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At least 649 records · Page 36

Cryogenic Vacuum Insulation for Vessels and Piping

Cryogenic vacuum insulation systems, with proper materials selection and execution, can offer the highest levels of thermal performance. Three areas of consideration are vital to achieve the optimum result: materials, representative test conditions, and engineering approach for the particular application. Deficiency in one of these three areas can prevent optimum performance and lead to severe inefficiency. Materials of interest include micro-fiberglass, multilayer insulation, and composite arrangements. Cylindrical liquid nitrogen boil-off calorimetry methods were used. The need for standard thermal conductivity data is addressed through baseline testing. Engineering analysis and design factors such as layer thickness, density, and practicality are also considered.

Kogan, A.↗

NASA Tech Briefs, November 2011

The topics include: 1) Flight Test Results from the Rake Airflow Gage Experiment on the F-15B; 2) Telemetry and Science Data Software System; 3) CropEx Web-Based Agricultural Monitoring and Decision Support; 4) High-Performance Data Analysis Tools for Sun-Earth Connection Missions; 5) Experiment in Onboard Synthetic Aperture Radar Data Processing; 6) Microfabrication of a High-Throughput Nanochannel Delivery/Filtration System; 7) Improved Design and Fabrication of Hydrated-Salt Pills; 8) Monolithic Flexure Pre-Stressed Ultrasonic Horns; 9) Cryogenic Quenching Process for Electronic Part Screening; 10) Broadband Via-Less Microwave Crossover Using Microstrip-CPW Transitions; 11) Wheel-Based Ice Sensors for Road Vehicles; 12) G-DYN Multibody Dynamics Engine; 13) Multibody Simulation Software Testbed for Small-Body Exploration and Sampling; 14) Propulsive Reaction Control System Model; 15) Licklider Transmission Protocol Implementation; 16) Core Recursive Hierarchical Image Segmentation; 17) Two-Stage Centrifugal Fan; 18) Combined Structural and Trajectory Control of Variable-Geometry Planetary Entry Systems; 19) Pressure Regulator With Internal Ejector Circulation Pump, Flow and Pressure Measurement Porting, and Fuel Cell System Integration Options; 20) Temperature-Sensitive Coating Sensor Based on Hematite; 21) Standardization of a Volumetric Displacement Measurement for Two-Body Abrasion Scratch Test Data Analysis; 22) Detection of Carbon Monoxide Using Polymer-Carbon Composite Films; 23) Substituted Quaternary Ammonium Salts Improve Low-Temperature Performance of Double-Layer Capacitors; 24) Sustainably Sourced, Thermally Resistant, Radiation Hard Biopolymer; 25) Integrated Lens Antennas for Multi-Pixel Receivers; 26) 180-GHz Interferometric Imager; 27) Maturation of Structural Health Management Systems for Solid Rocket Motors; 28) Validating Phasing and Geometry of Large Focal Plane Arrays; 29) Transverse Pupil Shifts for Adaptive Optics Non-Common Path Calibration; 30) Qualification of Fiber Optic Cables for Martian Extreme Temperature Environments; 31) Solid-State Spectral Light Source System; 32) Multiple-Event, Single-Photon Counting Imaging Sensor; 33) Surface Modeling to Support Small-Body Spacecraft Exploration and Proximity Operations; and 34) Achieving Exact and Constant Turnaround Ratio in a DDS-Based Coherent Transponder.

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Thermal Vacuum Chamber Repressurization with Instrument Purging

At the conclusion of cryogenic vacuum testing of the James Webb Space Telescope Optical Telescope Element Integrated Science Instrument Module (JWST-OTIS) in NASA Johnson Space Center’s (JSCs) thermal vacuum (TV) Chamber A, contamination control (CC) engineers are postulating that chamber particulate material stirred up by the repressurization process may be kept from falling into the Integrated Science Instrument Module (ISIM) interior to some degree by activating instrument purge flows over some initial period before opening the chamber valves. This manuscript describes development of a series of models designed to describe this process. The models are strung together in tandem with a fictitious set of conditions to estimate overpressure evolution from which net outflow velocity behavior may be obtained. Creeping flow assumptions are then used to determine the maximum particle size that may be kept suspended above the ISIM aperture, keeping smaller particles from settling within the instrument module.

Repressurization↗

Telescience Testbed Program: A study of software for SIRTF instrument control

As a continued element in the Telescience Testbed Program (TTP), the University of Arizona Steward Observatory and the Electrical and Computer Engineering Department (ECE) jointly developed a testbed to evaluate the Operations and Science Instrument System (OASIS) software package for remote control of an instrument for the Space Infrared Telescope Facility (SIRTF). SIRTF is a cryogenically-cooled telescope with three focal plane instruments that will be the infrared element of NASA's Great Observatory series. The anticipated launch date for SIRTF is currently 2001. Because of the complexity of the SIRTF mission, it was not expected that the OASIS package would be suitable for instrument control in the flight situation, however, its possible use as a common interface during the early development and ground test phases of the project was considered. The OASIS package, developed at the University of Colorado for control of the Solar Mesosphere Explorer (SME) satellite, serves as an interface between the operator and the remote instrument which is connected via a network. OASIS provides a rudimentary windowing system as well as support for standard spacecraft communications protocols. The experiment performed all of the functions required of the MIPS simulation program. Remote control of the instrument was demonstrated but found to be inappropriate for SIRTF at this time for the following reasons: (1) programming interface is too difficult; (2) significant computer resources were required to run OASIS; (3) the communications interface is too complicated; (4) response time was slow; and (5) quicklook of image data was not possible.

Young, Erick T.↗

Boundary-Layer-Ingesting Inlet Flow Control

This paper gives an overview of a research study conducted in support of the small-scale demonstration of an active flow control system for a boundary-layer-ingesting (BLI) inlet. The effectiveness of active flow control in reducing engine inlet circumferential distortion was assessed using a 2.5% scale model of a 35% boundary-layer-ingesting flush-mounted, offset, diffusing inlet. This experiment was conducted in the NASA Langley 0.3-meter Transonic Cryogenic Tunnel at flight Mach numbers with a model inlet specifically designed for this type of testing. High mass flow actuators controlled the flow through distributed control jets providing the active flow control. A vortex generator point design configuration was also tested for comparison purposes and to provide a means to examine a hybrid vortex generator and control jets configuration. Measurements were made of the onset boundary layer, the duct surface static pressures, and the mass flow through the duct and the actuators. The distortion and pressure recovery were determined by 40 total pressure measurements on 8 rake arms each separated by 45 degrees and were located at the aerodynamic interface plane. The test matrix was limited to a maximum free-stream Mach number of 0.85 with scaled mass flows through the inlet for that condition. The data show that the flow control jets alone can reduce circumferential distortion (DPCPavg) from 0.055 to about 0.015 using about 2.5% of inlet mass flow. The vortex generators also reduced the circumferential distortion from 0.055 to 0.010 near the inlet mass flow design point. Lower inlet mass flow settings with the vortex generator configuration produced higher distortion levels that were reduced to acceptable levels using a hybrid vortex generator/control jets configuration that required less than 1% of the inlet mass flow.

Owens, Lewis R.↗

Boundary-Layer-Ingesting Inlet Flow Control

This paper gives an overview of a research study conducted in support of the small-scale demonstration of an active flow control system for a boundary-layer-ingesting (BLI) inlet. The effectiveness of active flow control in reducing engine inlet circumferential distortion was assessed using a 2.5% scale model of a 35% boundary-layer-ingesting flush-mounted, offset, diffusing inlet. This experiment was conducted in the NASA Langley 0.3-meter Transonic Cryogenic Tunnel at flight Mach numbers with a model inlet specifically designed for this type of testing. High mass flow actuators controlled the flow through distributed control jets providing the active flow control. A vortex generator point design configuration was also tested for comparison purposes and to provide a means to examine a hybrid vortex generator and control jets configuration. Measurements were made of the onset boundary layer, the duct surface static pressures, and the mass flow through the duct and the actuators. The distortion and pressure recovery were determined by 40 total pressure measurements on 8 rake arms each separated by 45 degrees and were located at the aerodynamic interface plane. The test matrix was limited to a maximum free-stream Mach number of 0.85 with scaled mass flows through the inlet for that condition. The data show that the flow control jets alone can reduce circumferential distortion (DPCP(sub avg)) from 0.055 to about 0.015 using about 2.5% of inlet mass flow. The vortex generators also reduced the circumferential distortion from 0.055 to 0.010 near the inlet mass flow design point. Lower inlet mass flow settings with the vortex generator configuration produced higher distortion levels that were reduced to acceptable levels using a hybrid vortex generator/control jets configuration that required less than 1% of the inlet mass flow.

Owens, Lewis R.↗

NASA's Space Launch System Gains Momentum Toward Integration and Testing

NASA's Space Launch System (SLS) entered a new phase in 2017, completing major structural manufacturing on the core stage and delivering the first flight hardware to NASA's Kennedy Space Center (KSC). The program is now transitioning to integration, assembly and testing in preparation for launch readiness in late 2019. Core stage prime contractor Boeing concluded welding of the major core stage components for Exploration Mission 1 (EM-1) with the liquid hydrogen flight tank, following completion of the engine section, liquid oxygen tank, and forward skirt. Technicians also completed assembly of the bolted intertank, and all sections are currently in hardware integration. The engine section structural test article was shipped to NASA's Marshall Space Flight Center (MSFC) and began testing in 2017. The core stage pathfinder shipped to NASA's Michoud Assembly Facility (MAF). Booster prime contractor Orbital ATK made significant progress casting motor segments for SLS, with several segments finishing processing and in storage. Forward and aft sections of the boosters are being refurbished at KSC. RS-25 prime contractor Aerojet Rocketdyne completed SLS adaptation testing and qualification of four new EM-1 controllers. The four EM-1 engines are ready and waiting for shipment from NASA's Stennis Space Center (SSC) to Michoud Assembly Facility (MAF) for core stage integration in preparation for green run testing at SSC. The EM-1 Interim Cryogenic Propulsion System (ICPS) became the first major piece of SLS to arrive at KSC. Welding is complete on the EM-1 Launch Vehicle Stage Adapter (LVSA) and the flight Orion Stage Adapter (OSA). SLS is critical to U.S. leadership in future human and robotic space exploration, including a presence on the moon in preparation for missions deeper into space. This paper will elaborate on 2017 SLS progress and progress envisioned for 2018.

Askins, Bruce R.↗

Operational Techniques in Microgravity for Cryogenic Fluid Management

Management of cryogens in microgravity is a critical challenge for exploration missions to the Moon and Mars. Operational strategies to aid in cryogenic fluid management (CFM) are proposed and demonstrated using computational fluid dynamics simulations. Application of axial settling thrust is an essential – but potentially expensive – tool for CFM. Demonstrations show that its utilization and timing are important during certain unsettling events, such as engine cutoff. At other times, substantial savings can be realized by reducing the average acceleration (through pulsing thrusters, for example). If the metric for reaching a settled condition is a particular number of slosh periods, then fewer settling resources are needed with a lower acceleration. Alternatively, if a target wave amplitude is the settling objective, then a lower average acceleration will also allow for a higher allowable amplitude for the same heat transfer. Savings can also be obtained by rolling the vehicle, which can mitigate lateral slosh. Advantages and disadvantages of anti-slosh baffles are also discussed along with practical examples of their impact on CFM and ullage collapse. Ullage collapse examples are presented along with recommendations for slewing a vehicle with angular and translational acceleration to mitigate mixing between liquid and ullage.

Cryogenic Fluid Management↗

Low Leakage Valves for Long Duration Missions

I.Nomenclaturemtypical_mission=internal mass of propellant lost over the course of a mission with Qtypicalmmission_goal=mass of propellant loss over the course of a mission with Qgoaltmission=theoretical mission durationQtypical=internal leakage rate found in commercially available valvesQgoal=internal leakage rate design goalρH2_STP=density of hydrogen at standard temperature and pressure.1NASA AST, Liquid Propulsion Valve Engineer.Valves, Actuators, and Ducts Design and Development Branch (ER14)2NASA AST, Liquid Propulsion Valve Engineer.Valves, Actuators, and Ducts Design and Development Branch (ER14)3NASA AST, Liquid Propulsion Valve Engineer (Retired).Valves, Actuators, and Ducts Design and Development Branch (ER14)4JSEG ESSCA, Engineering Specialist.Valves Actuators and Ducts Design and Development Branch (ER14)5NASA AST, Liquid Propulsion Valve Engineer.Valves, Actuators, and Ducts Design and Development Branch (ER14)6JSEG ESSCA, Valve Design and Development Engineer.Valves Actuators and Ducts Design and Development Branch (ER14) II.IntroductionCurrent aerospace cryogenic valves present challenges to potential long duration missions that utilize cryogenic propellants. Small interplanetary and long-life communication satellites typically utilize hypergolic propellants that operate at higher temperatures, making it easier to achieve very low internal leakage rates. Larger vehicles for long duration missions will likely need to utilize cryogenic-based chemical and nuclear systems to achieve mission requirements. Some early propulsion concepts are projected to require valves with a nominal size ranging from 3” to 10”.Currently available cryogenic aerospace valves typically have internal leakage rates which can range from 100 to 300 SCIM for 3” valves, or upwards of 2,000 SCIM for 10” valves. With just a few of these valves in a system, internal leakage could account for multiple tons of propellant loss over the course of a potential Mars mission, as shown in Figure 1.Figure 1 - Potential Propellant Loss Over the Course of a Long Duration MissionMost internal leakage rates can be attributed to inherent imperfections and misalignments, which result in imperfect contact between sealing surfaces, as shown in Figure 2.Figure 2 - Imperfections and Misalignments Between Sealing Surfaces The ER14 Branch at Marshall Space Flight Center (MSFC) has created a self-aligning seat and poppet design (shown in Figure 3) that allows a valve to be more tolerant of imperfect contacts. This design utilizes a metallic poppet head with five degrees of freedom that allows the poppet toself-align with the seat, reducing the need for tight tolerances.Figure 3 - Self-Aligning Seat and Poppet DesignIII.Test Valve DescriptionA series of development tasks have been conducted to study potential improvements to internal leakage rates. These tasks include 3 test valves (shown in Figure 4) to demonstrate the potential application to various configurations and sizes:A 3” isolation valve for liquid flows (similar to a fill and drain valve)A 3” relief valve for low temperature gas flows.An 8” pre-valve (similar to the engine isolation valve needed on a Nuclear Thermal Propulsion (NTP) engine).Figure 4 - Low Leakage Development Test ValvesThese valves have been developed and are currently being tested at liquid nitrogen (LN2) temperatures, and are anticipated to undergo testing at liquid hydrogen (LH2) temperatures in late 2022

Cody L Gilliland↗

An Active Broad Area Cooling Model of a Cryogenic Propellant Tank with a Single Stage Reverse Turbo-Brayton Cycle Cryocooler

As focus shifts towards long-duration space exploration missions, an increased interest in active thermal control of cryogenic propellants to achieve zero boil-off of cryogens has emerged. An active thermal control concept of considerable merit is the integration of a broad area cooling system for a cryogenic propellant tank with a combined cryocooler and circulator system that can be used to reduce or even eliminate liquid cryogen boil-off. One prospective cryocooler and circulator combination is the reverse turbo-Brayton cycle cryocooler. This system is unique in that it has the ability to both cool and circulate the coolant gas efficiently in the same loop as the broad area cooling lines, allowing for a single cooling gas loop, with the primary heat rejection occurring by way of a radiator and/or aftercooler. Currently few modeling tools exist that can size and characterize an integrated reverse turbo-Brayton cycle cryocooler in combination with a broad area cooling design. This paper addresses efforts to create such a tool to assist in gaining a broader understanding of these systems, and investigate their performance in potential space missions. The model uses conventional engineering and thermodynamic relationships to predict the preliminary design parameters, including input power requirements, pressure drops, flow rate, cycle performance, cooling lift, broad area cooler line sizing, and component operating temperatures and pressures given the cooling load operating temperature, heat rejection temperature, compressor inlet pressure, compressor rotational speed, and cryogenic tank geometry. In addition, the model allows for the preliminary design analysis of the broad area cooling tubing, to determine the effect of tube sizing on the reverse turbo-Brayton cycle system performance. At the time this paper was written, the model was verified to match existing theoretical documentation within a reasonable margin. While further experimental data is needed for full validation, this tool has already made significant steps towards giving a clearer understanding of the performance of a reverse turbo-Brayton cycle cryocooler integrated with broad area cooling technology for zero boil-off active thermal control.

Guzik, Monica C.↗

Chemical Engineering in Space

The aerospace industry has long been perceived as the domain of both physicists and mechanical engineers. This perception has endured even though the primary method of providing the thrust necessary to launch a rocket into space is chemical in nature. The chemical engineering and chemistry personnel behind the systems that provide access to space have labored in the shadows of the physicists and mechanical engineers. As exploration into the cosmos moves farther away from Earth, there is a very distinct need for new chemical processes to help provide the means for advanced space exploration. The state of the art in launch systems uses chemical propulsion systems, primarily liquid hydrogen and liquid oxygen, to provide the energy necessary to achieve orbit. As we move away from Earth, there are additional options for propulsion. Unfortunately, few of these options can compare to the speed or ease of use provided by the chemical propulsion agents. It is with great care and significant cost that gaseous compounds such as hydrogen and oxygen are liquefied and become dense enough to use for rocket fuel. These low-temperature liquids fall within a specialty area known as cryogenics. Cryogenics, the science and art of producing cold operating conditions for use on Earth, in orbit, or on some other nonterrestrial body, has become increasingly important to our ability to travel within our solar system. The production of cryogenic fuels and the long-term storage of these fluids are necessary for travel. As our explorations move farther away from Earth, we need to address how to produce the necessary fuels to make a round-trip. The cost and the size of these expeditions are extreme at best. If we take everything necessary for our survival for the round-trip, we invalidate any chance of travel in the near future. As with the early explorers on Earth, we need to harvest much of our energy and our life support from the celestial bodies. The in situ production of these energy sources is paramount to success. We are currently working on several processes to produce the propellants that would allow us to visit and explore the surface of Mars. The capabilities currently at our disposal for launching and delivering equipment to another planet or satellite dictate that the size and scale of any hardware must be extremely small. The miniaturization of the processes needed to prepare the in situ propellants and life support commodities is a real challenge. Chemical engineers are faced with the prospect of reproducing an entire production facility in miniature so the complex can be lifted into space and delivered to our destination. Another area that does not normally concern chemical engineers is the extreme physical aspects payloads are subjected to with the launch of a spacecraft. Extreme accelerations followed by the sudden loss of nearly all gravitational forces are well outside normal equipment design conditions. If the equipment cannot survive the overall trip, then it obviously will not be able to yield the needed products upon arrival. These launch constraints must be taken into account. Finally, we must consider both the effectiveness and efficiencies of the processes. A facility located on the Moon or Mars will not have an unlimited supply of power or other ancillary utilities. For a Mars expedition, the available electric power is severely limited. The design of both the processes and the equipment must be considered. With these constraints in mind, only the most efficient designs will be viable. Cryogenics, in situ resource utilization, miniaturization, launchability, and power/process efficiencies are only a few of the areas that chemical engineers provide support and expertise for the exploration of space.

Lobmeyer, Dennis A.↗

Propulsion Technology Needs for Exploration

The objectives of currently planned exploration efforts, as well as those further in the future, require significant advancements in propulsion technologies. The current Lunar exploration architecture has set goals and mission objectives that necessitate the use of new systems and the extension of existing technologies beyond present applications. In the near term, the majority of these technologies are the result of a need to apply high performing cryogenic propulsion systems to long duration in-space applications. Advancement of cryogenic propulsion to these applications is crucial to provide higher performing propulsion systems that reduce the vehicle masses; enhance the safety of vehicle systems and ground operations; and provide a path for In-situ Resource Utilization (ISRU).Use of a LOX/LH2 main propulsion system for Lunar Lander Descent is a top priority because more conventional storable propellants are far from meeting the performance needs of the current architecture. While LOX/LH2 pump feed engines have been used in flight applications for many years, these engines have limited throttle capabilities. Engines that are capable of much greater throttling while still meeting high performance goals are a necessity to achieving exploration goals. Applications of LOX/CH4 propulsion to Lander ascent propulsion systems and reaction control systems are also if interest because of desirable performance and operations improvements over conventional storable systems while being more suitable for use of in-situ produced propellants. Within the current lunar architecture, use of cryogenic propulsion for the Earth Departure Stage and Lunar Lander elements also necessitate the need for advanced Cryogenic Fluid Management technologies. These technologies include long duration propellant storage/distribution, low-gravity propellant management, cryogenic couplings and disconnects, light weight composite tanks and support structure, and subsystem integration. In addition to the propulsive and fluid management system technologies described, many component level technologies are also required to enable to the success if the integrated systems. The components include, but are not limited to, variable/throttling valves, variable position actuators, leak detectors, light weight cryogenic fluid pumps, sensor technology and others. NASA, partnering with the Aerospace Industry must endeavor to develop these, and other promising propulsion technologies, to enable the implements of the country's goals in exploration of the Moon, Mars and beyond.

Brown, Thomas↗

High-temperature, high-pressure optical port for rocket engine applications

This paper discusses the design, fabrication, and test of a window assembly for instrumentation of liquid-fueled rocket engine hot gas systems. The window was designed to allow optical measurements of hot gas in the SSME fuel preburner and appears to be the first window designed for application in a rocket engine hot gas system. Such a window could allow the use of a number of remote optical measurement technologies including: Raman temperature and species concentration measurement, Raleigh temperature measurements, flame emission monitoring, flow mapping, laser-induced florescence, and hardware imaging during engine operation. The window assembly has been successfully tested to 8,000 psi at 1000 F and over 11,000 psi at room temperature. A computer stress analysis shows the window will withstand high temperature and cryogenic thermal shock.

Delcher, Ray↗

Initial Jitter Analysis of Lynx, A Proposed Future Large Astrophysics Facility

Lynx, formerly known as the X-Ray surveyor, is one of the large strategic mission concepts being studied for input into the 2020 Astrophysics Decadal Survey. Lynx is the first future X-ray mission concept planning to match Chandra's angular-resolution and will combine this with very high throughput, large field of view, and high-resolution spectroscopy for point-like and extended sources. These ambitious performance requirements clearly merit early detailed engineering to demonstrate feasibility. An on-going structural dynamic analysis is being performed on the Lynx structural design to predict dynamic responses, jitter, to expected on-board vibrational disturbances. Applicable disturbance sources include a cryogenic pump, and six reaction wheels. The structural design, disturbances, analysis, and results are presented. Ultimately, responses will be compared to Lynx performance requirements as they relate to a system error budget.

Knight, J. Brent↗

Reliable Ignition of LOX-LCH4 Propellants

No cryogenic Reaction Control System (RCS) has ever flown in space. Cryogenic propellants are baselined by HLS and CLPS partners and are the key use case for future ISRU manufactured propellants. A reliable LOX/LCH 4 RCS is an enabling technology for human Lunar and Mars exploration. In previous thermal vacuum (<275 F, <10 torr) testing at NASA GRC Plum Brook, the team uncovered anomalous LOX/LCH4 engine ignition phenomena where flame kernels quenched at these ultra cold hardware temperatures, leading to many pulses where the engines would not light. In 2022, the project was able to recreate the no light condition with an upgraded Frost-Mint test stand at JSC. This project implemented test stand improvements and procured propellants and follow on engine components for a hot fire campaign beginning in November 2024 which will attempt to ignite the RCS engine at ultra cold vacuum conditions by modifying the engine mixture ratio. New modeling techniques were implemented to account for past no lights and are an enabling method to make lunar surface go no go predictions based on hardware conditions. This was enabled by significant improvements to the Frost Mint system, which reduced moisture build up and leaks, increased propellant availability, leading to more attempts at thermal vacuum hot-fires.

Propulsion↗

Radiation cooler for 10 micrometer wavelength engineering model receiver model no. 7172, serial no. 201

The design, fabrication, and testing of a radiative cooler are described. This cooler is an engineering model suitable for bench testing in the laboratory as a part of the 10-micrometer wavelength engineering model receiver, and conforms to the standard radiative cooler configuration, except that the inner stage and its support system were redesigned to accommodate the larger, heavier SAT detector. This radiative cooler will cool the detector to cryogenic temperature levels when the receiver is in a space environment or in a suitable thermal vacuum chamber. Equipment specifications are given along with the results of thermal tests, vibration tests, and electrical integrity tests.

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