Results for “process cooling” — Page 35

NASA NTRSDate not supplied

Exploring Cryogenic Propellant Behavior in Low-Gravity Environments, Insights from the Saturn AS-203 Vent Experiments and CFD Analysis

In the 1960s, NASA embarked on a series of groundbreaking flight tests on the Saturn AS-203, aiming to understand the complex dynamics of propellants in the distinctive low-gravity lunar environment. These tests centered on venting experiments, subjecting cryogenic liquid hydrogen to conditions beneath its saturation pressure while accelerating the vehicle to manage the propellant's positioning. During these experiments, NASA meticulously scrutinized the propellant tank using a suite of instruments, including temperature and pressure sensors, as well as a camera placed internal to the liquid hydrogen tank. The outcomes provided anecdotal evidence revealing the phenomenon of boiling along the tank's walls and the intriguing formation of liquid globules and droplets in the ullage during the venting process. Notably, the substantial drop in liquid temperature during these tests suggests adiabatic cooling as liquid hydrogen evaporates. This evaporation leads to a cooling of the remaining hydrogen due to the heat it releases. This paper presents the outcomes of our initial analysis, wherein CFD models were used to simulate the observed boiling phenomena and the bulk movement of the liquid hydrogen propellant, both qualitatively and quantitatively. The implications of these findings may extend to mission and vehicle designers, providing invaluable insights for crafting more efficient and effective in-space propulsion systems utilizing cryogenic propellant including impacts to vehicle control systems. Understanding propellant behavior under these conditions may better inform GNC teams, ensuring more stable vehicle operations when utilizing cryogenic propellants. This includes essential considerations for cryogenic propellant transfer and storage systems, integral to NASA's forthcoming Artemis missions. While we recognize the challenges tied to CFD models, this study represents a step forward, highlighting current progress and signaling the potential for refining our predictive understanding in the future.

Computational Fluid Dynamics↗

NASA NTRSDate not supplied

Exploring Cryogenic Propellant Behavior in Low-Gravity Environments, Insights from the Saturn AS-203 Vent Experiments and CFD Analysis

In the 1960s, NASA embarked on a series of groundbreaking flight tests on the Saturn AS-203, aiming to understand the complex dynamics of propellants in the distinctive low-gravity lunar environment. These tests centered on venting experiments, subjecting cryogenic liquid hydrogen to conditions beneath its saturation pressure while accelerating the vehicle to manage the propellant's positioning. During these experiments, NASA meticulously scrutinized the propellant tank using a suite of instruments, including temperature and pressure sensors, as well as a camera placed internal to the liquid hydrogen tank. The outcomes provided anecdotal evidence revealing the phenomenon of boiling along the tank's walls and the intriguing formation of liquid globules and droplets in the ullage during the venting process. Notably, the substantial drop in liquid temperature during these tests suggests adiabatic cooling as liquid hydrogen evaporates. This evaporation leads to a cooling of the remaining hydrogen due to the heat it releases. This paper presents the outcomes of our initial analysis, wherein CFD models were used to simulate the observed boiling phenomena and the bulk movement of the liquid hydrogen propellant, both qualitatively and quantitatively. The implications of these findings may extend to mission and vehicle designers, providing invaluable insights for crafting more efficient and effective in-space propulsion systems utilizing cryogenic propellant including impacts to vehicle control systems. Understanding propellant behavior under these conditions may better inform GNC teams, ensuring more stable vehicle operations when utilizing cryogenic propellants. This includes essential considerations for cryogenic propellant transfer and storage systems, integral to NASA's forthcoming Artemis missions. While we recognize the challenges tied to CFD models, this study represents a step forward, highlighting current progress and signaling the potential for refining our predictive understanding in the future.

Computational Fluid Dynamics↗

NASA NTRS1992

H2 fueled flightweight ramjet construction and test

The ACES Program began the investigation of regeneratively cooled ramjet engines for propelling aircraft at Mach 6 to 8 flight regimes while collecting and processing air for later use as oxidizer in rocket propulsion into an orbit flight mode. The Marquardt Company had as its prime task the design and demonstration of a ramjet capable of steady state operating using hydrogen as the regenerative coolant and with fuel flow limited to a theta = 1. Marquardt progressed from shell type combustors to advanced tubular combustion chambers in direct connect test rigs. The first tests were made with water cooled center bodies and plug nozzles using a pebble bed air heater to simulate flight air temperature. Later tests were made on completely H2 cooled flight weight V/G assemblies direct connected to a SUE burner heater. Design studies were also conducted on integrated systems for take-off capability using offset turbojets connected to 2-D or axisymmetric inlets. An 18 inch hypersonic ramjet evaluation scale model was designed based on the hot test results using a fully V/G inlet and exit nozzle. This thruster would provide 25000 lbs. of thrust with an estimated weight of 250 lbs. A V/G inlet would also incorporate an inlet seal for possible take-off thrust by rocket operation. Hypersonic ramjet construction features and chamber thrust development are discussed.

Malek, Albert↗

NASA NTRS1986

Applications of a Venus thermospheric circulation model

A variety of Pioneer Venus observations suggest a global scale, day-to-night Venus thermospheric circulation. Model studies of the dynamics and energetics of the Venus thermosphere are presented in order to address new driving, mixing and cooling mechanisms for an improved model simulation. The adopted approach was to reexamine the circulation by first using a previous two dimensional code to quantify those physical processes which can be inferred from the Pioneer Venus observations. Specifically, the model was used to perform sensitivity studies to determine the degree to which eddy cooling, eddy or wave drag, eddy diffusion and 15 micrometer radiational cooling are necessary to bring the model temperature and composition fields into agreement with observations. Three EUV heating cases were isolated for study. Global temperature and composition fields in good agreement with Pioneer data were obtained. Large scale horizontal winds 220 m/s were found to be consistent with the observed cold nightside temperatures and dayside bulges of O, CO and CO2. Observed dayside temperatures were obtained by using a 7 to 19% EUV heating efficiency profile. The enhanced 15 micrometer cooling needed for thermal balance is obtained using the best rate coefficient available for atomic O collisional excitation of CO2(0,1,0). Eddy conduction was not found to be a viable cooling mechanism due to the weakened global circulation. The strong 15 micrometer damping and low EUV efficiency imply a very weak dependence of the general circulation to solar cycle variability. The NCAR terrestrial thermospheric general circulation model was adapted for Venus inputs using the above two dimensional model parameters, to give a three dimensional benchmark for future Venus modelling work.

Bougher, S. W.↗

NASA NTRS2018

Channel Wall Nozzle Manufacturing and Hot-Fire Testing Using a Laser Wire Direct Closeout Technique for Liquid Rocket Engines

A regeneratively-cooled nozzle for liquid rocket engine applications is a significant cost of the overall engine due to the complexities of manufacturing a large thin-walled structure that must operate in extreme temperature and pressure environments. The National Aeronautics and Space Administration (NASA) has been investigating and advancing methods for fabrication of liquid rocket engine channel wall nozzles to realize further cost and schedule improvements over traditional techniques. The methods being evaluated are targeting increased scale required for current NASA and commercial space programs. Several advanced rapid fabrication methods are being investigated for forming of the inner liner, producing the coolant channels, closeout of the coolant channels, and fabrication of the manifolds. NASA's Marshall Space Flight Center (MSFC) has completed process development and subscale hot-fire testing of a series of these advanced fabrication channel wall nozzle technologies to gather performance data in a relevant environment. The primary fabrication technique being discussed in this paper is Laser Wire Direct Closeout (LWDC). This process has been developed to significantly reduce the time required for closeouts of regeneratively-cooled slotted liners. It allows for channel closeout to be formed in place in addition to the structural jacket without the need for channel fillers or complex tooling. Additional technologies were also tested as part of this program including water jet milling and arc-based additive manufacturing deposition. Each nozzle included different fabrication features, materials, and methods to demonstrate durability in a hot-fire environment. The results of design, fabrication, and hot-fire testing are discussed in this paper.

Gradl, Paul R.↗

NASA NTRS2010

Advanced Vacuum Plasma Spray (VPS) for a Robust, Longlife and Safe Space Shuttle Main Engine (SSME)

In 1984, the Vacuum Plasma Spray Lab was built at NASA/Marshall Space Flight Center for applying durable, protective coatings to turbine blades for the space shuttle main engine (SSME) high pressure fuel turbopump. Existing turbine blades were cracking and breaking off after five hot fire tests while VPS coated turbine blades showed no wear or cracking after 40 hot fire tests. Following that, a major manufacturing problem of copper coatings peeling off the SSME Titanium Main Fuel Valve Housing was corrected with a tenacious VPS copper coating. A patented VPS process utilizing Functional Gradient Material (FGM) application was developed to build ceramic lined metallic cartridges for space furnace experiments, safely containing gallium arsenide at 1260 degrees centigrade. The VPS/FGM process was then translated to build robust, long life, liquid rocket combustion chambers for the space shuttle main engine. A 5K (5,000 Lb. thrust) thruster with the VPS/FGM protective coating experienced 220 hot firing tests in pristine condition with no wear compared to the SSME which showed blanching (surface pulverization) and cooling channel cracks in less than 30 of the same hot firing tests. After 35 of the hot firing tests, the injector face plates disintegrated. The VPS/FGM process was then applied to spraying protective thermal barrier coatings on the face plates which showed 50% cooler operating temperature, with no wear after 50 hot fire tests. Cooling channels were closed out in two weeks, compared to one year for the SSME. Working up the TRL (Technology Readiness Level) to establish the VPS/FGM process as viable technology, a 40K thruster was built and is currently being tested. Proposed is to build a J-2X size liquid rocket engine as the final step in establishing the VPS/FGM process TRL for space flight.

Holmes, Richard R.↗

NASA NTRS1992

Cooling of the magma ocean due to accretional disruption of the surface insulating layer

Planetary accretion has been considered as a process to heat planets. Some fraction of the kinetic energy of incoming planetesimals is trapped to heat the planetary interior (Kaula, 1979; Davies, 1984). Moreover, blanketing effect of a primary atmosphere (Hayashi et al., 1979; Sasaki, 1990) or a degassed atmosphere (Abe and Matsui, 1986; Zahnle et al., 1988) would raise the surface temperature of the Earth-size planets to be higher than the melting temperature. The primordial magma ocean was likely to be formed during accretion of terrestrial planets. In the magma ocean, if crystallized fractions were heavier than melt, they would sink. But if solidified materials were lighter than the melt (like anorthosite of the lunar early crust) they would float to form a solid shell surrounding the planet. (In an icy satellite, solidified water ice should easily float on liquid water because of its small density.) The surface solid lid would prevent efficient convective heat transfer and slow the interior cooling. Consider that the accretion of planetesimals still continues in this cooling stage. Shock disruption at planetesimal impact events may destroy the solid insulating layer. Even if the layer survives impacts, the surface layer is finally overturned by Rayleigh-Taylor instability, since accreting materials containing metals are heavier than the surface solidified lid of silicates.

Sasaki, Sho↗

NASA NTRSDate not supplied

Process Development and Hot-fire Testing of Additively Manufactured NASA HR-1 for Liquid Rocket Engine Applications

Additive manufacturing (AM) has provided new design and manufacturing opportunities to reduce cost and schedules, consolidate parts, and optimize performance. One technique being evaluated is Laser Powder Directed Energy Deposition (LP-DED), which provides a significant increase in scale compared to Laser Powder Bed Fusion (L-PBF). NASA along with industry partners have been developing the LP-DED process to demonstrate internal channel geometry and development components for use in liquid rocket engine channel cooled nozzles. Optimized materials in the extreme high pressure and hydrogen environment for liquid rocket engines remains a key challenge. NASA has advanced an enabling material called NASA HR-1 (Hydrogen Resistant -1) as a solution using AM techniques. NASA HR-1 is a high-strength Fe-Ni superalloy designed to resist high pressure, hydrogen environment embrittlement, oxidation, and corrosion. NASA HR-1 meets materials requirements for liquid rocket engine components, including good hydrogen resistance, high conductivity, good low cycle fatigue performance, and high elongation and strength for components in high heat flux environments. Material properties and process characterization have been completed on the high density thin-wall material in addition to advancements of the supply chain. NASA has also completed fabrication of several subscale and full-scale channel wall nozzles in LP-DED NASA HR-1 and completed hot-fire testing. This includes refinement of the process to produce thin-walls and various channel geometries to meet the requirements for channel wall nozzle applications. This paper will provide an overview of the LP-DED process development, material characterization and properties, component manufacturing, and hot-fire testing. Hot-fire testing was completed for a lander-class 7K-lbf thrust chamber using Liquid Oxygen (LOX)/Methane. The design overview and results from hot-fire testing will be presented in addition to hardware development for future testing on 2K-lbf and 35k-lbf thrust chambers and large-scale manufacturing technology demonstrators.

Additive Manufacturing↗

NASA NTRSDate not supplied

Process Development and Hot-fire Testing of Additively Manufactured NASA HR-1 for Liquid Rocket Engine Applications

Additive manufacturing (AM) has provided new design and manufacturing opportunities to reduce cost and schedules, consolidate parts, and optimize performance. One technique being evaluated is Laser Powder Directed Energy Deposition (LP-DED), which provides a significant increase in scale compared to Laser Powder Bed Fusion (L-PBF). NASA along with industry partners have been developing the LP-DED process to demonstrate internal channel geometry and development components for use in liquid rocket engine channel cooled nozzles. Optimized materials in the extreme high pressure and hydrogen environment for liquid rocket engines remains a key challenge. NASA has advanced an enabling material called NASA HR-1 (Hydrogen Resistant -1) as a solution using AM techniques. NASA HR-1 is a high-strength Fe-Ni superalloy designed to resist high pressure, hydrogen environment embrittlement, oxidation, and corrosion. NASA HR-1 meets materials requirements for liquid rocket engine components, including good hydrogen resistance, high conductivity, good low cycle fatigue performance, and high elongation and strength for components in high heat flux environments. Material properties and process characterization have been completed on the high density thin-wall material in addition to advancements of the supply chain. NASA has also completed fabrication of several subscale and full-scale channel wall nozzles in LP-DED NASA HR-1 and completed hot-fire testing. This includes refinement of the process to produce thin-walls and various channel geometries to meet the requirements for channel wall nozzle applications. This paper will provide an overview of the LP-DED process development, material characterization and properties, component manufacturing, and hot-fire testing. Hot-fire testing was completed for a lander-class 7K-lbf thrust chamber using Liquid Oxygen (LOX)/Methane. The design overview and results from hot-fire testing will be presented in addition to hardware development for future testing on 2K-lbf and 35k-lbf thrust chambers and large-scale manufacturing technology demonstrators.

DED↗

NASA NTRS2013

20 K Helium Refrigeration System for NASA-JSC Chamber-A

A new 20 K helium refrigerator installed at NASA Johnson Space Center's Space Environment Simulation Laboratory (SESL) was successfully commissioned and tested in 2012. The refrigerator is used to create a deep space environment within SESL s Chamber A to perform ground testing of the James Webb Space Telescope. The chamber previously and currently still has helium cryopumping panels (CPP) and LN2 shrouds used to create Low Earth Orbit environments. Now with the new refrigerator and new helium shrouds (45 x 65 ) the chamber can create a deep space environment. The process design, system analysis, specification development, and commissioning oversight were performed by the cryogenics department at Jefferson Labs, while the contracts and system installation was performed by the ESC group at JSC. Commissioning data indicate a inverse coefficient of performance better than 70 W/W for a 18 KW load at 20 K (accounting for liquid nitrogen precooling power) that remains essentially constant down to 1/3 of this load. Even at 10 percent of the maximum capacity, the performance is better than 140 W/W at 20K. The refrigerator exceeded all design goals and demonstrated the ability to support a wide load range from 10kW at 15 K to 100 kW at 100K. The refrigerator is capable of operating at any load temperature from 15K to ambient with tight temperature stability. The new shroud (36 tons of aluminum) can be cooled from room temperature to 20 K in 24 hours. This paper will outline the process design and commissioning results.

Homan, J.↗

NASA NTRS1978

Analysis of data user's needs for performance evaluation of solar heating and cooling systems

In a successful data acquisition program, the information needs must be evaluated, the design and cost factors of the program must be determined, and a data management loop must be organized and operated in order to collect, process, and disseminate the needed information in useable formats. This paper describes each of these program elements in detail as an aid for the solar heating and cooling data manager and user to implement effective data acquisition and monitoring systems. Consideration is given to the development of evaluation techniques which will aid in the determination of solar energy systems performances.

Christensen, D. L.↗

NASA NTRS1987

Growth of Triglycine Sulfate (TGS) crystals aboard Spacelab-3

An experiment to study the growth of single crystals of triglycine sulfate (NH2CH2COOH)3 H2SO4 (TGS) was successfully carried out on the Spacelab-3 mission during April 29 to May 6, 1985. Two crystals of TGS were grown during the flight, using a specially developed cooled sting technique of solution crystal growth. For the first time in any flight experiment the growth was monitored on-board as well as on ground by video-schlieren technique. Hundreds of holograms were taken for the solution/crystal interaction during the growth process. Preliminary results indicate that the optical system worked very well and the quality of reconstructed holograms is satisfactory. The cooled sting technique was successfully demonstrated. Holographic interferograms indicate convection free, diffusion limited growth. Some of the preliminary results of crystal quality are also presented.

Lal, R. B.↗

NASA NTRS1962

PROGRESS REPORT ON THE DEVELOPMENT OF PROTECTED CONSTRUCTION FOR HYPERSONIC VEHICLES

The structural problems of re-entry occasioned by aerodynamic heating are now generally well known. Typical of these heating problems is the environment experienced by the manned lifting vehicle re-entering from a low altitude orbit. Figure 1 shows typical curves of lower surface temperature as a function of time for a wing loading of 25 Ibs/ft(exp 2), and a lift-drag ratio of 2.5. The two curves cover a practical range of re-entry angles, the lower curve representing an ideal re-entry path with zero dive angle and the upper curve assuming a 2° error in the re-entry angle. Maneuvers for course change or correction are also added to the upper curve. Significant factors from this curve are the relationship between the maximum temperatures and the capabilities of available metallic material, and also the long re-entry time and its effect on total heat load. If a very shallow re-entry is made, maximum lower surface temperatures reach 2000°F which is just within the range of conventional superalloys. To accommodate practical re-entry angles and maneuvers, however, the temperature capability must reach about 2500°F which requires refractory metals. The re-entry time may be as high as 100 minutes, which gives total heat loads of approximately 40,000 BTU/ft(exp 2). A heat load of this magnitude, with equilibrium surface temperatures of the values shown, suggests that a lighter airframe can be constructed by dissipating the heat by radiation from the surface, rather than by absorbing it with a heat sink, or surface cooling, or ablation. Air Force programs to provide airframes for this type of environment have involved the parallel development of a number of different structural concepts. The development to be discussed here was carried out by Bell Aerosystems Company for the Fabrication Branch, Manufacturing Technology Laboratory, Directorate of Materials and Processes, Aeronautical Systems' Division, Wright-Patterson Air Force Base, Ohio, under Contract AF33(600)-40100 (Double-Wall Cooled Structure).

Reentry vehicle↗

NASA NTRS2012

Demonstration of Passive Fuel Cell Thermal Management Technology

The NASA Glenn Research Center is developing advanced passive thermal management technology to reduce the mass and improve the reliability of space fuel cell systems for the NASA Exploration program. The passive thermal management system relies on heat conduction within highly thermally conductive cooling plates to move the heat from the central portion of the cell stack out to the edges of the fuel cell stack. Using the passive approach eliminates the need for a coolant pump and other cooling loop components within the fuel cell system which reduces mass and improves overall system reliability. Previous development demonstrated the performance of suitable highly thermally conductive cooling plates and integrated heat exchanger technology to collect the heat from the cooling plates (Ref. 1). The next step in the development of this passive thermal approach was the demonstration of the control of the heat removal process and the demonstration of the passive thermal control technology in actual fuel cell stacks. Tests were run with a simulated fuel cell stack passive thermal management system outfitted with passive cooling plates, an integrated heat exchanger and two types of cooling flow control valves. The tests were run to demonstrate the controllability of the passive thermal control approach. Finally, successful demonstrations of passive thermal control technology were conducted with fuel cell stacks from two fuel cell stack vendors.

Burke, Kenneth A.↗

NASA NTRS2016

Atmospheric Diabatic Heating in Different Weather States and the General Circulation

Analysis of multiple global satellite products identifies distinctive weather states of the atmosphere from the mesoscale pattern of cloud properties and quantifies the associated diabatic heating/cooling by radiative flux divergence, precipitation, and surface sensible heat flux. The results show that the forcing for the atmospheric general circulation is a very dynamic process, varying strongly at weather space-time scales, comprising relatively infrequent, strong heating events by ''stormy'' weather and more nearly continuous, weak cooling by ''fair'' weather. Such behavior undercuts the value of analyses of time-averaged energy exchanges in observations or numerical models. It is proposed that an analysis of the joint time-related variations of the global weather states and the general circulation on weather space-time scales might be used to establish useful ''feedback like'' relationships between cloud processes and the large-scale circulation.

Cooling↗

NASA NTRS1975

Hypersonic research engine project. Phase 2: Some combustor test results of NASA aerothermodynamic integration model

Combustor test results of the NASA Aerothermodynamic Integration Model are presented of a ramjet engine developed for operation between Mach 3 and 8. Ground-based and flight experiments which provide the data required to advance the technology of hypersonic air-breathing propulsion systems as well as to evaluate facility and testing techniques are described. The engine was tested with synthetic air at Mach 5, 6, and 7. The hydrogen fuel was heated to 1500 R prior to injection to simulate a regeneratively cooled system. Combustor efficiencies up to 95 percent at Mach 6 were achieved. Combustor process in terms of effectiveness, pressure integral factor, total pressure recovery and Crocco's pressure-area relationship are presented and discussed. Interactions between inlet-combustor, combustor stages, combustor-nozzle, and the effects of altitude, combustor step, and struts are observed and analyzed.

Sun, Y. H.↗

NASA NTRS1980

Ground cloud related weather modification effects

The principal concerns about inadvertent weather modification by the solar power satellite system rocket effluents are discussed, namely the possibility that the ground cloud might temporarily modify local weather and the cumulative effects of nearly 500 launches per year. These issues are discussed through the consideration of (1) the possible alteration of the microphysical processes of clouds in the general area due to rocket effluents and debris and cooling water entrained during the launch and (2) the direct dynamical and thermodynamical responses to the inputs of thermal energy and moisture from the rocket exhaust for given ambient meteorological conditions. The huge amount of thermal energy contained in the exhaust of the proposed launch vehicle would in some situations induce a saturated, wet convective cloud or enhance an existing convective activity. Nevertheless, the effects would be limited to the general area of the launch site. The observed long lasting high concentrations of cloud condensation nuclei produced during and after a rocket launch may appreciably affect the frequency of occurrence and persistence of fogs and haze. In view of the high mission frequency proposed for the vehicle launches, a potential exists for a cumulative effect.

Lee, J.↗

NASA NTRS1983

A note on compressibility and energy cascade in turbulent molecular clouds

Observed velocity-size correlations are reexamined in the light of an improved theory of turbulent energy cascade that is developed. It is shown that observed velocity-size correlations cannot be compared with the Kolmogorov law, which is based on incompressible turbulent flow. The fact that the log v-log(l/rho) scaling law (v the turbulent velocity, l the associated region size, and rho the fluid density) predicted for compressible energy cascade is always steeper than that observed in molecular clouds indicates the injection rather than the dissipation of mechanical energy at smaller scales of motion. It is also shown that the concept of strict energy cascade may not be generally applicable in the interstellar medium. The agreement between theory and observation turns out to be best for small cool clouds and cloud cores, suggesting that, for these regions at least, the dominant process in establishing the observed v-l-rho correlation is a turbulent energy cascade.

Fleck, R. C., Jr.↗