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At least 577 records · Page 32

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NASA NTRS1948

Free-Spinning-Tunnel Tests of a 1/24-Scale Model of the Grumman XF9F-2 Airplane with Wing-Tip Tanks Installed

An investigation of the spin and recovery characteristics of a 1/24-scale model of the Grumman XF9F-2 airplane with wing-tip tanks installed has been conducted-in the Langley 20-foot free-spinning tunnel. The effects of control settings and movements on the erect spin and recovery characteristics of the model for a range of possible loadings of the tip tanks were determined. Spin and recovery characteristics without tanks were determined in a previous investigation. The model results indicated that the airplane spins will generally be oscillatory and that recoveries will be satisfactory for all loadings by normal recovery technique (full rudder reversal followed approximately one-half turn later by moving the elevator down). The rudder force necessary for recovery should be within the physical capability of the pilot but the elevator force may be excessive so that some type of balance or booster might be necessary, or it might be necessary to jettison the wing-tip tanks.

Berman, Theodore↗

NASA NTRS2004

Hybrid Tank Technology

Researchers have accomplished great advances in pressure vessel technology by applying high-performance composite materials as an over-wrap to metal-lined pressure vessels. These composite over-wrapped pressure vessels (COPVs) are used in many areas, from air tanks for firefighters and compressed natural gas tanks for automobiles, to pressurant tanks for aerospace launch vehicles and propellant tanks for satellites and deep-space exploration vehicles. NASA and commercial industry are continually striving to find new ways to make high-performance pressure vessels safer and more reliable. While COPVs are much lighter than all-metal pressure vessels, the composite material, typically graphite fibers with an epoxy matrix resin, is vulnerable to impact damage. Carbon fiber is most frequently used for the high-performance COPV applications because of its high strength-to-weight characteristics. Other fibers have been used, but with limitations. For example, fiberglass is inexpensive but much heavier than carbon. Aramid fibers are impact resistant but have less strength than carbon and their performance tends to deteriorate.

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NASA NTRS2006

Momentum Transfer in a Spinning Fuel Tank Filled with Xenon

Transient spin-up and spin-down flows inside of spacecraft fuel tanks need to be analyzed in order to properly design spacecraft control systems. Knowledge of the characteristics of angular momentum transfer to and from the fuel is used to size the de-spin mechanism that places the spacecraft in a controllable in-orbit state. In previous studies, several analytical models of the spin-up process were developed. However, none have accurately predicted all of the flow dynamics. Several studies have also been conducted using Navier-Stokes based methods. These approaches have been much more successful at simulating the dynamic processes in a cylindrical container, but have not addressed the issue of momentum transfer. In the current study, the spin-up and spin-down of a fuel tank filled with gaseous xenon has been investigated using a three-dimensional unsteady Navier-Stokes code. Primary interests have been concentrated on the spin-up/spin-down time constants and the initial torque imparted on the system. Additional focus was given to the relationship between the dominant flow dynamics and the trends in momentum transfer. Through the simulation of both a cylindrical and a spherical tank, it was revealed that the transfer of angular momentum is nonlinear at early times and tends toward a linear pattern at later times. Further investigation suggests that the nonlinear spin up is controlled by the turbulent transport of momentum, while the linear phase is controlled by a Coriolis driven (Ekman) flow along the outer wall. These results indicate that the spinup and spin-down processes occur more quickly in tanks with curved surfaces than those with defined top, bottom, and side walls. The results also provide insights for the design of spacecraft de-spin mechanisms.

Peugeot, John W.↗

NASA NTRS2006

Review of Current State of the Art and Key Design Issues With Potential Solutions for Liquid Hydrogen Cryogenic Storage Tank Structures for Aircraft Applications

Due to its high specific energy content, liquid hydrogen (LH2) is emerging as an alternative fuel for future aircraft. As a result, there is a need for hydrogen tank storage systems, for these aircraft applications, that are expected to provide sufficient capacity for flight durations ranging from a few minutes to several days. It is understood that the development of a large, lightweight, reusable cryogenic liquid storage tank is crucial to meet the goals of and supply power to hydrogen-fueled aircraft, especially for long flight durations. This report provides an annotated review (including the results of an extensive literature review) of the current state of the art of cryogenic tank materials, structural designs, and insulation systems along with the identification of key challenges with the intent of developing a lightweight and long-term storage system for LH2. The broad classes of insulation systems reviewed include foams (including advanced aerogels) and multilayer insulation (MLI) systems with vacuum. The MLI systems show promise for long-term applications. Structural configurations evaluated include single- and double-wall constructions, including sandwich construction. Potential wall material candidates are monolithic metals as well as polymer matrix composites and discontinuously reinforced metal matrix composites. For short-duration flight applications, simple tank designs may suffice. Alternatively, for longer duration flight applications, a double-wall construction with a vacuum-based insulation system appears to be the most optimum design. The current trends in liner material development are reviewed in the case that a liner is required to minimize or eliminate the loss of hydrogen fuel through permeation.

Mital, Subodh K.↗

NASA NTRS2006

An Overview of Spray-On Foam Insulation Applications on the Space Shuttle's External Tank: Foam Applications and Foam Shedding Mechanisms

The Columbia Accident Investigation Board (CAIB) concluded that the cause of the tragic loss of the Space Shuttle Columbia and its crew was a breach in the thermal protection system on the leading edge of the left wing. The breach was initiated by a piece of insulating foam that separated from the left bipod ramp of the External Tank and struck the wing in the vicinity of the lower half of Reinforced Carbon-Carbon panel No. 8 at 81.9 seconds after launch. The CAIB conclusion has spawned numerous studies to identify the cause of and factors influencing foam shedding and foam debris liberation from the External Tank during ascent. The symposium on the Thermo-mechanics and Fracture of Space Shuttle External Tank Spray-On Foam Insulation is a collection of presentations that discuss the physics and mechanics of the ET SOFI with the objective of improving analytical and numerical methods for predicting foam thermo-mechanical and fracture behavior. This keynote presentation sets the stage for the presentations contained in this symposium by introducing the audience to the various types of SOFI applications on the Shuttle s External Tank and by discussing the various mechanisms that are believed to be the cause of foam shedding during the Shuttle s ascent to space

Sullivan, Roy M.↗

NASA NTRS1992

Method of providing a lunar habitat from an external tank

A lunar habitat is provided by placing an external tank of an orbiter in a low Earth orbit where the hydrogen tank is separated from the intertank and oxygen tank which form a base structure. The base structure is then outfitted with an air lock, living quarters, a thermal control system, an environmental control and life support system, and a propulsion system. After the mounting of an outer sheath about the base structure to act as a micrometeoroid shield, the base structure is propelled to a soft landing on the moon. The sheath is mounted at a distance from the base structure to provide a space therebetween which is filled with regolith after landing. Conveniently, a space station is used to outfit the base structure. Various elements of the oxygen tank and intertank are used in outfitting.

King, Charles B.↗

NASA NTRS2008

Risk Assessment for Titanium Pressure Vessels Operating Inside the ARES I's Liquid Hydrogen Tank Environment

Titanium alloy (Ti-6-4) is currently being proposed for the manufacturing of pressure vessels (PV) for storage of compressed helium gas, which are mounted inside the ARES I's liquid hydrogen (LH2) tank. At cryogenic temperature, titanium alloys usually have the highest strength-to-weight ratio property and have been considered as the metallic materials of choice for lightweight PV operating in LH2 environment. Titanium PV s are also considered as heritage hardware because they have been used by NASA for the Saturn IV-B rocket s LH2 tank in the mid 1960 s. However, hydrogen embrittlement is possible if Ti-6-4 alloy is exposed to gaseous hydrogen at certain pressure and temperature during the LH2 tank filling and draining operations on the launch pad, and during the J2X engine burn period for the ARES I s upper stage. Additionally, the fracture toughness and ductility properties of Ti-6-4 are significantly decreased at cryogenic temperature. These factors do not necessary preclude the use of titanium PV in hydrogen or at cryogenic applications; however, their synergistic effects and the material damage tolerance must be accounted for in the mission life assessment for PV s, which are considered as fracture critical hardware. In this paper, an overview of the risk assessment for Ti-6-4 alloy, strategy to control hydrogen embrittlement and brief metallic material trade study for PV operating in LH2 tank will be presented.

Lee, Jonathan A.↗

NASA NTRS2008

Cryogenic Pressure Control Modeling for Ellipsoidal Space Tanks in Reduced Gravity

A computational fluid dynamics (CFD) model is developed to simulate pressure control of an ellipsoidal-shaped liquid hydrogen tank under external heating in low gravity. Pressure control is provided by an axial jet thermodynamic vent system (TVS) centered within the vessel that injects cooler liquid into the tank, mixing the contents and reducing tank pressure. The two-phase cryogenic tank model considers liquid hydrogen in its own vapor with liquid density varying with temperature only and a fully compressible ullage. The axisymmetric model is developed using a custom version of the commercially available FLOW-3D software and simulates low gravity extrapolations of engineering checkout tests performed at Marshall Space Flight Center in 1999 in support of the Solar Thermal Upper Stage Technology Demonstrator (STUSTD) program. Model results illustrate that stable low gravity liquid-gas interfaces are maintained during all phases of the pressure control cycle. Steady and relatively smooth ullage pressurization rates are predicted. This work advances current low gravity CFD modeling capabilities for cryogenic pressure control and aids the development of a low cost CFD-based design process for space hardware.

Hedayat, Ali↗

NASA NTRS2009

LOX Tank Helium Removal for Propellant Scavenging

System studies have shown a significant advantage to reusing the hydrogen and oxygen left in these tanks after landing on the Moon in fuel cells to generate power and water for surface systems. However in the current lander concepts, the helium used to pressurize the oxygen tank can substantially degrade fuel cell power and water output by covering the reacting surface with inert gas. This presentation documents an experimental investigation of methods to remove the helium pressurant while minimizing the amount of the oxygen lost. This investigation demonstrated that significant quantities of Helium (greater than 90% mole fraction) remain in the tank after draining. Although a single vent cycle reduced the helium quantity, large amounts of helium remained. Cyclic venting appeared to be more effective. Three vent cycles were sufficient to reduce the helium to small (less than 0.2%) quantities. Two vent cycles may be sufficient since once the tank has been brought up to pressure after the second vent cycle the helium concentration has been reduced to the less than 0.2% level. The re-pressurization process seemed to contribute to diluting helium. This is as expected since in order to raise the pressure liquid oxygen must be evaporated. Estimated liquid oxygen loss is on the order of 82 pounds (assuming the third vent cycle is not required).

Chato, David J.↗

NASA NTRS2010

Liquid Oxygen Propellant Densification Production and Performance Test Results With a Large-Scale Flight-Weight Propellant Tank for the X33 RLV

This paper describes in-detail a test program that was initiated at the Glenn Research Center (GRC) involving the cryogenic densification of liquid oxygen (LO2). A large scale LO2 propellant densification system rated for 200 gpm and sized for the X-33 LO2 propellant tank, was designed, fabricated and tested at the GRC. Multiple objectives of the test program included validation of LO2 production unit hardware and characterization of densifier performance at design and transient conditions. First, performance data is presented for an initial series of LO2 densifier screening and check-out tests using densified liquid nitrogen. The second series of tests show performance data collected during LO2 densifier test operations with liquid oxygen as the densified product fluid. An overview of LO2 X-33 tanking operations and load tests with the 20,000 gallon Structural Test Article (STA) are described. Tank loading testing and the thermal stratification that occurs inside of a flight-weight launch vehicle propellant tank were investigated. These operations involved a closed-loop recirculation process of LO2 flow through the densifier and then back into the STA. Finally, in excess of 200,000 gallons of densified LO2 at 120 oR was produced with the propellant densification unit during the demonstration program, an achievement that s never been done before in the realm of large-scale cryogenic tests.

Tomsik, Thomas M.↗

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 NTRS2011

Seal Joint Analysis and Design for the Ares-I Upper Stage LOX Tank

The sealing capability of the Ares-I Upper Stage liquid oxygen tank-to-sump joint is assessed by analyzing the deflections of the joint components. Analyses are performed using three-dimensional symmetric wedge finite element models and the ABAQUS commercial finite element software. For the pressure loads and feedline interface loads, the analyses employ a mixed factor of safety approach to comply with the Constellation Program factor of safety requirements. Naflex pressure-assisted seals are considered first because they have been used successfully in similar seal joints in the Space Shuttle External Tank. For the baseline sump seal joint configuration with a Naflex seal, the predicted joint opening greatly exceeds the seal design specification. Three redesign options of the joint that maintain the use of a Naflex seal are studied. The joint openings for the redesigned seal joints show improvement over the baseline configuration; however, these joint openings still exceed the seal design specification. RACO pressure-assisted seals are considered next because they are known to also be used on the Space Shuttle External Tank, and the joint opening allowable is much larger than the specification for the Naflex seals. The finite element models for the RACO seal analyses are created by modifying the models that were used for the Naflex seal analyses. The analyses show that the RACO seal may provide sufficient sealing capability for the sump seal joint. The results provide reasonable data to recommend the design change and plan a testing program to determine the capability of RACO seals in the Ares-I Upper Stage liquid oxygen tank sump seal joint.

Phillips, Dawn R.↗

NASA NTRS2011

Method for CFD Simulation of Propellant Slosh in a Spherical Tank

Propellant sloshing can impart unwanted disturbances to spacecraft, especially if the spacecraft controller is driving the system at the slosh frequency. This paper describes the work performed by the authors in simulating propellant slosh in a spherical tank using computational fluid dynamics (CFD). ANSYS-CFX is the CFD package used to perform the analysis. A 42 in spherical tank is studied with various fill fractions. Results are provided for the forces on the walls and the frequency of the slosh. Snapshots of slosh animation give a qualitative understanding of the propellant slosh. The results show that maximum slosh forces occur at a tank fill fraction of 0.4 and 0.6 due to the amount of mass participating in the slosh and the room available for sloshing to occur. The slosh frequency increases as the tank fill fraction increases.

Benson, David J.↗

NASA NTRS2012

Summary of Activities for Nondestructive Evaluation of Insulation in Cryogenic Tanks

This project was undertaken to investigate methods to non-intrusively determine the existence and density of perlite insulation in the annular region of the cryogenic storage vessels, specifically considering the Launch Complex 39 hydrogen tanks at Kennedy Space Center. Lack of insulation in the tanks (as existed in the pad B hydrogen tank at Kennedy Space Center) results in an excessive loss of commodity and can pose operational and safety risks if precautions are not taken to relieve the excessive gas build-up. Insulation with a density that is higher than normal (due to settling or compaction) may also pose an operational and safety risk if the insulation prevents the system from moving and responding to expansions and contractions as fluid is removed and added to the tank.

Arens, Ellen↗

NASA NTRS2012

Validation of Slosh Model Parameters and Anti-Slosh Baffle Designs of Propellant Tanks by Using Lateral Slosh Testing

The slosh dynamics of propellant tanks can be represented by an equivalent mass-pendulum-dashpot mechanical model. The parameters of this equivalent model, identified as slosh mechanical model parameters, are slosh frequency, slosh mass, and pendulum hinge point location. They can be obtained by both analysis and testing for discrete fill levels. Anti-slosh baffles are usually needed in propellant tanks to control the movement of the fluid inside the tank. Lateral slosh testing, involving both random excitation testing and free-decay testing, are performed to validate the slosh mechanical model parameters and the damping added to the fluid by the anti-slosh baffles. Traditional modal analysis procedures were used to extract the parameters from the experimental data. Test setup of sub-scale tanks will be described. A comparison between experimental results and analysis will be presented.

Perez, Jose G.↗

NASA NTRS2012

Development of Non-Optimum Factors for Launch Vehicle Propellant Tank Bulkhead Weight Estimation

Non-optimum factors are used during aerospace conceptual and preliminary design to account for the increased weights of as-built structures due to future manufacturing and design details. Use of higher-fidelity non-optimum factors in these early stages of vehicle design can result in more accurate predictions of a concept s actual weights and performance. To help achieve this objective, non-optimum factors are calculated for the aluminum-alloy gores that compose the ogive and ellipsoidal bulkheads of the Space Shuttle Super-Lightweight Tank propellant tanks. Minimum values for actual gore skin thicknesses and weld land dimensions are extracted from selected production drawings, and are used to predict reference gore weights. These actual skin thicknesses are also compared to skin thicknesses predicted using classical structural mechanics and tank proof-test pressures. Both coarse and refined weights models are developed for the gores. The coarse model is based on the proof pressure-sized skin thicknesses, and the refined model uses the actual gore skin thicknesses and design detail dimensions. To determine the gore non-optimum factors, these reference weights are then compared to flight hardware weights reported in a mass properties database. When manufacturing tolerance weight estimates are taken into account, the gore non-optimum factors computed using the coarse weights model range from 1.28 to 2.76, with an average non-optimum factor of 1.90. Application of the refined weights model yields non-optimum factors between 1.00 and 1.50, with an average non-optimum factor of 1.14. To demonstrate their use, these calculated non-optimum factors are used to predict heavier, more realistic gore weights for a proposed heavy-lift launch vehicle s propellant tank bulkheads. These results indicate that relatively simple models can be developed to better estimate the actual weights of large structures for future launch vehicles.

Wu, K. Chauncey↗

NASA NTRS2013

Global Response of the Space Shuttle External Tank with the Presence of Intertank Stringer Cracks and Radius Blocks

After propellant was loaded into the external tank (ET), the November 5, 2010 launch of Space Shuttle mission STS-133 was scrubbed due to a gaseous hydrogen leak located in a vent line near the ground umbilical and ET connection. Subsequent visual inspections identified cracks in the sprayed-on foam insulation in the forward end of the ET intertank segment, adjacent to the liquid oxygen (LOX) tank, as shown in Figure 1. These cracks necessitated repair of the foam due to debris concerns that violated launch constraints. As part of the repair process, the affected foam was removed to reveal cracks in the underlying external hat stiffeners on the intertank, as shown in Figure 2. Ultimately, five stiffeners were discovered to be cracked adjacent to the LOX tank. As the managing center for the ET Project, NASA Marshall Space Flight Center (MSFC) coordinated failure investigation and repair activities among multiple organizations, which included the ET prime contractor (Lockheed Martin Space Systems Michoud Operations), the Space Shuttle Program Office at the NASA Johnson Space Center (JSC), the NASA Kennedy Space Center (KSC), and the NASA Engineering and Safety Center (NESC). STS-133 utilized the external tank designated as ET-137. Many aspects of the investigation have been reported previously in Refs. 1-7, which focus on the root cause of the failures, the flight readiness rationale and the local analyses of the stringer failures and repair. This paper summarizes the global analyses that were conducted on ET-137 as part of the NESC effort during the investigation, which was conducted primarily to determine if the repairs that were introduced to the stringers would alter the global response of the ET. In the process of the investigation, a new STAGS tabular input capability was developed to more easily introduce the aerodynamic pressure loads using a method that could easily be extended to incorporate finite element property data such as skin and stiffener thicknesses and beam cross-sectional properties.

Lovejoy, Andrew E.↗

NASA NTRS2007

Fluid Sloshing Characteristics in Spacecraft Propellant Tanks with Diaphragms

All spacecraft are launched from the Earth as payloads on a launch vehicle. During portions of the launch profile, the spacecraft could be subjected to nearly purely translational oscillatory lateral motions as the launch vehicle control system guides the rocket along its flight path. All partially-filled liquids tanks, even those with diaphragms, exhibit sloshing behavior under these conditions and some tanks can place large loads on their support structures if the sloshing is in resonance with the control system oscillation frequency. The objectives of this project were to conduct experiments using a full-scale model of a flight tank to 1) determine whether launch vehicle vibrations can cause the diaphragm to achieve a repeatable configuration, regardless of initial condition, and 2) identify the slosh characteristics of the propellant tank under flight-like lateral motions for different diaphragm shapes and vibration levels. The test results show that 1) the diaphragm shape is not affected by launch vibrations, and 2) the resonance-like behavior of the fluid and diaphragm is strongly affected by the nonlinear stiffness and damping provided by the diaphragm.

Green, Steve↗