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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

Design, Manufacture and Test of Cryotank Components

On the composite cryotank technology development (CCTD) project, the Boeing Company built two cryotanks as a means of advancing technology and manufacturing readiness levels (TRL and MRL) and lowering the risk of fabricating full-scale fuel containment vessels.1 CCTD focused on upper stage extended duration applications where long term storage of propellants is required. The project involved the design, analysis, fabrication, and test of manufacturing demonstration units (MDU), a 2.4 m (precursor) and a 5.5 m composite cryotank. Key design features included one-piece wall construction to minimize overall weight (eliminating the need for a bellyband joint), 3-dimensionally (3D) reinforced y-joint material to alleviate stress concentrations at the tank to skirt interface and a purge-able fluted core skirt to carry high axial launch loads. The tanks were made with OoA curing pre-impregnated (prepreg) carbon/epoxy (C/E) slit-tape tow (STT) that contained thin micro-crack resistant plies in the tank wall center to impede permeation. The tanks were fabricated at Boeing's Seattle-based Advanced Development Center (ADC) using RAFP and multipiece break-down tooling. The tooling was designed and built by Janicki Industries (JI) at Sedro Woolley, Washington. Tank assemblage consisted of co-bonded dome covers, one-piece fluted core skirts and mechanical fastened cover/sump. Ultrasonic inspection was performed after every cure or bond and a structural health monitoring system (SHMS) was installed to identify potential impact damage events (in-process and/or during transportation). The tanks were low temperature tested at NASA's George C. Marshall Space Flight Center (MSFC) in Huntsville, Alabama. The testing, which consisted of a sequence of fill/drain pressure and thermal cycles using LH2, was successfully concluded in 2012 on the 2.4 m tank and in 2014 on the 5.5 m tank. Structural, thermal, and permeation performance data was obtained. 2 Critical design features and manufacturing advancements, which helped to validate 25% weight and 30% cost reduction projections, were matured. These advancements will help to guide future composite tank integration activities on next generation long duration aircraft and space launch vehicles. Because CCTD addressed innovative design features, heavy lift size scale-up, multipiece captured tooling, new generation automated material placement (AMP) equipment and OoA materials, this chapter should be of interest to educators, students and manufacturers of composite hardware and flight vehicles.

McCarville, Douglas A.↗
NASA NTRS1974

Correlation for estimating vortex rotational velocity downstream dependence

Description of a correlation, derived from water tank measurements in the wake of wings towed under water, that makes it possible to predict the downstream distance behind an aircraft in flight where its trailing vortex will begin to decay. Comparisons of measured and predicted data are discussed.

Ciffone, D. L.↗
NASA NTRS1933

A Complete Tank Test of a Model of a Flying-boat Hull - N.A.C.A. Model No.11-A

Model No. 11-A was designed as an improvement over N.A.C.A. Model No. 11, a complete test of which is described in N.A.C.A. Technical Note No. 464. In contrast with the longitudinal upward curvature in the planing bottom forward of the main step on Model 11-A was made as flat as practicable. Otherwise, the two models have very nearly the same form. The results of towing tests made on Model 11-A in the N.A.C.A. tank over a wide range of speed, load on the water, and trim angle are presented, both as original test data and as non dimensional coefficients. A comparison is made with similar results from the test of Model No. 11. The practical significance of the improvement obtained is demonstrated by applying the data from the new form to the illustrative design problem use in the note on Model NO. 11.

Parkinson, John B↗
NASA NTRS1991

STS-39 Discovery in the VAB and Columbia Tow From HB-2

The orbiter Discovery sits inside the Vehicle Assembly Building (VAB) after its rollover from the Orbiter Processing Facility (OPF). In the VAB, Discovery will be mated with an external tank and solid rocket boosters for its launch. Shown also is Columbia orbiter being towed from the High Bay 2.

Source record↗
NASA NTRS1934

Tank Tests of Auxiliary Vanes as a Substitute for Planing Area

The results of towing tests made on two models at the request of the Bureau of Aeronautics, Navy Department, are presented. The first model represents the hull of the U.S. Navy PN-8 flying boat, in which the sponsors of the original hull are removed and auxiliary lifting vanes are fitted at the chines immediately forward of the main step. The tests showed that the altered form gave a large increase in hump resistance and a very undesirable spray formation through a large part of the speed range.

Parkinson, John B↗
NASA NTRS2018

Fabrication of a Composite Tow-Steered Structure for Air-Launch Vehicle Applications

Generation Orbit (GO) is developing the GO Launcher-1 (GO-1), a single stage liquid rocket that is launched from a Gulfstream III carrier aircraft platform. The vehicle is designed as the next generation platform for hypersonic flight testing and suborbital microgravity research. To reduce mass and increase payload, GO partnered with NASA Langley Research Center to design, analyze, optimize, and fabricate a tow-steered manufacturing development unit of a cylindrical section of a liquid oxygen tank. The fabrication process of using the ISAAC (Integrated Structural Assembly of Advanced Composites) system is described. The structural design challenges and the concept design solutions are also presented to provide the context for the fabrication process. The in-situ nondestructive evaluation supporting the effort is also described.

Grenoble, Ray↗
NASA NTRS1985

External tank processing from barge to pad

Delivery and launch readiness events for the External Tanks (ET) are discussed. The ET is off-loaded at the KSC Barge Turning Basin and towed to the Vertical Assembly Building (VAB), High Bay Transfer Aisle. It is erected vertically and placed in the ET Checkout Area of High Bay 2 or 4 for standalone checkout. At the completion of checkout the ET is transferred to storage or to the Integration Area of High Bay 1 or 3 for SRB and Orbiter Mate. A Systems Integration Test performed with the Orbiter and Solid Rocket Booster is described. Final checkout activities are also described.

Carpenter, J. E.↗
NASA NTRS1942

An Investigation of Hydrofoils in the NACA Tank I : Effect of Dihedral and Depth of Submersion

Tests were conducted on hydrofoil assemblies approximating an arrangement for use under seaplanes or surface boats. A series of hydrofoils, each supported by two struts, was towed at various depths ranging from partial submersions to a depth of 5-chord lengths. At depths greater than 4 or 5 chords, the influence of the surface of the water is small; hydrofoils operating at low speed will have characteristics similar to those of airfoils of the same section.

HYDROFOILS - NACA - CHARACTERISTICS TANK TESTS (NA↗
NASA NTRS2005

STS-114: Discovery Mission Status Briefing

Phil Engelauf, STS-114 Mission Operations Representative reports: the orbital rendezvous was successful, and today's activities includes initial preparations of the next day's extravehicular activities (EVA); he specifically mentioned tile repair, wiring on the outside of the vehicle to try to recover CMG2 (Control Moment Gyro), and preparation for the external stowage platform. John Shannon, Manager of the Space Shuttle Operations and Integration reports from Engineering standpoint that the composites of the underside of the tile surface seen from pictures taken during the pitch maneuver were extremely clean; the Engineering staff continues to look at the focus inspection data from the orbital boom sensor system (OBSS) and other data to assess the condition of the vehicle. Solid rocket boosters were retrieved and are towed back to the Air Force hangar in Cape Carneval. Six target inspection (nose gear doors, gap fillers, chine area, external tank doors, trailing edge, and ice), and arm operations, foam, conservation measures, shuttle air lock, aerodynamics assessment and re-entry were topics covered with the News media.

Source record↗
NASA NTRS1939

The Enlarged N.A.C.A. Tank, and Some of Its Work

The most conspicuous of the features of the enlarged N.A.C.A. tank are derived directly from those of the original tank and owe their present form not only to the reasons for their first use but also to the experience obtained with them. As in the original tank, there are: 1) A basin of great length (new 2,880 feet); 2) Rails made of structural H beams, without machining; 3) A towing carriage of very high speed (now 80 mph maximum); 4) Rubber tires on all the wheels, pneumatic on the running wheels and solid on the guide wheels.

Truscott, Starr↗
DOE OSTI2024

Low-Cost, High-Performance Carbon Fiber for Compressed Natural Gas Storage Tanks (Final Technical Report – Down Select Report)

The aim of this project is to reduce the cost of Type IV, carbon fiber (CF) composite overwrap compressed gas storage tanks by reducing the cost of CF and CF composites. The project team worked to reduce the cost of CF by exploring and testing opportunities for a low-cost alternative precursor material for CF production to supplant market-dominant and costly polyacrylonitrile (PAN). Concurrently, the team aimed to reduce the cost of the tanks at the composite level by improving the interfacial adhesion between the fibers and the matrix resin through the incorporation of low-cost nanoparticles recycled from waste materials, which would reduce the volume of costly CF required to achieve the same tank performance. At the end of the first year, the project team selected mesophase pitch as the primary precursor candidate from a field of materials based on the superior mechanical performance and cost-saving potential. During the second year, the team produced CFs derived from mesophase pitch achieving an average tensile strength of 365.6 ksi and average tensile modulus of 40.74 Msi. Facility availability for spinning and converting these fibers at greater scale has hindered scale-up demonstration, but the team has identified opportunities to conduct this work in the near term. Cost modeling shows that these mesophase pitch-derived CFs can be up to 40% less expensive than PAN-derived CFs due to the lower cost of the feedstock material, higher throughput, greater conversion yield, and lower cost spinning method and compared to PAN. Additionally, the team has demonstrated at lab-scale that nanoparticle coating CFs can significantly increase the interfacial shear strength and load transfer efficiency of CFs in a matrix. Single filament pull-out testing showed a 27% average increase in max interfacial shear strength due to this coating. A continuous method of applying these coatings to a tow of CF has been developed for scale-up. 26 m tows of coated CFs were produced using this system and formed into composite ring samples for ASTM ring burst testing. Issues with the testing protocol have limited assessment of these results. A prototype Type IV tank was designed to meet ANSI HGV2 standards, and the design criteria set out by DOE, using the CF properties developed by the team paired with a proprietary resin matrix, a polyamide liner, and aluminum end bosses. The tank weighs 153.1 kg and with a total capacity of 5.8 kg H2 (5.6 kg usable), which yields a gravimetric capacity of 1.17 kWh/kg. Cost modeling predicts that the tank will have a projected cost of $15.73/kWh. Tank performance modeling does not include considerations for fiber-matrix load transfer efficiency improvements offered by nanoparticle coating method.

08 HYDROGEN↗
NASA NTRS2011

Hybrid Composite Cryogenic Tank Structure

A hybrid lightweight composite tank has been created using specially designed materials and manufacturing processes. The tank is produced by using a hybrid structure consisting of at least two reinforced composite material systems. The inner composite layer comprises a distinct fiber and resin matrix suitable for cryogenic use that is a braided-sleeve (and/or a filamentwound layer) aramid fiber preform that is placed on a removable mandrel (outfitted with metallic end fittings) and is infused (vacuum-assisted resin transfer molded) with a polyurethane resin matrix with a high ductility at low temperatures. This inner layer is allowed to cure and is encapsulated with a filamentwound outer composite layer of a distinct fiber resin system. Both inner and outer layer are in intimate contact, and can also be cured at the same time. The outer layer is a material that performs well for low temperature pressure vessels, and it can rely on the inner layer to act as a liner to contain the fluids. The outer layer can be a variety of materials, but the best embodiment may be the use of a continuous tow of carbon fiber (T-1000 carbon, or others), or other high-strength fibers combined with a high ductility epoxy resin matrix, or a polyurethane matrix, which performs well at low temperatures. After curing, the mandrel can be removed from the outer layer. While the hybrid structure is not limited to two particular materials, a preferred version of the tank has been demonstrated on an actual test tank article cycled at high pressures with liquid nitrogen and liquid hydrogen, and the best version is an inner layer of PBO (poly-pphenylenebenzobisoxazole) fibers with a polyurethane matrix and an outer layer of T-1000 carbon with a high elongation epoxy matrix suitable for cryogenic temperatures. A polyurethane matrix has also been used for the outer layer. The construction method is ideal because the fiber and resin of the inner layer has a high strain to failure at cryogenic temperatures, and will not crack or produce leaks. The outer layer serves as more of a high-performance structural unit for the inner layer, and can handle external environments.

DeLay, Thomas↗
NASA NTRS2004

Liquid-Crystal Thermosets, a New Generation of High-Performance Liquid-Crystal Polymers

One of the major challenges for NASA's next-generation reusable-launch-vehicle (RLV) program is the design of a cryogenic lightweight composite fuel tank. Potential matrix resin systems need to exhibit a low coefficient of thermal expansion (CTE), good mechanical strength, and excellent barrier properties at cryogenic temperatures under load. In addition, the resin system needs to be processable by a variety of non-autoclavable techniques, such as vacuum-bag curing, resin-transfer molding (RTM), vacuum-assisted resin-transfer molding (VaRTM), resin-film infusion (RFI), pultrusion, and advanced tow placement (ATP). To meet these requirements, the Advanced Materials and Processing Branch (AMPB) at NASA Langley Research Center developed a new family of wholly aromatic liquid-crystal oligomers that can be processed and thermally cross-linked while maintaining their liquid-crystal order. All the monomers were polymerized in the presence of a cross-linkable unit by use of an environmentally benign melt-condensation technique. This method does not require hazardous solvents, and the only side product is acetic acid. The final product can be obtained as a powder or granulate and has an infinite shelf life. The obtained oligomers melt into a nematic phase and do not exhibit isotropization temperatures greater than the temperatures of decomposition (Ti > T(sub dec)). Three aromatic formulations were designed and tested and included esters, ester-amides, and ester-imides. One of the major advantages of this invention, named LaRC-LCR or Langley Research Center-Liquid Crystal Resin, is the ability to control a variety of resin characteristics, such as melting temperature, viscosity, and the cross-link density of the final part. Depending on the formulation, oligomers can be prepared with melt viscosities in the range of 10-10,000 poise (100 rad/s), which can easily be melt-processed using a variety of composite-processing techniques. This capability provides NASA with custom-made matrix resins that meet the required processing conditions for the fabrication of textile composites. Once the resin is in place, the temperature is raised to 375 C and the oligomers are cross-linked into a high-glass-transition-temperature (Tg) nematic network without releasing volatiles. The mechanical properties of the fully crosslinked, composite articles are comparable to typical composites based on commercially available epoxy resins.

Dingemans, Theo↗