A large-scale storage and transfer system for distribution of liquid helium as a refrigerant medium.
Large-scale liquid helium storage and transfer system for ground prechill of Centaur engine components
REFRIGERATING EQUIPMENT↗
SEARCH · Engineering Papers
Results for “cryogenic engineering”
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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Cryogenic Boil-Off Reduction System Testing
Cryogenic propellants such as liquid hydrogen (LH2) and liquid oxygen (LO2) are a part of NASA's future space exploration due to the high specific impulse that can be achieved using engines suitable for moving 10's to 100's of metric tons of payload mass to destinations outside of low earth orbit. However, the low storage temperatures of LH2 and LO2 cause substantial boil-off losses for missions with durations greater than several days. The losses can be greatly reduced by incorporating high performance cryocooler technology to intercept heat load to the propellant tanks and by the integration of self-supporting multi-layer insulation. The active thermal control technology under development is the integration of the reverse turbo- Brayton cycle cryocooler to the propellant tank through a distributed cooling network of tubes coupled to a shield in the tank insulation and to the tank wall itself. Also, the self-supporting insulation technology was utilized under the shield to obtain needed tank applied LH2 performance. These elements were recently tested at NASA Glenn Research Center in a series of three tests, two that reduced LH2 boil-off and one to eliminate LO2 boil-off. This test series was conducted in a vacuum chamber that replicated the vacuum of space and the temperatures of low Earth orbit. The test results show that LH2 boil-off was reduced 60% by the cryocooler system operating at 90K and that robust LO2 zero boil-off storage, including full tank pressure control was achieved.
Propellant Storage↗
The Navy/NASA Engine Program (NNEP89): Interfacing the program for the calculation of complex Chemical Equilibrium Compositions (CEC)
The NNEP is a general computer program for calculating aircraft engine performance. NNEP has been used extensively to calculate the design and off-design (matched) performance of a broad range of turbine engines, ranging from subsonic turboprops to variable cycle engines for supersonic transports. Recently, however, there has been increased interest in applications for which NNEP is not capable of simulating, such as the use of alternate fuels including cryogenic fuels and the inclusion of chemical dissociation effects at high temperatures. To overcome these limitations, NNEP was extended by including a general chemical equilibrium method. This permits consideration of any propellant system and the calculation of performance with dissociation effects. The new extended program is referred to as NNEP89.
Gordon, Sanford↗
Modeling and Validation of a Propellant Mixer for Controller Design
A mixing chamber used in rocket engine testing at the NASA Stennis Space Center is modelled by a system of two nonlinear ordinary differential equations. The mixer is used to condition the thermodynamic properties of cryogenic liquid propellant by controlled injection of the same substance in the gaseous phase. The three inputs of the mixer are the positions of the valves regulating the liquid and gas flows at the inlets, and the position of the exit valve regulating the flow of conditioned propellant. Mixer operation during a test requires the regulation of its internal pressure, exit mass flow, and exit temperature. A mathematical model is developed to facilitate subsequent controller designs. The model must be simple enough to lend itself to subsequent feedback controller design, yet its accuracy must be tested against real data. For this reason, the model includes function calls to thermodynamic property data. Some structural properties of the resulting model that pertain to controller design, such as uniqueness of the equilibrium point, feedback linearizability and local stability are shown to hold under conditions having direct physical interpretation. The existence of fixed valve positions that attain a desired operating condition is also shown. Validation of the model against real data is likewise provided.
Richter, Hanz↗
Launching and Deploying the James Webb Space Telescope
On December 25, 2021, at 12:20 UTC, the James Webb Space Telescope lifted off and onward to its destination in orbit at the second Lagrange point. With more than two decades in development, and an international collaboration between NASA, CSA, and ESA, Webb is one of the most anticipated science missions ever launched. After a dramatic and flawless launch, Webb's toughest and riskiest days lie ahead. Unprecedented in its complexity and ambition, over the next two weeks Webb would undergo the most complex on-orbit deployment sequence ever attempted, with any single deployment anomaly carrying the risk of full mission failure. An exquisite design, years of ground testing, a exhaustively trained and rehearsed operations and engineering team, and an unprecedented level of contingency planning, all resulted in a fully and successfully deployed Webb observatory, on its way to L2, and nominally cooling to its cryogenic temperatures. Although Webb still had many more months of commissioning left, there was a collective sigh of relief heard round the world. This incredible achievement was not by chance but was years in the making. We go behind the scenes of Webb's first month on orbit, starting with the unique and challenging launch itself, the time criticality of its mid-course corrections, and a summary of nearly 14 days to undergo nearly 50 major deployments. We discuss what went better than planned and how years of robust and detailed contingency planning were prepared for unanticipated events and on-orbit spacecraft behavior. And finally, we provide a brief overview of the entire commissioning process which successfully completed on July 10th, 2022.
Keith A Parrish↗
Reciprocating Feed System Development Status
The reciprocating feed system (RFS) is an alternative means of providing high pressure propellant flow at low cost and system mass, with high fail-operational reliability. The RFS functions by storing the liquid propellants in large, low-pressure tanks and then expelling each propellant through two or three small, high-pressure tanks. Each RFS tank is sequentially filled, pressurized, expelled, vented, and refilled so as to provide a constant, or variable, mass flow rate to the engine. This type of system is much lighter than a conventional pressure fed system in part due to the greatly reduced amount of inert tank weight. The delivered payload for an RFS is superior to that of conventional pressure fed systems for conditions of high total impulse and it is competitive with turbopump systems, up to approximately 2000 psi. An advanced version of the RFS uses autogenous pressurization and thrust augmentation to achieve higher performance. In this version, the pressurization gases are combusted in a small engine, thus making the pressurization system, in effect, part of the propulsion system. The RFS appears to be much less expensive than a turbopump system, due to reduced research and development cost and hardware cost, since it is basically composed of small high- pressure tanks, a pressurization system, and control valves. A major benefit is the high reliability fail-operational mode; in the event of a failure in one of the three tank-systems, it can operate on the two remaining tanks. Other benefits include variable pressure and flow rates, ease of engine restart in micro-gravity, and enhanced propellant acquisition and control under adverse acceleration conditions. We present a system mass analysis tool that accepts user inputs for various design and mission parameters and calculates such output values payload and vehicle weights for the conventional pressure fed system, the RFS, the Autogenous Pressurization Thrust Augmentation (APTA) RFS, and turbopump systems. Using this tool, a preliminary design of a representative crew exploration vehicle (CEV) has been considered. The design parameters selected for a representative system were modeled after the orbital maneuvering system (OMS) on the Shuttle Orbiter, with an increase of roughly a factor of ten in the delta- V capability and a greater thrust (30,000 lbs, vs. 12,000 lbs). Both storable and cryogenic propellants were considered. Results show that a RFS is a low mass alternative to conventional pressure fed systems, with a substantial increase in payload capability and that it is weight-competitive with turbopump systems at low engine pressure (a few hundred psi); at high engine pressures, the APTA RFS appears to offer the highest payload. We also present the status of the RFS test bed fabrication, assembly, and checkout. This test bed is designed to provide flow rates appropriate for engines in the roughly 10,000 to 30,000 lb thrust range.
Trewek, Mary↗
Layer size polydispersity in hydrated montmorillonite creates multiscale porosity networks
The aluminosilicate layers of the swelling clay mineral montmorillonite, and the saturated pores they delineate, control the mechanical properties and the transport of solutes in many natural and engineered environments. However, the structural basis of montmorillonite porosity remains poorly characterized due to the difficulty in visualizing hydrated samples in their native state. Here in this paper, we used cryogenic transmission electron microscopy (cryo-TEM) and cryo electron tomography (cryo-ET) to show that stacking defects within minimally altered, fully hydrated montmorillonite particles define multiscale porosity networks. Variations in layer lateral dimensions over tens to thousands of nanometers cause a range of topological and dynamic defects that generate pervasive curvature and introduce previously uncharacterized solute transport pathways. Observations of long-range rotational order between neighboring layers indicate that the layer-layer interactions that govern clay swelling involve three dimensional orienting forces that operate across nanoscale pores. These direct observations of the hierarchical structure of hydrated montmorillonite pore networks with nanoscale resolution reveal potentially general aspects of colloidal interactions in fluid-saturated clay minerals.
36 MATERIALS SCIENCE↗
The dynamic behavior and compliance of a stream of cavitating bubbles.
Study of the dynamic response of streams of cavitating bubbles to imposed pressure fluctuations to determine the role played by turbopump cavitation in the POGO instability of liquid rockets. Both quasi-static and more general linearized dynamic analyses are made of the perturbations to a cavitating flow through a region of reduced pressure in which the bubbles first grow and then collapse. The results, when coupled with typical bubble number density distribution functions, yield compliances which compare favorably with the existing measurements. Since the fluids involved are frequently cryogenic, a careful examination was made of the thermal effects both on the mean flow and on the perturbations. As a result, the discrepancy between theory and experiment for particular engines could be qualitatively ascribed to reductions in the compliance caused either by these thermal effects or by relatively high reduced frequencies.
Brennen, C.↗
Booster and orbiter configurations
In the recent Future Space Transportation System (FSFS) study, a mission model was selected and a baseline vehicle which best met model requirements was shaped. This baseline was then analyzed for flight performance, structural and subsystem weight, and operation. Figures related to a payload of 150,000 lb in a 20-ft-diam by 90-ft-long envelope became the baseline. The existence of both space-based orbital transfer vehicles (OTVs) and a space station was assumed, taking into account a transfer of the payload from the launch vehicle to OTVs at the space station for final delivery to geosynchronous orbit (GEO). A computer-aided engineering system called Aerospace Vehicle Interactive Design (AVID) was employed in connection with baseline vehicle development. It was found that approximately three-fifth of the payload weight would be cryogenic propellants for OTVs. Attention is given to problems regarding the packaging of cryogenic tankage, a payload shroud, and studies of staging for two different booster propulsion units.
Wilhite, A. W.↗
SSTAC/ARTS Review of the Draft Integrated Technology Plan (ITP). Volume 2: Propulsion Systems
The topics addressed are: (1) space propulsion technology program overview; (2) space propulsion technology program fact sheet; (3) low thrust propulsion; (4) advanced propulsion concepts; (5) high-thrust chemical propulsion; (6) cryogenic fluid management; (7) NASA CSTI earth-to-orbit propulsion; (8) advanced main combustion chamber program; (9) earth-to-orbit propulsion turbomachinery; (10) transportation technology; (11) space chemical engines technology; (12) nuclear propulsion; (13) spacecraft on-board propulsion; and (14) low-cost commercial transport.
Source record↗
Use of Shuttle Heritage Hardware in Space Launch System (SLS) Application-Structural Assessment
NASA is moving forward with the development of the next generation system of human spaceflight to meet the Nation's goals of human space exploration. To meet these goals, NASA is aggressively pursuing the development of an integrated architecture and capabilities for safe crewed and cargo missions beyond low-Earth orbit. Two important tenets critical to the achievement of NASA's strategic objectives are Affordability and Safety. The Space Launch System (SLS) is a heavy-lift launch vehicle being designed/developed to meet these goals. The SLS Block 1 configuration (Figure 1) will be used for the first Exploration Mission (EM-1). It utilizes existing hardware from the Space Shuttle inventory, as much as possible, to save cost and expedite the schedule. SLS Block 1 Elements include the Core Stage, "Heritage" Boosters, Heritage Engines, and the Integrated Spacecraft and Payload Element (ISPE) consisting of the Launch Vehicle Stage Adapter (LVSA), the Multi-Purpose Crew Vehicle (MPCV) Stage Adapter (MSA), and an Interim Cryogenic Propulsion Stage (ICPS) for Earth orbit escape and beyond-Earth orbit in-space propulsive maneuvers. When heritage hardware is used in a new application, it requires a systematic evaluation of its qualification. In addition, there are previously-documented Lessons Learned (Table -1) in this area cautioning the need of a rigorous evaluation in any new application. This paper will exemplify the systematic qualification/assessment efforts made to qualify the application of Heritage Solid Rocket Booster (SRB) hardware in SLS. This paper describes the testing and structural assessment performed to ensure the application is acceptable for intended use without having any adverse impact to Safety. It will further address elements such as Loads, Material Properties and Manufacturing, Testing, Analysis, Failure Criterion and Factor of Safety (FS) considerations made to reach the conclusion and recommendation.
Aggarwal, Pravin↗
ASC Poster - Concentration of Xe from Simulated Dissolver Off-gas Streams Utilizing a Solid Sorbent, AgZ-PAN
Idaho National Laboratory (INL) has developed and tested engineered sorbents to separate and capture volatile fission products such iodine (I), xenon (Xe), and krypton (Kr) from off-gas streams. As noble gases, Xe and Kr can be difficult to capture and separate. Historically, cryogenic distillation has been used to execute the separation, but this method can pose significant hazards. INL has successfully developed two sorbents for Xe and Kr capture, silver mordenite polyacrylonitrile (AgZ-PAN) and hydrogen mordenite polyacrylonitrile (HZ-PAN). Adsorption studies to date successfully separated and captured Xe from carrier gas streams, but those studies focused primarily on initial separation and capture. In addition, the ability to concentrate Xe through multiple adsorption and desorption cycles has not been studied and therefore is the focus on this presentation. Concentrating Xe during desorption is ideal to produce Xe that can be used for commercial and research applications.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Brush Seals for Cryogenic Applications: Performance, Stage Effects, and Preliminary Wear Results in LN2 and LH2
Brush seals are compliant contacting seals and have significantly lower leakage than labyrinth seals in gas turbine applications. Their long life and low leakage make them candidates for use in rocket engine turbopumps. Brush seals, 50.8 mm (2 in.) in diameter with a nominal 127-micron (0.005-in.) radial interference, were tested in liquid nitrogen (LN2) and liquid hydrogen (LH2) at shaft speeds up to 35,000 and 65,000 rpm, respectively, and at pressure drops up to 1.21 MPa (175 psid) per brush. A labyrinth seal was also tested in liquid nitrogen to provide a baseline. The LN2 leakage rate of a single brush seal with an initial radial shaft interference of 127 micron (0.005 in.) measured one-half to one-third the leakage rate of a 12-tooth labyrinth seal with a radial clearance of 127 micron (0.005 in.). Two brushes spaced 7.21 micron (0.248 in.) apart leaked about one-half as much as a single brush, and two brushes tightly packed together leaked about three-fourths as much as a single brush. The maximum measured groove depth on the Inconel 718 rotor with a surface finish of 0.81 micron (32 microinch) was 25 micron (0.0010 in.) after 4.3 hr of shaft rotation in liquid nitrogen. The Haynes-25 bristles wore approximately 25 to 76 micron (0.001 to 0.003 in.) under the same conditions. Wear results in liquid hydrogen were significantly different. In liquid hydrogen the rotor did not wear, but the bristle material transferred onto the rotor and the initial 127 micron (0.005 in.) radial interference was consumed. Relatively high leakage rates were measured in liquid hydrogen. More testing is required to verify the leakage performance, to validate and calibrate analysis techniques, and to determine the wear mechanisms. Performance, staging effects, and preliminary wear results are presented.
Proctor, Margaret P.↗
A Nuclear Cryogenic Propulsion Stage for Near-Term Space Missions
The potential capability of NTP is game changing for space exploration. A first generation NCPS could provide high thrust at a specific impulse above 900 s, roughly double that of state of the art chemical engines. Near-term NCPS systems would provide a foundation for the development of significantly more advanced, higher performance systems. John F. Kennedy made his historic special address to Congress on the importance of space on May 25, 1961, "First, I believe that this nation should commit itself to achieving the goal, before this decade is out, of landing a man on the Moon and returning him safely to the Earth..." This was accomplished. John F. Kennedy also made a second request, "Secondly... accelerate development of the Rover nuclear rocket. This gives promise of some day providing a means for even more exciting and ambitious exploration of space, perhaps beyond the Moon, perhaps to the very end of the solar system itself." The investment in the Rover nuclear rocket program provided the foundation of technology that gives us assurance for greater performing rockets that are capable of taking us further into space. Combined with current technologies, the vision to go beyond the Moon and to the very end of the solar system can be realized with space nuclear propulsion and power.
Houts, Michael G.↗
Cryogenic hydrogen-induced air-liquefaction technologies
Extensive use of a special advanced airbreathing propulsion archives data base, as well as direct contacts with individuals who were active in the field in previous years, a technical assessment of cryogenic hydrogen induced air liquefaction, as a prospective onboard aerospace vehicle process, was performed and documented in 1986. The resulting assessment report is summarized. Technical findings relating the status of air liquefaction technology are presented both as a singular technical area, and also as that of a cluster of collateral technical areas including: Compact lightweight cryogenic heat exchangers; Heat exchanger atmospheric constituents fouling alleviation; Para/ortho hydrogen shift conversion catalysts; Hydrogen turbine expanders, cryogenic air compressors and liquid air pumps; Hydrogen recycling using slush hydrogen as heat sinks; Liquid hydrogen/liquid air rocket type combustion devices; Air Collection and Enrichment System (ACES); and Technically related engine concepts.
Escher, William J. D.↗
Generating Cryogenic Lunar Simulants Within the Planetary Exploration & Astromaterials Research Laboratory
The Planetary Exploration & Astromaterials Research Laboratory (PEARL) aims to provides capabilities for the creation of—and research on—cryogenic lunar regolith simulants (CRS) containing surface volatile analytes. CRS represent regolith samples that might be collected from lunar Permanently Shadowed Regions (PSRs) during future missions. Handling CRS requires procedural and engineering development due to extremely cold (i.e. ≤ - 196°C) working temperatures. However, there is an imperative to understand the physical and chemical alteration of samples during collection, transport, and curation processes throughout the Artemis missions. The chemistries that will be encountered within the PSRs need to be understood based upon prior mission data analysis. The ability to utilize these techniques provides future tests that could be relevant to planetary protection applications regarding future robotic sample return.
Lunar↗
A study of electric motors for use in liquid and gaseous helium Engineering report no. 3530
Electric motor design and operation in liquid and gaseous helium environments
ELECTRIC MOTOR↗
James Webb Space Telescope Optical Telescope Element / Integrated Science Instrument Module (OTIS) Cryogenic Vacuum Test Part I: Thermal Architecture
The James Webb Space Telescope (JWST), set to launch in early 2019, is currently undergoing a series of system-level environmental tests to verify its workmanship and end-to-end functionality. As part of this series, the Optical Telescope Element and Integrated Science Instrument Module (OTIS) Cryo-Vacuum (CV) test, the most complex cryogenic test executed to date by NASA, was completed in 2017 at the Johnson Space Center's Chamber A facility. The OTIS CV test was intended as a comprehensive test of the integrated instrument and telescope systems to fully understand its optical, structural, and thermal performance within its intended flight environment. Due to its complexity, extensive pre-test planning was required to ensure payload safety and compliance with all limits and constraints. A comprehensive thermal analysis campaign was undertaken to predict the behavior of the test payload during its transition to cryogenic temperatures and back to ambient, and exhaustive preparations for off-nominal scenarios were studied due to the increased possibility of unanticipated events during the 100-day test length. This current four-part online course for the NASA Engineering and Safety Center (NESC) Academy gives a thorough overview of the mutiple years of preparation executed by hundreds of individuals to ensure the success of the JWST OTIS CV Test. Part I will introduce the major components of James Webb and specifically the OTIS CV Test thermal architecture. Part II will encompass the extensive thermal analysis performed to prepare for the test. Part III will talk about the preparations for off-nominal events: what analysis was done, and how steps were taken pre-test to anticipate unexpected circumstances and mitigate their impacts to hardware and test timeline. Part IV is a recap of the lessons learned from the thermal perspective for both the payload and ground support equipment (GSE) test conductors. It is hoped that the insight gained from the OTIS CV test campaign will benefit planning and execution for upcoming large cryogenic missions.
OTIS↗