies were conducted which indicated that a hybrid permanent magnet bias homopolar magnetic bearing design would be smaller, lighter, and much more efficient than conventional industrial bearings. A test bearing of this type was designed for the test rig for use at both room temperature and cryogenic temperature (-320 F). The bearing was fabricated from state-of-the-art materials and incorporated into the CMBTF. Testing at room temperature was accomplished at Avcon's facility. These preliminary tests indicated that this magnetic bearing is a feasible alternative to older bearing technologies. Analyses showed that the hybrid magnetic bearing is one-third the weight, considerably smaller, and uses less power than previous generations of magnetic bearings.

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NASA NTRS2013

Self-Healing Nanocomposites for Reusable Composite Cryotanks

Composite cryotanks, or composite overwrapped pressure vessels (COPVs), offer advantages over currently used aluminum-lithium cryotanks, particularly with respect to weight savings. Future NASA missions are expected to use COPVs in spaceflight propellant tanks to store fuels, oxidizers, and other liquids for launch and space exploration vehicles. However, reliability, reparability, and reusability of the COPVs are still being addressed, especially in cryogenic temperature applications; this has limited the adoption of COPVs in reusable vehicle designs. The major problem with composites is the inherent brittleness of the epoxy matrix, which is prone to microcrack formation, either from exposure to cryogenic conditions or from impact from different sources. If not prevented, the microcracks increase gas permeation and leakage. Accordingly, materials innovations are needed to mitigate microcrack damage, and prevent damage in the first place, in composite cryotanks. The self-healing technology being developed is capable of healing the microcracks through the use of a novel engineered nanocomposite, where a uniquely designed nanoparticle additive is incorporated into the epoxy matrix. In particular, this results in an enhancement in the burst pressure after cryogenic cycling of the nanocomposite COPVs, relative to the control COPVs. Incorporating a novel, self-healing, epoxy-based resin into the manufacture of COPVs allows repeatable self-healing of microcracks to be performed through the simple application of a low-temperature heat source. This permits COPVs to be reparable and reusable with a high degree of reliability, as microcracks will be remediated. The unique phase-separated morphology that was imparted during COPV manufacture allows for multiple self-healing cycles. Unlike single-target approaches where one material property is often improved at the expense of another, robustness has been introduced to a COPV by a combination of a modified resin and nanoparticle additives. Unique nanoparticles were used that have been surface-functionalized to be compatible with the resin. Both organic and inorganic components toughen the matrix and result in a more impact-resistant COPV. In one resin system containing an inorganic nanomaterial additive, a significant improvement in burst performance was observed after the COPV was cryo-impact-damaged and then self-healed, with a greater than 10% improvement in burst pressure after the self-healing process was performed. Initial cross-sectional analysis via microscopy showed good resin infiltration of the carbon fibers and without voids. To further enhance the capability between the nanomaterial additives and the resin, a surface modification was successfully performed. A second specialty epoxy resin was prepared using a surface modified nanomaterial additive, and COPVs were fabricated. Steps were taken to improve the mechanical properties of the COPVs by using a low-viscosity resin system that contained a different curing agent. This lower viscosity improves the processing of the COPV, and preliminary results show that the burst pressure of these new vessels is 20 to 25% higher than that of the original. The self-healing concept demonstrated in this research and development effort represents a platform technology, and the self-healing property is neither restricted to the particular epoxy system used here, nor to the COPV application. Self-healing is a direct result of a unique phase separated morphology created via the resin and is aided by the nanoparticles. The self-healing function can be introduced to other customer-specific resin systems in coating, bulk, or composite applications provided that the unique phase separated morphology can be enabled in those systems.

Eberly, Daniel↗

NASA NTRS2013

Interferometers Sharpen Measurements for Better Telescopes

Over the last decade, there have been a number of innovations that have made possible the largest and most powerful telescope of its time: the James Webb Space Telescope (JWST). Scheduled to launch in 2018, JWST will provide insight into what the oldest, most distant galaxies look like. When engineers build a first-of-its-kind instrument like the JWST, they often must make new tools to construct the new technology. Throughout the decades of planning, development, and construction of the JWST, NASA has worked with numerous partners to spur innovations that have enabled the telescope s creation. Though the JWST s launch date is still several years away, a number of these innovations are spinning off to provide benefits here on Earth. One of these spinoffs has emerged from the extensive testing the JWST must undergo to ensure it will function in the extreme environment of space. In order to test the JWST instruments in conditions that closely resemble those in space, NASA uses a cryogenic vacuum chamber. By dropping the temperatures down to -400 F and employing powerful pumps to remove air from the chamber, engineers can test whether the JWST instruments will function once the spacecraft leaves Earth. Traditionally, a phase-shifting interferometer is used to measure optics like the JWST s mirrors to verify their precise shape, down to tens of nanometers, during manufacturing. However, the large size of the mirrors, coupled with vibration induced by the cryo-pumps, prohibits the use of traditional phase-shifting interferometers to measure the mirrors within the chamber environment. Because the JWST will be located in deep space, far from any possible manned service mission, it was essential to find a robust solution to guarantee the performance of the mirrors.

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NASA NTRS2019

NASA's Space Launch System: Payload Opportunities for Lunar Exploration, Science Missions

Nearing its first launch, the Space Launch System (SLS), NASA’s new super heavy-lift launch vehicle, offers highly energetic launches that deliver more mass and provide more volume in 8.4 m-diameter and potentially larger fairings to make a new generation of deep space missions possible. An evolvable launcher available in crew, crew with a co-manifested payload (CPL) and cargo-only configurations, SLS is a crucial capability to enable astronauts to return to the Moon, but it also offers key benefits for science missions. NASA’s 21st-century return to the Moon recently received a formal name: the Artemis program. In addition to the core enabling capabilities of SLS and the Orion crew spacecraft, NASA will also enlist international and commercial partnerships for Artemis. The Agency intends to build a scientific outpost in lunar orbit, the Gateway, from which human and robotic missions to and from the surface can rendezvous. SLS will launch Orion on a series of missions leading to landing the first woman and the next man on the Moon as part of Artemis. SLS uses proven propulsion systems: two solid rocket boosters and four RS-25s engines that have been upgraded to provide more thrust and operate in the SLS environment. SLS Block 1 uses a modified Delta IV Heavy upper stage, called the Interim Cryogenic Propulsion Stage (ICPS) and lifts at least 26 metric tons (t) to trans-lunar injection (TLI). The Block 1 vehicle can also be outfitted with a 5 m-diameter fairing. Block 1B, the next major variant, also uses solid rocket boosters and RS-25 engines to achieve Earth escape velocity, but replaces the single-engine liquid hydrogen (LH2)/liquid oxygen (LOX) ICPS with a four-engine LH2/LOX Exploration Upper Stage (EUS) to increase mass to TLI to 34-37 t, depending on crew or cargo configuration. In the Block 1B crew configuration, a 10 m-tall Universal Stage Adapter (USA) connects the vehicle to Orion and can carry a CPL up to 10 t. The USA provides 286 m3 of unpressurized volume for payloads. For large payloads, 8.4 m- and 10 m-diameter cargo fairings in 19.1 m and 27.4 m lengths are possible. The ultimate SLS vehicle, Block 2, incorporates evolved boosters to reach a lift capacity of more than 45 t to TLI. The capabilities of SLS not only make new missions to the Moon possible, but also game-changing science missions, such as deployment of large-aperture space telescopes, spacecraft to the ice giants or even probes to the interstellar medium. This paper will discuss the capabilities of SLS, the vehicle’s planned evolution, missions that can effectively utilize the vehicle and manufacturing status of the vehicle.

Creech, Stephen D.↗

NASA NTRS2019

NASA's Space Launch System: Payload Opportunities for Lunar Exploration, Science Missions

Nearing its first launch, the Space Launch System (SLS), NASA’s new super heavy-lift launch vehicle, offers highly energetic launches that deliver more mass and provide more volume in 8.4 m-diameter and potentially larger fairings to make a new generation of deep space missions possible. An evolvable launcher available in crew, crew with a co-manifested payload (CPL) and cargo-only configurations, SLS is a crucial capability to enable astronauts to return to the Moon, but it also offers key benefits for science missions. NASA’s 21st-century return to the Moon recently received a formal name: the Artemis program. In addition to the core enabling capabilities of SLS and the Orion crew spacecraft, NASA will also enlist international and commercial partnerships for Artemis. The Agency intends to build a scientific outpost in lunar orbit, the Gateway, from which human and robotic missions to and from the surface can rendezvous. SLS will launch Orion on a series of missions leading to landing the first woman and the next man on the Moon as part of Artemis. SLS uses proven propulsion systems: two solid rocket boosters and four RS-25s engines that have been upgraded to provide more thrust and operate in the SLS environment. SLS Block 1 uses a modified Delta IV Heavy upper stage, called the Interim Cryogenic Propulsion Stage (ICPS) and lifts at least 26 metric tons (t) to trans-lunar injection (TLI). The Block 1 vehicle can also be outfitted with a 5 m-diameter fairing. Block 1B, the next major variant, also uses solid rocket boosters and RS-25 engines to achieve Earth escape velocity, but replaces the single-engine liquid hydrogen (LH2)/liquid oxygen (LOX) ICPS with a four-engine LH2/LOX Exploration Upper Stage (EUS) to increase mass to TLI to 34-37 t, depending on crew or cargo configuration. In the Block 1B crew configuration, a 10 m-tall Universal Stage Adapter (USA) connects the vehicle to Orion and can carry a CPL up to 10 t. The USA provides 286 m3 of unpressurized volume for payloads. For large payloads, 8.4 m- and 10 m-diameter cargo fairings in 19.1 m and 27.4 m lengths are possible. The ultimate SLS vehicle, Block 2, incorporates evolved boosters to reach a lift capacity of more than 45 t to TLI. The capabilities of SLS not only make new missions to the Moon possible, but also game-changing science missions, such as deployment of large-aperture space telescopes, spacecraft to the ice giants or even probes to the interstellar medium. This paper will discuss the capabilities of SLS, the vehicle’s planned evolution, missions that can effectively utilize the vehicle and manufacturing status of the vehicle.

Creech, Steve↗

DOE OSTI2021

In-Situ Calibrated Modeling of Residual Stresses Induced in Machining under Various Cooling and Lubricating Environments

Although many functional characteristics, such as fatigue life and damage resistance depend on residual stresses, there are currently no industrially viable ‘Digital Process Twin’ models (DPTs) capable of efficiently and quickly predicting machining-induced stresses. By leveraging advances in ultra-high-speed in-situ experimental characterization of machining and finishing processes under plane strain (orthogonal/2D) conditions, we have developed a set of physics-based semi-analytical models to predict residual stress evolution in light of the extreme gradients of stress, strain and temperature, which are unique to these thermo-mechanical processes. Initial validation trials of this novel paradigm were carried out in Ti-6Al4V and AISI 4340 alloy steel. A variety dry, cryogenically cooled and oil lubricated conditions were evaluated to determine the model’s ability to capture the tribological changes induced due to lubrication and cooling. The preliminarily calibrated and validated model exhibited an average correlation of better than 20% between the predicted stresses and experimental data, with calculation times of less than a second. Based on such fast-acting DPTs, the authors envision future capabilities in pro-active surface engineering of advanced structural components (e.g., turbine blades).

36 MATERIALS SCIENCE↗

NASA NTRS1991

Thin film thermocouples for high temperature turbine application

The objective is to develop thin film thermocouples (TFTC) for Space Shuttle Main Engine (SSME) components such as the high pressure fuel turbopump (HPFTP) blades and to test TFTC survivability and durability in the SSME environment. The purpose for developing TFTC's for SSME components is to obtain blade temperatures for computational models developed for fluid mechanics and structures. The TFTC must be able to withstand the presence of high temperature, high pressure hydrogen as well as a severe thermal transient due to a cryogenic to combustion temperature change. The TFTC's will eventually be installed and tested on SSME propulsion system components in the SSME test bed engine. The TFTC's were successfully fabricated on flat coupons of MAR-M 246 (Hf+), which is the superalloy material used for HPFTP turbine blades. The TFTC's fabricated on flat coupons survived thermal shock cycling as well as testing in a heat flux measurement facility which provided a rapid thermal transient. The same fabrication procedure was used to deposit TFTC's on HPFTP first stage rotor blades. Other results from the experiments are presented, and future testing plans are discussed.

Martin, Lisa C.↗

NASA NTRS2009

Insulating Foams Save Money, Increase Safety

Scientists at Langley Research Center created polyimide foam insulation for reusable cryogenic propellant tanks on the space shuttle. Meanwhile, a small Hialeah, Florida-based business, PolyuMAC Inc., was looking for advanced foams to use in the customized manufacturing of acoustical and thermal insulation. The company contacted NASA, licensed the material, and then the original inventors worked with the company's engineers to make a new material that was better for both parties. The new version, a high performance, flame retardant, flexible polyimide foam, is used for insulating NASA cryogenic propellant tanks and shows promise for use on watercraft, aircraft, spacecraft, electronics and electrical products, automobiles and automotive products, recreation equipment, and building and construction materials.

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NASA NTRS1967

Summary of NERVA radiation effects tests at cryogenic temperatures.

NERVA radiation effects tests at cryogenic temperatures

CRYOGENIC TEMPERATURE↗

NASA NTRS1987

Propellant Tanks for Tethered Orbital Refueling Facility

Thermodynamics, mechanical stability, and mass penalties affect design. Pair of reports presents design study for propellant tanks used in low gravity. Each tank, which most likely contains liquid H2 or O2, part of fuel depot tethered to station in orbit around Earth. Some engineering concepts in study applied to design of tanks for use on Earth in transport and storage of cryogenic liquids and other fluids requiring special handling.

Rudolph, L. Kevin↗