Results for “Cavitation” — Page 39

NASA NTRS2014

The ISS 2B PVTCS Ammonia Leak: An Operational History

In 2006, the Photovoltaic Thermal Control System (PVTCS) for the International Space Station's 2B power channel began leaking ammonia at a rate of approximately 1.5lbm/year (out of a starting approximately 53lbm system ammonia mass). Initially, the operations strategy was "feed the leak," a strategy successfully put into action via Extra Vehicular Activity during the STS‐134 mission. During this mission the system was topped off with ammonia piped over from a separate thermal control system. This recharge was to have allowed for continued power channel operation into 2014 or 2015, at which point another EVA would have been required. Without these periodic EVAs to refill the 2B coolant system, the channel would eventually leak enough fluid as to risk pump cavitation and system failure, resulting in the loss of the 2B power channel - the most critical of the Space Station's 8 power channels. In mid‐2012, the leak rate increased to approximately 5lbm/year. Once discovered, an EVA was planned and executed within a 5 week timeframe to drastically alter the architecture of the PVTCS via connection to a dormant thermal control system not intended to be utilized as anything other than spare components. The purpose of this rerouting of the TCS was to increase system volume and to isolate the photovoltaic radiator, thought to be the likely leak source. This EVA was successfully executed on November 1st, 2012 and left the 2B PVTCS in a configuration where the system was now being adequately cooled via a totally different radiator than what the system was designed to utilize. Unfortunately, data monitoring over the next several months showed that the isolated radiator was not leaking, and the system itself continued to leak steadily until May 9th, 2013. It was on this day that the ISS crew noticed the visible presence of ammonia crystals escaping from the 2B channel's truss segment, signifying a rapid acceleration of the leak from 5lbm/year to 5lbm/day. Within 48 hours of the crew noticing the leak, an EVA was in progress to replace the coolant pump - the only other replaceable leak source. This paper will explore the management of the 2B PVTCS leak from the operations perspective. It will discuss the methodology of performing the STS‐134 refill, the considerations and contingency plans which went into the architectural overhaul of the system in 2012, and the unprecedented effort which went into the EVA response to the visible leak of May 2013. In particular the paper will focus on the techniques utilized by flight controllers to monitor the system health and to respond to such instances as the rapid May 2013 leak by putting the electrical system in a safe configuration for loss of cooling, and will use recorded telemetry of these events to describe system response to EVA crew and ground actions. It will discuss the innovative design for redundancy of the integrated truss structure's cooling systems which allowed for this leak to be managed with minimal impact to other ISS operations and electrical services, contrasted against the real unintended operations consequences of utilizing the flexibility of the spacecraft's design in this manner. The paper will discuss how the training of the crew and flight controller personnel has adapted to the changing architecture of the power system and the unpredictable nature of the 2B leak.

Vareha, Anthony↗

NASA NTRS2014

Cleaning Process Development for Metallic Additively Manufactured Parts

Additive Manufacturing of metallic components for aerospace applications offers many advantages over traditional manufacturing techniques. As a new technology, many aspects of its widespread utilization remain open to investigation. Among these are the cleaning processes that can be used for post finishing of parts and measurements to verify effectiveness of the cleaning processes. Many cleaning and drying processes and measurement methods that have been used for parts manufactured using conventional techniques are candidates that may be considered for cleaning and verification of additively manufactured parts. Among these are vapor degreasing, ultrasonic immersion and spray cleaning, followed by hot air drying, vacuum baking and solvent displacement drying. Differences in porosity, density, and surface finish of additively manufactured versus conventionally manufactured parts may introduce new considerations in the selection of cleaning and drying processes or the method used to verify their effectiveness. This presentation will review the relative strengths and weaknesses of different candidate cleaning and drying processes as they may apply to additively manufactured metal parts for aerospace applications. An ultrasonic cleaning technique for exploring the cleanability of parts will be presented along with an example using additively manufactured Inconel 718 test specimens to illustrate its use. The data analysis shows that this ultrasonic cleaning approach results in a well-behaved ultrasonic cleaning/extraction behavior. That is, it does not show signs of accelerated cavitation erosion of the base material, which was later confirmed by neutron imaging. In addition, the analysis indicated that complete cleaning would be achieved by ultrasonic immersion cleaning at approximately 5 minutes, which was verified by subsequent cleaning of additional parts.

Tramel, Terri L.↗

NASA NTRS2014

Surge Pressure Mitigation in the Global Precipitation Measurement Mission Core Propulsion System

The Global Precipitation Measurement (GPM) mission is an international partnership between NASA and JAXA whose Core spacecraft performs cutting-edge measurements of rainfall and snowfall worldwide and unifies data gathered by a network of precipitation measurement satellites. The Core spacecraft's propulsion system is a blowdown monopropellant system with an initial hydrazine load of 545 kg in a single composite overwrapped propellant tank. At launch, the propulsion system contained propellant in the tank and manifold tubes upstream of the latch valves, with low-pressure helium gas in the manifold tubes downstream of the latch valves. The system had a relatively high beginning-of- life pressure and long downstream manifold lines; these factors created conditions that were conducive to high surge pressures. This paper discusses the GPM project's approach to surge mitigation in the propulsion system design. The paper describes the surge testing program and results, with discussions of specific difficulties encountered. Based on the results of surge testing and pressure drop analyses, a unique configuration of cavitating venturis was chosen to mitigate surge while minimizing pressure losses during thruster maneuvers. This paper concludes with a discussion of overall lessons learned with surge pressure testing for NASA Goddard spacecraft programs.

Pressure↗

NASA NTRS2014

In-Service Monitoring of Steam Pipe Systems at High Temperatures

A system and method for monitoring the properties of a fluid, such as water, in a steam pipe without mechanically penetrating the wall of the pipe. The system uses a piezoelectric transducer to launch an ultrasonic probe signal into the pipe. Reflected ultrasonic signals are captured in a transducer, which can be the same transducer that launched the probe signal. The reflected signals are subjected to data processing, which can include filtering, amplification, analog-to-digital conversion and autocorrelation analysis. A result is extracted which is indicative of a property of the fluid, such as a height of the condensed fluid, a cavitation of the condensed fluid, and a surface perturbation of the condensed fluid. The result can be recorded, displayed, and/or transmitted to another location. One embodiment of the system has been constructed and tested based on a general purpose programmable computer using instructions recorded in machine-readable non-volatile memory.

Bar-Cohen, Yoseph↗

NASA NTRS2011

Fluid Line Evacuation and Freezing Experiments for Digital Radiator Concept

The digital radiator technology is one of three variable heat rejection technologies being investigated for future human-rated NASA missions. The digital radiator concept is based on a mechanically pumped fluid loop with parallel tubes carrying coolant to reject heat from the radiator surface. A series of valves actuate to start and stop fluid flow to di erent combinations of tubes, in order to vary the heat rejection capability of the radiator by a factor of 10 or more. When the flow in a particular leg is stopped, the fluid temperature drops and the fluid can freeze, causing damage or preventing flow from restarting. For this reason, the liquid in a stopped leg must be partially or fully evacuated upon shutdown. One of the challenges facing fluid evacuation from closed tubes arises from the vapor generated during pumping to low pressure, which can cause pump cavitation and incomplete evacuation. Here we present a series of laboratory experiments demonstrating fluid evacuation techniques to overcome these challenges by applying heat and pumping to partial vacuum. Also presented are results from qualitative testing of the freezing characteristics of several different candidate fluids, which demonstrate significant di erences in freezing properties, and give insight to the evacuation process.

human space flight↗

NASA NTRS2016

Apparatus for and Method of Monitoring Condensed Water in Steam Pipes at High Temperature

A system and method for monitoring the properties of a fluid, such as water, in a steam pipe without mechanically penetrating the wall of the pipe. The system uses a piezoelectric transducer to launch an ultrasonic probe signal into the pipe. Reflected ultrasonic signals are captured in a transducer, which can be the same transducer that launched the probe signal. The reflected signals are subjected to data processing, which can include filtering, amplification, analog-to-digital conversion and autocorrelation analysis. A result is extracted which is indicative of a property of the fluid, such as a height of the condensed fluid, a cavitation of the condensed fluid, and a surface perturbation of the condensed fluid. The result can be recorded, displayed, and/or transmitted to another location. One embodiment of the system has been constructed and tested based on a general purpose programmable computer using instructions recorded in machine-readable non-volatile memory.

Lih, Shyh-Shiuh↗

NASA NTRS2017

Flow Cage Assemblies

Apparatus, systems and methods for implementing flow cages and flow cage assemblies in association with high pressure fluid flows and fluid valves are provided. Flow cages and flow assemblies are provided to dissipate the energy of a fluid flow, such as by reducing fluid flow pressure and/or fluid flow velocity. In some embodiments the dissipation of the fluid flow energy is adapted to reduce erosion, such as from high-pressure jet flows, to reduce cavitation, such as by controllably increasing the flow area, and/or to reduce valve noise associated with pressure surge.

Sherrit, Stewart↗

NASA NTRS2017

Axial Flow Conditioning Device for Mitigating Instabilities

A flow conditioning device for incrementally stepping down pressure within a piping system is presented. The invention includes an outer annular housing, a center element, and at least one intermediate annular element. The outer annular housing includes an inlet end attachable to an inlet pipe and an outlet end attachable to an outlet pipe. The outer annular housing and the intermediate annular element(s) are concentrically disposed about the center element. The intermediate annular element(s) separates an axial flow within the outer annular housing into at least two axial flow paths. Each axial flow path includes at least two annular extensions that alternately and locally direct the axial flow radially outward and inward or radially inward and outward thereby inducing a pressure loss or a pressure gradient within the axial flow. The pressure within the axial flow paths is lower than the pressure at the inlet end and greater than the vapor pressure for the axial flow. The invention minimizes fluidic instabilities, pressure pulses, vortex formation and shedding, and/or cavitation during pressure step down to yield a stabilized flow within a piping system.

Ahuja, Vineet↗

NASA NTRS2020

PACE Propulsion Subsystem Surge Analysis and Testing

Propulsion subsystem surge analysis and testing was performed at NASA Goddard Space Flight Center (GSFC) in order to analytically and experimentally determine the potential for damaging dynamic pressure events in the Plankton Aerosol Cloud and ocean Ecosystem (PACE) propulsion subsystem. Surge pressures occur when propellant flow is initiated following the actuation of an isolation valve separating an upstream high pressure fluid from a downstream low pressure manifold. By design, the PACE propulsion subsystem mitigates surge pressures using an orifice, or a cavitating venturi, placed upstream of each thruster bank isolation latch valve. Venturi sizing is a balancing act due to the competing performance goals of staying within the margins of an acceptable pressure loss and maintaining surge pressures below the proof pressure rating of the subsystem components. Subsystem pressure loss is dependent upon the venturi throat diameter and is higher for smaller venturi sizes. A venturi with a smaller throat diameter incurs an increased pressure loss through the orifice resulting in a reduced thruster inlet pressure and diminished thruster performance. The PACE propulsion subsystem surge analysis and testing supports system optimization, i.e. pressure drop minimization, while still meeting the surge pressure requirements to maximize overall system performance. In this paper a new approach to surge pressure analytical gauging is discussed, as well as its accuracy when compared to traditional surge testing campaign.

Space↗

NASA NTRSDate not supplied

Uncertainty Quantification of Inducer Natural Frequency using Conditional Assessment of Modeling and Modal Testing of Simpler Systems

The low pressure fuel pump inducer of the new Space Launch System RS25 core stage engine operates in a highly complex environment that substantially affects its modal characteristics. Some of the more important effects are fluid-added mass resulting from operation within a light liquid (Hydrogen), and the magnification of this effect due to tight tip clearance. Since higher order cavitation has been identified as a significant harmonic driver, knowledge of the natural frequency of potentially excitable modes is critical for safe operation, but this frequency cannot be measured during the severe operational environment. A comprehensive testing and analysis program has therefore been performed over the last four years to identify the nominal value and uncertainty of the frequency by modeling and testing four simpler structures which share some of the characteristics of the operational inducer. This testing was used to assess and adjust modeling techniques and excellent correlation was achieved. Identification of the uncertainty in the inducer frequency itself was still problematic, however. This difficulty led to an investigation of Bayesian uncertainty quantification techniques, and to the application of the relatively simple technique of Multi-Variate Normal conditional distributions to calculate the inducer natural frequency uncertainty. Assumptions on prior distributions of uncertainty of the fluid-added mass and tip clearance effect are initially applied to models of each of the simple structures and the inducer itself, and these uncertainties are propagated to generate natural frequencies using design of experiments. Simple response surfaces are then created from this data in order to calculate a Covariance Matrix relating all of these natural frequencies. Finally, the results from modal test of the simple structures are considered to be observations and used to calculate the conditional variance of the desired inducer frequencies. As this method is less rigorous than more complicated Bayesian methods reported in the literature, a conservative factor is applied to the result, but the resulting uncertainty is still significantly less than originally estimated and will greatly assist certification of the inducer for use in the engine.

Uncertainty Quantification↗

NASA NTRSDate not supplied

Uncertainty Quantification of Inducer Eigenvalues using Conditional Assessment of Models and Modal Test of Simpler Systems

The low pressure fuel pump inducer of the new Space Launch System RS25 core stage engine operates in a highly complex environment that substantially affects its modal characteristics. Some of the more important effects are fluid-added mass resulting from operation within a light liquid (Hydrogen), and the magnification of this effect due to tight tip clearance. Since higher order cavitation has been identified as a significant harmonic driver, knowledge of the natural frequency of potentially excitable modes is critical for safe operation, but this frequency cannot be measured during the severe operational environment. A comprehensive testing and analysis program has therefore been performed over the last four years to identify the nominal value and uncertainty of the frequency by modeling and testing four simpler structures which share some of the characteristics of the operational inducer. This testing was used to assess and adjust modeling techniques and excellent correlation was achieved. Identification of the uncertainty in the inducer frequency itself was still problematic, however. This difficulty led to an investigation of Bayesian uncertainty quantification techniques, and to the application of the relatively simple technique of Multi-Variate Normal conditional distributions to calculate the inducer natural frequency uncertainty. Assumptions on prior distributions of uncertainty of the fluid-added mass and tip clearance effect are initially applied to models of each of the simple structures and the inducer itself, and these uncertainties are propagated to generate natural frequencies using design of experiments. Simple response surfaces are then created from this data in order to calculate a Covariance Matrix relating all of these natural frequencies. Finally, the results from modal test of the simple structures are considered to be observations and used to calculate the conditional variance of the desired inducer frequencies. As this method is less rigorous than more complicated Bayesian methods reported in the literature, a conservative factor is applied to the result, but the resulting uncertainty is still significantly less than originally estimated and will greatly assist certification of the inducer for use in the engine.

Uncertainty Quantification↗

NASA NTRS2021

Propellant Delivery via VDC Driven Pump

The SMART (Scalable Mobile Autonomous Rocket engine Test) testbed system initiative at SSC was conceived to attempt to address many of the principal cost drivers in developing and maintaining a rocket engine test facility. The system (optimized to test engines and components generating up to 10K lbf nominal thrust) is serving as a testbed for innovative technologies and processes to provide lower cost test services with a rapid test cadence and expedient turnaround times. The system can also potentially be used as a testbed to test other related technologies relevant to surface situations (e.g., moon, Mars associated with crogenic fluid management, engine/component testing, autonomous operations, etc.). This FY20 CIF project, being conducted as part of the SMART testbed system, is developing and testing a propellant delivery system via electrically driven centrifugal pumps (obviating dependence upon Multi-Layer Pressure Vessels) with configuration and operation by a minimal number of personnel. During FY20 the team identified the requirements and worked with P3 and Masten Space Systems to develop the long lead (9 months after receipt of order) items, the 400 VDC pumps, for delivery in mid FY21. Since control of the 400 VDC pump motor is not well developed the team has established heuristics to control flows in LN2 at off nominal shaft speeds to allow deep throttling of the pump in flow test scenarios. Various test scenarios including nominal i.e. high flow high pressure, high flow low pressure, low flow high pressure, low flow low pressure, minimum throttle step change, and low inlet pressure cavitation testing were developed ahead of the anticipated hardware delivery and test. FY20 COVID Stage 3 conditions restricted access to the center and hindered lab work, so efforts focused on the system design and testing plans along with the project procurement paperwork for the hardware... now with its anticipated delivery in spring FY21. Some limited access to the center is expected by spring/summer FY21 for the continuing second year (FY21) CIF project effort meant to be focused upon system integration and initial testing.

Aaron Head↗

NASA NTRSDate not supplied

Autogenous Pressurization of a Cryogenic Tank Using Computational Fluid Dynamics

Well-validated simulation tools can be used to predict long-term storage and transfer of cryogenic propellants, which are essential to NASA’s mission plan to return to the Moon and continue to Mars. Autogenous pressurization of propellant tanks is used to supply rocket engine turbopumps with pressurized liquid fuel and oxidizer, preventing cavitation. Additionally, autogenous pressurization can be used to pressurize propellant tanks to support on-orbit propellant transfer. In lieu of expensive tests conducted on-orbit, accurate predictive computational models of these processes can be used to reduce system and propellant mass as well as mission risk. Using simulation tools also reduces the cost of analyzing and developing this technology. This study presents a multiphase computational fluid dynamics model capable of simulating autogenous pressurization of a large cryogenic tank using the commercial code STAR-CCM+. Experimental data from a full-scale tank pressurization test under terrestrial gravity is compared to simulation results using transient error metrics. Comparisons show good agreement and give confidence in using these and other validated simulation tools to develop cryogenic pressurization systems.

Cryogenics↗

NASA NTRSDate not supplied

Autogenous Pressurization of a Cryogenic Tank using Computational Fluid Dynamics

Well-validated simulation tools can be used to predict long-term storage and transfer of cryogenic propellants, which are essential to NASA’s mission plan to return to the Moon and continue to Mars. Autogenous pressurization of propellant tanks is used to supply rocket engine turbopumps with pressurized liquid fuel and oxidizer, preventing cavitation. Additionally, autogenous pressurization can be used to pressurize propellant tanks to support on-orbit propellant transfer. In lieu of expensive tests conducted on-orbit, accurate predictive computational models of these processes can be used to reduce system and propellant mass as well as mission risk. Using simulation tools also reduces the cost of analyzing and developing this technology. This study presents a multiphase computational fluid dynamics model capable of simulating autogenous pressurization of a large cryogenic tank using the commercial code STAR-CCM+. Experimental data from a full-scale tank pressurization test under terrestrial gravity is compared to simulation results using transient error metrics. Comparisons show good agreement and give confidence in using these and other validated simulation tools to develop cryogenic pressurization systems. Note: There is no audio file included or available for this presentation.

cryogenics↗

NASA NTRS2022

Snapping Shrimp Have Helmets That Protect Their Brains By Dampening Shock Waves

Shock waves are supersonic high-amplitude pressure waves that cause barotrauma when they transfer kinetic energy to the tissues of animals.1–4 Snapping shrimp (Alpheidae) produce shock waves and are exposed to them frequently, so we asked if these animals have evolved mechanisms of physical protection against them. Snapping shrimp generate shock waves by closing their snapping claws rapidly enough to form cavitation bubbles that release energy as an audible ‘‘snap’’ and a shock wave when they collapse.5–8 We tested if snapping shrimp are protected from shock waves by a helmet-like extension of their exoskeleton termed the orbital hood. Using behavioral trials, we found shock wave exposure slowed shelterseeking and caused a loss of motor control in Alpheus heterochaelis from which we had removed orbital hoods but did not significantly affect behavior in shrimp with unaltered orbital hoods. Shock waves thus have the potential to harm snapping shrimp but may not do so under natural conditions because of protection provided to shrimp by their orbital hoods. Using pressure recordings, we discovered the orbital hoods of A. heterochaelis dampen shock waves. Sealing the anterior openings of orbital hoods diminished how much they altered the magnitudes of shock waves, which suggests these helmet-like structures dampen shock waves by trapping and expelling water so that kinetic energy is redirected and released away from the heads of shrimp. Our results indicate orbital hoods mitigate blast-induced neurotrauma in snapping shrimp by dampening shock waves, making them the first biological armor system known to have such a function.

Alexandra C.N. Kingston↗

NASA NTRSDate not supplied

Optimization Considerations for Annular Linear Electromagnetic Pumps for Space Nuclear Power and Propulsion

The Need for High Performance Liquid Metal Pumps Testing Power and Efficiency Considerations Liquid metal cooled reactors is one option for space nuclear power for settlements and electric propulsion vehicles (Snap 10 A, SP100, Soviet Topaz reactors) • High heat capacity • High boiling point (NaK~1200K) • Simplified heat transfer loop • Good neutronics Liquid metal EM pumps are desired over conventional pumps owing to lack of seals, bearings elimination of cavitation issues, lower mass and eliminates mechanical impeller • Conduction pumps (typically DC-high current, low voltage; ~5% efficiency) • Induction pumps (typically AC, high efficiency ~40%) Annular linear induction pump is an EM pump with no moving parts and of cylindrical/tubular geometry which makes it straightforward to integrate in conventional piping architectures • Higher inherent reliability • Invented by Einstein and Szilard

ALIP↗

NASA NTRSDate not supplied

Numerical analysis of Microgravity Bubble Separation in Open Channels with ISS Bemchmarks

Spacecraft fluid systems often require specific considerations to operate in a manner similar to those on Earth. For instance, an open wedge shaped channel can serve as a pathway for passively separating bubbles from a liquid in a two phase flow, analogous to buoyancy effects on Earth. As the bubbles merge within the channel, they become increasingly confined in the wedge, driving them upwards and outwards toward the free surface due to capillary forces. These same forces ensure coalescence and allow the bubbles to escape through the free surface. However, in low gravity environments, a challenge arises when bubbles are not sufficiently large. Under such conditions, the bubbles tend to follow trajectories near their inscribed elevations, never fully leaving the liquid. Such unseparated bubbles can lead to downstream pump failure, cavitation, flow instabilities, dryout, and other adverse effects aboard spacecraft. Understanding and exploiting the underlying mechanisms behind this behavior is crucial for enhancing the reliability of passive capillary fluids management in space applications, including cryogenic and storable fuels transport, thermal fluids circulation, water recycling for life support, plant watering systems, and more. The joint German Aerospace Center (DLR) and NASA Capillary Channel Flow (CCF) experiment conducted on the International Space Station has provided an extensive publicly available database documenting such phenomena (https://science.nasa.gov/physical sciences informatics psi). Leveraging this resource, we aim to establish benchmarks for our numerical investigation of zero gravity bubbly two phase flow in open wedge channels. Specifically, we seek to quantitatively understand the mechanisms governing ‘inscribed’ bubble motion, considering the apparent interplay of two competing forces: Saffman lift (causing upward/outward motion) and the Magnus effect (causing downward/inward motion). Our cross cutting findings directly inform the development of robust passive phase separation methods within spacecraft plumbing systems.

bubble↗

NASA NTRS2026

Influences of Introduced Yttrium Oxide Particles on Superalloy 718

Additive manufacturing has proven useful for introducing oxide particles into superalloys, to provide oxide dispersion strengthening (ODS) at high temperatures. This study screened how such an approach can influence microstructure and failure modes for superalloy 718. The objective of this study was to compare tensile and creep failure modes for additively manufactured superalloy 718 having introduced oxide particles. Fine yttrium-oxide (yttria) particles were introduced into 718 powder using two different powder mixing methods. Additive manufacturing by laser powder bed fusion was then used to prepare specimen blanks for each case, oriented parallel and transverse to the building direction. These were subsequently given consistent stress relief, hot isostatic pressurization, and final heat treatments, then subjected to tensile and creep tests at varied temperatures. Additively manufactured 718 without ODS (“no-ODS”) had nearly equiaxed grains at 50 μm in width. Roll-mixed ODS material had a bimodal grain size distribution, with fine grains at 9 μm and coarse grains at 66 μm in average width. The fine grains were elongated about 5x in the building direction. Acoustic-mixed ODS materials had grains at 10 μm in width that were elongated about 10x in the build direction. Compared to no-ODS, roll-mixed and acoustic mixed ODS materials did not show improved tensile strengths at room temperature, 760 °C, and 1093 °C. The tensile failure strains parallel to the building direction of roll-mixed ODS material were lowest in these tests. Flattened clumps of yttria had formed transverse to the building direction in roll-mixed material, which were easily cracked. Creep rupture response at 760 °C in the building direction was highest for acoustic-mixed material test. Creep tests at 1093 °C showed varied results, with low rupture lives associated with enhanced cavitation at grain boundaries and surface oxidation. Transverse to the building direction, all three materials had low failure strains in tests at 760 °C. The elongated grain boundaries failed readily in all transverse specimens tested at 760 °C and 1093 °C.

oxide dispersion strengthening↗