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At least 685 records · Page 38
All sourcesNASA NTRSDOE OSTI
NASA NTRS2005

Assessment of Technologies for the Space Shuttle External Tank Thermal Protection System and Recommendations for Technology Improvement - Part III: Material Property Characterization, Analysis, and Test Methods

The objective of this report is to contribute to the independent assessment of the Space Shuttle External Tank Foam Material. This report specifically addresses material modeling, characterization testing, data reduction methods, and data pedigree. A brief description of the External Tank foam materials, locations, and standard failure modes is provided to develop suitable background information. A review of mechanics based analysis methods from the open literature is used to provide an assessment of the state-of-the-art in material modeling of closed cell foams. Further, this report assesses the existing material property database and investigates sources of material property variability. The report presents identified deficiencies in testing methods and procedures, recommendations for additional testing as required, identification of near-term improvements that should be pursued, and long-term capabilities or enhancements that should be developed.

Gates, Thomas S.↗
DOE OSTI2020

Technical Gaps in Hanford High-Level Waste Solids Settling Behavior and Settling Time Evaluation for Direct Feed High-Level Waste (DFHLW) Operations

Settling of high-level waste (HLW) solids in process vessels is a key conceptual process step in providing HLW feed directly to the Hanford Waste Treatment and Immobilization Plant (WTP) HLW Vitrification Facility. Direct Feed High-Level Waste (DFHLW) is a potential approach to initiating HLW vitrification prior to completing of the WTP Pretreatment Facility. Settling would be used with subsequent supernatant decant to concentrate HLW feed. To support planning for DFHLW, Washington River Protection Solutions (WRPS) requested support from the Pacific Northwest National Laboratory to evaluate the current data set available to predict the time needed for HLW solids to settle, to identify gaps in the understanding and predictive capability of HLW solids waste settling times, and to provide scoping estimates of the potential settling time. Eight technical gaps were identified for predicting settling times and characteristics of the formed sediment layers including: Gap 1: In-Tank Settling Rates Faster than Settling of Laboratory Samples, Gap 2: Effect of Sludge Leaching/Washing on Predicted Settling Times, Gap 3: Predicting Waste Settling from Waste Chemistry (Waste Type), Gap 4: Predicting Waste Settling from Particle Size and Density Distributions (PSDDs), Gap 5: Insufficient Laboratory and In-Tank Settling Data to Represent Hanford Waste, Gap 6: Methods for Real-Time, In-Tank Tracking of Settling, Gap 7: Prediction of Sediment Erosion Resistance as a Function of Settling Time, and Gap 8: Prediction of Sediment Solids Content as a Function of Settling Time. In addition to the data gaps, an overarching observation of the settling rate and settled layer data is the significant variation in behavior. At similar solids concentrations, settling rates can vary by as much as 3 orders of magnitude depending on the source waste tank, and significantly different settling rates are noted between laboratory and in situ tests for the same waste tank. The range of average solids concentration in existing HLW sediment, which may have been quiescent for decades, can vary from less than 7 wt% to greater than 74 wt% solids. The shear strengths (or yield stresses) measured on laboratory samples range from less than 27 Pa to greater than 6400 Pa. These variations can challenge process planning for the application of a settle/decant process for DFHLW. This report describes the significance of the gaps to the settle/decant process and presents uncertainties by way of examples. Potential technical approaches for resolving these gaps are described and the estimated difficulty in resolving these gaps is evaluated. Based on the significance of the gap and the difficulty of resolution, recommendations are made to address specific gaps. Scoping estimates of the potential settling times for DFHLW solids have been made based on the existing data set with its associated gaps. Depending on the process vessel depth and final sediment concentration, substantial fractions of the scoping estimate results for settling times for characterized HLW exceed the 2-week period that has been previously assumed for process planning. There is also significant disparity, potentially greater than a factor of 5000 difference, in the estimated settling times depending on process vessel depth and final sediment solid concentration. This variation in results underscores the significance of the identified gaps and uncertainties with respect to process planning for utilizing settle/decant operations for DFHLW.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1946

Ditching Tests of a 1/9-Size Model of the Army P-38 Airplane in Langley Tank No. 2 and at the Outdoor Catapult

A dynamically similar model of the Army P-38 airplane was tested to determine the best way to land this airplane on the water and to determine its probable ditching performance. The tests consisted of ditching the model at various landing attitudes, flap settings, speeds, weights, and conditions of simulated damage. The model was ditched in calm water from the tank towing carriage and a few ditching were made in both calm and rough water at the outdoor catapult. The performance of the model was determined by making visual observations, by recording lengths of run and time histories of decelerations, and by taking motion pictures of the ditchings.

Jarvis, George A.↗
NASA NTRS1979

Preflight status of the External Tank portion of the Space Shuttle Main Propulsion System

The development progress of the External Tank (ET) of the Shuttle Main Propulsion System (MPS) is described. 87% of ET propulsion components have satisfactorily completed qualification tests in preparation for the first Shuttle flight and their performance has been verified in the Main Propulsion Test Article (MPTA) firings of up to 100 seconds duration. The design changes in the LH2 tank pressurant diffuser, the LO2 feed system, and the ground test LO2 tank are discussed. Propellant loading information from MPTA tests may be used to predict loading operations and performance at KSC and VAFB, while ullage pressure profiles and boil-off rates during loading, chilldown rates, and final bulk density data have been obtained with geyser suppression evaluated and loading procedures established and verified. The MPTA test experience provided data to evaluate pressurization system and ET to Orbiter interface propellant performance noting thus that the fluid interface requirements will be satisfied for the first Shuttle flight. The Intertank inerting system was found to be effective in minimizing hazardous gas mixtures and full scale separation tests of the ET to Ground Umbilical Carrier Plate system were successfully completed.

Norquist, L.↗
NASA NTRS2015

Liquid Hydrogen Propellant Tank Sub-Surface Pressurization with Gaseous Helium

A series of tests were conducted to evaluate the performance of a propellant tank pressurization system with the pressurant diffuser intentionally submerged beneath the surface of the liquid. Propellant tanks and pressurization systems are typically designed with the diffuser positioned to apply pressurant gas directly into the tank ullage space when the liquid propellant is settled. Space vehicles, and potentially propellant depots, may need to conduct tank pressurization operations in micro‐gravity environments where the exact location of the liquid relative to the diffuser is not well understood. If the diffuser is positioned to supply pressurant gas directly to the tank ullage space when the propellant is settled, then it may become partially or completely submerged when the liquid becomes unsettled in a microgravity environment. In such case, the pressurization system performance will be adversely affected requiring additional pressurant mass and longer pressurization times. This series of tests compares and evaluates pressurization system performance using the conventional method of supplying pressurant gas directly to the propellant tank ullage, and then supplying pressurant gas beneath the liquid surface. The pressurization tests were conducted on the Engineering Development Unit (EDU) located at Test Stand 300 at NASA Marshall Space Flight Center (MSFC). EDU is a ground based Cryogenic Fluid Management (CFM) test article supported by Glenn Research Center (GRC) and MSFC. A 150 ft3 propellant tank was filled with liquid hydrogen (LH2). The pressurization system used regulated ambient helium (GHe) as a pressurant, a variable position valve to maintain flow rate, and two identical independent pressurant diffusers. The ullage diffuser was located in the forward end of the tank and was completely exposed to the tank ullage. The submerged diffuser was located in the aft end of the tank and was completely submerged when the tank liquid level was 10% or greater. The ullage diffuser tests were conducted as a baseline to evaluate the performance of the pressurization system, and the submerged diffuser tests showed how the performance of the pressurization system was compromised when the diffuser was submerged in LH2. The test results are evaluated and compared, and included in this report for various propellant tank fill levels.

Stephens, J. R.↗
NASA NTRS2016

CryoCart Restoration and Vacuum Pipe Construction

Propulsion systems that utilize hypergolic propellants have been used to power space vehicles since the beginning of the space program. Liquid methane and oxygen propulsion systems have emerged as an alternative and have proven to be more environmentally friendly. The incorporation of liquid methane/liquid oxygen (LOX) into the propulsion system has demonstrated an increase in engine performance, as well as a reduction in the volume, size and complexity of the system. Consequently, reducing the total mass of the vehicle which is a crucial aspect that is considered when planning space missions to both the Moon and Mars [1]. Project Morpheus has made significant advancements in liquid oxygen/liquid methane propulsion system technologies by incorporating a LOX/methane propulsion system to a vertical test bed. The vehicle consisted of a 5,000 lb main engine and four 20 lb remote control system (RCS) engines that utilize liquid methane/LOX as its propellant [1]. The vehicle completed successful flight testing at Kennedy Space Center in 2014 which marked the completion of the Morpheus project. Subsequent projects utilizing Morpheus' vertical test bed have been developed to make further advancements. One of the subsequent projects consisted of the addition of a smaller 2,000 lb main engine and a cold helium heat exchanger which would make it possible for a pressurant tank systems to be send to Mars or the Moon by significantly decreasing the overall mass and volume of the pressurant tank. The hot fire tests of the integrated system with the smaller main engine and cold helium heat exchanger were successful at sea level, but further studies are being conducted to better understand how the vertical test bed will behave under thermal-vacuum conditions. For this reason, the integrated vehicle will be taken to Plum Brook to be tested in a chamber capable of simulating these conditions. To ensure that the vehicle will function properly under vacuum conditions, testing will be first completed at the component level. During this process, the igniter of the main engine and the RCS thrusters will be tested under a vacuum. To complete the testing of the components, the test setup first needed to be finalized. The CryoCart is being used to feed the propellants to the test article. The CryoCart is a movable test set-up that was developed in 2009 to provide a mobile platform for testing oxygen/methane systems with hot-fire capability up to 100 lbf. The CryoCart consists of three different systems: Oxygen, Methane, and liquid Nitrogen. The Oxygen and Methane systems are placed into two different carts while the liquid nitrogen system is mainly located in the methane cart. Over the years, the CryoCart has been utilized for different projects and has undergone deterioration. For this reason, a new phase has been developed to rebuild it to working conditions once again. During my internship, I was aiding in the construction and restoration of the CryoCart. In the initial stages of the process, I updated the fluid and electrical schematics for the oxygen, methane, and test article systems. The original CryoCart consisted of an electrical panel that utilized electromechanical relays and a terminal to drive the igniter power and signal, as well as the main fuel and oxygen valves. This electrical panel connected to the CryoCart through various wire harnesses that could be found exiting from the CryoCart. First, it was determined how these harnesses connected to the electromechanical relays so that they worked correctly. Once the electrical system was understood, an alternative for the electromechanical relays and the Molex connectors used throughout the system was sought since these components can often prove to be unreliable. Solid State relays and MIL connectors were purchased to serve as replacements. Upon arrival of the parts, crimping and wiring was completed to install the new solid state relays and MIL connectors. During the replacement of the relays and connectors, system checks of the electrical system were ran to ensure that the system was working correctly. While completing system checks, the pressure transducers that were not functioning properly were also replaced and any issue with the wiring or signal was addressed. Once the electrical components were replaced, the restoration of the fluid system began. Parts of the tubing in the CryoCart had to be rebuild and often consisted of sizing, cutting, bending, filing, and sanding the tubing to prepare it to be flared. Many components had to be proof-tested to bring their certifications up to date, and several components had to be replaced. Various flex hoses, valves, and fittings were send to the Clean Lab because they were new, dirty, or had gone through proof-testing. Once they arrived from the cleaning lab they had to be put back to the system and leak checks and functional tests were conducted. In the Nitrogen system, the copper tubing located in the Oxygen cart was rebuild and Aerogel insulation was added to this section. A new gaseous nitrogen system was added to the CryoCart to purge the vacuum tube which will serve as the test chamber. Once the CryoCart was completed, construction of parts of the vacuum tube began. A flange was manufactured with welded fittings to hold the line of the vacuum pump as well as some extra fittings which will serve as extra inlets used to introduce fluid lines to the vacuum tube. Stress analysis was ran in this flange to ensure that it would not fail under vacuum conditions. The fluid lines leading from the air side of the vacuum to the test article were also constructed and added to the mount that had already been manufactured. Three different sets of tubing were constructed to accommodate the seven different RCS thruster and the main engine igniter that are going to be tested. Full electrical system checks were completed to ensure that all the wire harnesses and valves were functioning. Upon the completion of the CryoCart and the vacuum tube, hot fire testing for the RCS thrusters and the main engine igniter are going to begin. During this time any issues encountered with the engines or igniter will be addressed to ensure that the components function under vacuum conditions. After successful completion of testing, the vertical test bed, Morpheus, will be rebuilt and prepared to be sent to Plum Brook. In Plum Brook, the vehicle will be tested in the thermal-vacuum chamber to demonstrate that integrated lox-methane propulsion system operation in space-like conditions. This internship has allowed me the opportunity to gain valuable hands on experience and to develop skills that will aid in my education as well as in the workforce, while at the same time helping me determine that I would like to further pursue a career in propulsion engineering.

Chaidez, Mariana↗
NASA NTRS1993

Microbiological test results of the environmental control and life support systems vapors compression distillation subsystem recycle tank components following various pretreatment protocols

Microbiological samples were collected from the recycle tank of the vapor compression distillation (VCD) subsystem of the water recovery test at NASA MSFC following a 68-day run. The recycle tank collects rejected urine brine that was pretreated with a commercially available oxidant (Oxone) and sulfuric acid and pumps it back to the processing component of the VCD. Samples collected included a water sample and two swab samples, one from the particulate filter surface and a second from material floating on the surface of the water. No bacteria were recovered from the water sample. Both swab samples contained a spore-forming bacterium, Bacillus insolitus. A filamentous fungus was isolated from the floating material. Approximately 1 month after the pretreatment chemicals were changed to sodium hypochlorite and sulfuric acid, a swab of the particulate filter was again analyzed for microbial content. One fungus was isolated, and spore-forming bacteria were observed. These results indicate the inability of these pretreatments to inhibit surface attachment. The implications of the presence of these organisms are discussed.

Huff, Tim↗
NASA NTRSDate not supplied

Results of Use of Heat Flux Sensors on Liquid Hydrogen Tanks

Heat flux sensors were used to characterize the performance of insulation on the Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER), a large-scale test article designed to simulate upper stage cryogenic propellant tank thermal performance in simulated space environments. Usually, the insulation heat loads are derived from calculations removing all other heat sources and attributing the residual heat load to the insulation system. Testing for SHIIVER included the tank being just insulated with spray-on-foam insulation as well as covering the domes with multilayer insulation while leaving the barrel section insulated with spray-on-foam. Heat flux sensors were located at multiple locations on both domes as well as on the barrel section of the tank. Results from the SHIIVER testing using the heat flux sensors are compared to other calculated heat inputs for both liquid nitrogen and liquid hydrogen testing as a function of tank fill level. Further investigation into the transient nature of the SHIIVER testing including the heat flux sensors provided insight into heat flow patterns that may not have been otherwise seen using temperature sensors and calculated insulation heat loads. While the demonstrated uncertainties in the absolute values in the heat flux sensors are high, the values and the trends match well with other calculation methods. The results of SHIIVER allow for the use of heat flux sensors for measurements of insulation performance and dynamic system thermal response for future applications.

Cryogenic Fluid Management↗
NASA NTRS1976

Experimental study of transient liquid motion in orbiting spacecraft

A test program was conducted involving forty-five drops of liquid propellant in instrumented tanks. Biaxial, low-g accelerations were applied to the model propellant tanks during free-fall testing, and forces exerted during liquid reorientation were measured and recorded. High speed photographic records of the liquid reorientation were also made. The test data was used to verify a mechanical analog which portrays the liquid as a point mass moving on an ellipsoidal constraint surface. The mechanical analog was coded into two FORTRAN 4 digital computer programs. Results showed excellent correlation between test data and analytical predictions of reorientation forces and liquid center of mass motion, verifying the basic analytical approach.

Berry, R. L.↗
NASA NTRS1992

APU diaphragm testing. Test plan

Auxiliary Power Unit (APU) fuel (hydrazine) tanks have had to be removed from the Columbia Shuttle (OV-102) because they have been in service for 11 years, which is the limit of their useful life. As part of an effort to determine whether the useful life of the fuel tanks can be extended, examination of the ethylene propylene rubber (EPR) diaphragm and the metal from one of the APU tanks is required. The JSC Propulsion and Power Division has requested White Sands Test Facility (WSTF) to examine the EPR diaphragm thoroughly and the metal casing generally from one tank. The objective is to examine the EPR diaphragm for signs of degradation that may limit the life of its function in the APU propellant tank. The metal casing will also be examined for signs of surface corrosion.

Shelley, Richard↗
NASA NTRS1947

Acceleration Measurements During Landing in Rough Water of a 1/7-Scale Dynamic Model of Grumman XJR2F-1 Amphibian - Langley Tank Model 212, TED No. NACA 2378

Tests of a 1/7 size model of the Grumman XJR2F-1 amphibian were made in Langley tank no.1 to examine the landing behavior in rough water and to measure the normal and angular accelerations experienced by the model during these landings. All landings were made normal to the direction of wave advance, a condition assumed to produce the greatest accelerations. Wave heights of 4.4 and 8.0 inches (2.5 and 4.7 ft, full size) were used in the tests and the wave lengths were varied between 10 and 50 feet (70 and 350 ft, full size). Maximum normal accelerations of about 6.5g were obtained in 4.4 inch waves and 8.5g were obtained in 8.0 inch waves. A maximum angular acceleration corresponding to 16 radians per second per second, full size, was obtained in the higher waves. The data indicate that the airplane will experience its greatest accelerations when landing in waves of about 20 feet (140 ft, full size) in length.

Land, Norman S.↗
NASA NTRSDate not supplied

Results of Use of Heat Flux Sensors on Liquid Hydrogen Tanks

ABSTRACT: Heat flux sensors were used to characterize the performance of insulation on the Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER), a large-scale test article designed to simulate upper stage cryogenic propellant tank thermal performance in simulated space environments. Usually, the insulation heat loads are derived from calculations removing all other heat sources and attributing the residual heat load to the insulation system. Testing for SHIIVER included the tank being just insulated with spray-on-foam insulation as well as covering the domes with multilayer insulation while leaving the barrel section insulated with spray-on-foam. Heat flux sensors were located at multiple locations on both domes as well as on the barrel section of the tank. Results from the SHIIVER testing using the heat flux sensors are compared to other calculated heat inputs for both liquid nitrogen and liquid hydrogen testing as a function of tank fill level. Further investigation into the transient nature of the SHIIVER testing including the heat flux sensors provided insight into heat flow patterns that may not have been otherwise seen using temperature sensors and calculated insulation heat loads. While the demonstrated uncertainties in the absolute values in the heat flux sensors are high, the values and the trends match well with other calculation methods. The results of SHIIVER allow for the use of heat flux sensors for measurements of insulation performance and dynamic system thermal response for future applications.

Cryogenic Fluid Management↗
NASA NTRS2010

Thermographic Methods of Detecting Insulation Voids in Large Cryogenic Tanks

Four very large (900Kgal) cryogenic liquid hydrogen and oxygen storage tanks at Kennedy Space Center's LC-39 launch pads were constructed in 1965 to support the Apollo/Saturn V Program and continue to support the Space Shuttle Program. These double-walled spherical tanks with powdered insulation in the annular region, have received minimal refurbishment or even inspection over the years. Intrusively inspecting these tanks would mean a significant down time to the program as the cryogenic liquid and the perlite insulation would have to be removed which would be a significant task and long-term schedule disruption. A study of the tanks was performed to determine the extent to which performance and structural information could be revealed without intrusive inspection. Thermal images of the tanks were taken over a variety of environmental conditions to determine the best conditions under which to compare and use thermography as a health monitoring technique as the tanks continue to age. The settling and subsequent compaction of insulation is a serious concern for cryogenic tanks. Comparison of images from the tanks reveals significant variations in the insulation in the annual regions and point to the use of thermography as a way to monitor for insulation migration and possible compaction. These measurements, when combined with mathematical models of historical boil-off data provide key insight to the condition of the vessels. Acceptance testing methods for new tanks, before they are filled with cryogenic commodity (and thereby thermally cycled), are needed and we explore how thermography can be used to accomplish this.

Arens, Ellen↗
NASA NTRS2017

Integrated Cryogenic Propulsion Test Article Thermal Vacuum Hotfire Testing

In support of a facility characterization test, the Integrated Cryogenic Propulsion Test Article (ICPTA) was hotfire tested at a variety of simulated altitude and thermal conditions in the NASA Glenn Research Center Plum Brook Station In-Space Propulsion Thermal Vacuum Chamber (formerly B2). The ICPTA utilizes liquid oxygen and liquid methane propellants for its main engine and four reaction control engines, and uses a cold helium system for tank pressurization. The hotfire test series included high altitude, high vacuum, ambient temperature, and deep cryogenic environments, and several hundred sensors on the vehicle collected a range of system level data useful to characterize the operation of an integrated LOX/Methane spacecraft in the space environment - a unique data set for this propellant combination.

Morehead, Robert L.↗
NASA NTRS1995

The subscale orbital fluid transfer experiment

The work during the present year consisted of examining concepts for visual observation of the fluid transfer process, examination of methods for accurately metering the amount of liquid transferred between the two tanks, examination of possible test fluids, and consideration of the materials to use for the elastomeric diaphragm. The objective of the visual observation is to locate the fluid-vapor interfaces and, if possible, quantify the amount of vapor and the area of the interface. It is proposed to use video cameras to view the overall process in each tank and to place borescopes or other devices through the tank walls to obtain detailed, undistorted views inside the tanks of critical portions of the transfer process. Further work will continue to find an economical means for providing this detailed view, which clearly would increase the data obtained from the experiment.

Meserole, J. S.↗
NASA NTRS1994

Temperature-Control Apparatus For Hydrogen Maser

Thermal-control apparatus maintains hydrogen maser at nearly constant temperature during long-term operational test. Designed to maintain, in small cylindrical vacuum tank containing maser, nearly isothermal condition when test conducted in air. Provides approximation of more nearly isothermal condition expected to be maintained in intended application, in which maser operated in vacuum environment and losses of heat reduced further by multilayer reflective insulation.

Vessot, R. F. C.↗
NASA NTRS1998

Orbital Debris Impact Damage to Reusable Launch Vehicles

In an effort by the National Aeronautics and Space Administration (NASA), hypervelocity impact tests were performed on thermal protection systems (TPS) applied on the external surfaces of reusable launch vehicles (RLV) to determine the potential damage from orbital debris impacts. Three TPS types were tested, bonded to composite structures representing RLV fuel tank walls. The three heat shield materials tested were Alumina-Enhanced Thermal Barrier-12 (AETB-12), Flexible Reusable Surface Insulation (FRSI), and Advanced Flexible Reusable Surface Insulation (AFRSI). Using this test data, predictor equations were developed for the entry hole diameters in the three TPS materials, with correlation coefficients ranging from 0.69 to 0.86. Possible methods are proposed for approximating damage occurring at expected orbital impact velocities higher than tested, with references to other published work.

Robinson, Jennifer H.↗