Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Propellant Tank”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 829 records · Page 46

Spacecraft dynamical distribution of fluid stresses activated by gravity-jitter-induced slosh waves

The dynamical behavior of fluids, in particular the effect of surface tension on partially filled rotating fluids (cryogenic liquid helium and helium vapor) in a full-scale Gravity Probe-B Spacecraft propellant Dewar tank imposed by various frequencies of gravity jitters, has been investigated. Fluid stress distribution, caused by the excitation of slosh waves and their associated large-amplitude disturbances on the liquid-vapor interface, exerted on the outer and inner walls of a rotating Dewar container also has been investigated. Results show that fluid stress distributions near the outer and inner walls of the rotating Dewar are closely related to the characteristics of slosh waves excited on the liquid-vapor interface in the rotating Dewar tank. This can provide a useful tool for managing spacecraft dynamic control leading toward the control of spacecraft imbalance caused by the uneven fluid stress distribution due to slosh wave excitations at the interface between liquid and vapor propellants.

Hung, R. J.↗

Orbital Aggregation and Space Infrastructure Systems (OASIS)

This paper summarizes the results of a NASA lead study performed to identify synergistic opportunities and concepts between human exploration initiatives and commercialization of space. The goal of this initiative, called Orbital Aggregation & Space Infrastructure Systems (OASIS), is to develop an in-space architecture and associated concepts that provide common infrastructure for enabling a large class of space missions. The concepts include communications, navigation and power systems, propellant modules, tank farms, habitats, and in-space transportation systems using several propulsion technologies. OASIS features in-space aggregation of systems and resources in support of mission objectives. The concepts feature a high level of reusability and are supported by inexpensive launch of propellant and logistics payloads from the Earth/moon system. Industry, NASA and other users could share infrastructure costs. The anticipated benefits of synergistic utilization of space infrastructure are reduced mission costs and increased mission flexibility for future space exploration and commercialization initiatives.

Troutman, Patrick A.↗

Review of Orbital Propellant Transfer Techniques and the Feasibility of a Thermal Bootstrap Propellant Transfer Concepts

This study was performed in support of the NASA Task B-2 Study Plan for Space Basing. The nature of space-based operations implies that orbital transfer of propellant is a prime consideration. The intent of this report is (1) to report on the findings and recommendations of existing literature on space-based propellant transfer techniques, and (2) to determine possible alternatives to the recommended methods. The reviewed literature recommends, in general, the use of conventional liquid transfer techniques (i.e., pumping) in conjunction with an artificially induced gravitational field. An alternate concept that was studied, the Thermal Bootstrap Transfer Process, is based on the compression of a two-phase fluid with subsequent condensation to a liquid (vapor compression/condensation). This concept utilizes the intrinsic energy capacities of the tanks and propellant by exploiting temperature differentials and available energy differences. The results indicate the thermodynamic feasibility of the Thermal Bootstrap Transfer Process for a specific range of tank sizes, temperatures, fill-factors and receiver tank heat transfer coefficients.

Yoshikawa, H. H.↗

Fuel Distribution Estimate via Spin Period to Precession Period Ratio for the Advanced Composition Explorer

The spin period to precession period ratio of a non-axisymmetric spin-stabilized spacecraft, the Advanced Composition Explorer (ACE), was used to estimate the remaining mass and distribution of fuel within its propulsion system. This analysis was undertaken once telemetry suggested that two of the four fuel tanks had no propellant remaining, contrary to pre-launch expectations of the propulsion system performance. Numerical integration of possible fuel distributions was used to calculate moments of inertia for the spinning spacecraft. A Fast Fourier Transform (FFT) of output from a dynamics simulation was employed to relate calculated moments of inertia to spin and precession periods. The resulting modeled ratios were compared to the actual spin period to precession period ratio derived from the effect of post-maneuver nutation angle on sun sensor measurements. A Monte Carlo search was performed to tune free parameters using the observed spin period to precession period ratio over the life of the mission. This novel analysis of spin and precession periods indicates that at the time of launch, propellant was distributed unevenly between the two pairs of fuel tanks, with one pair having approximately 20% more propellant than the other pair. Furthermore, it indicates the pair of the tanks with less fuel expelled all of its propellant by 2014 and that approximately 46 kg of propellant remains in the other two tanks, an amount that closely matches the operational fuel accounting estimate. Keywords: Fuel Distribution, Moments of Inertia, Precession, Spin, Nutation

Moment of Inertia↗

Ultralight linerless composite tanks for the In-Space applications

A program has been proposed to NASA to develop a technology that will provide helium containment a the high strain levels required to create low mass tanks for in-space propulsion applications. The specific goal of the program is to develop linerless composite tanks that will successfully contain small molecule gases, such as, He, at 10,000 psia for a target mission life or 15 years.

lightweight propellant tanks↗

Sinda/Fluint Stratfied Tank Modeling

A general purpose SINDA/FLUINT (S/F) stratified tank model was created and used to simulate the Ksite1 LH2 liquid self-pressurization tests as well as axial jet mixing within the liquid region of the tank. The S/F model employed the use of stratified layers, i.e. S/F lumps, in the vapor ullage as well as in the liquid region. The model was constructed to analyze a general purpose stratified tank that could incorporate the following features: Multiple or singular lumps in the liquid and vapor regions of the tank, Real gases (also mixtures) and compressible liquids, Venting, pressurizing, and draining, Condensation and evaporation/boiling, Wall heat transfer, Elliptical, cylindrical, and spherical tank geometries. Extensive user logic was used to allow for tailoring of the above features to specific cases. Most of the code input for a specific case could be done through the Registers Data Block.

Sinda/Fluint↗

Opportunities and Strategies for Testing and Infusion of ISRU in the Evolvable Mars Campaign

HE Evolvable Mars Campaign (EMC) is developing the plans and systems needed for a robust, evolutionary strategy to explore cis-lunar space, the Mars sphere of influence (including the moons of Mars), and the surface of Mars. Recently, the emphasis of NASA's plans has changed to focus on the prolonged pioneering of space, rather than focusing on a single crewed mission as the ultimate goal. A sustainable, pioneering vision of space would include in-situ resource utilization (ISRU) in multiple forms and at multiple destinations: atmospheric capture of Mars CO2 and/or volatiles for consumables and propellants, regolith for bulk and refined materials, and in-situ manufacturing at the Moon, Mars, and other bodies. These resources would enable a reduction in the logistical needs from Earth for future missions, thus preparing the way for a sustained presence on Mars. Although the EMC initially relies only on propellant production for the Mars ascent vehicle via ISRU, one of its primary objectives is to prospect at every EMC destination to understand the potential for ISRU; this will permit true pioneering to be enabled after the first crew arrives at Mars. Recent and ongoing analysis has considered the possible prospecting measurements that can be performed at the asteroid returned to cis-lunar space by the Asteroid Robotic Redirect Mission (ARRM), at the lunar surface, at Phobos and Deimos, and on the surface of Mars to identify available resources for future use. These opportunities will be available on missions currently in the Evolvable Mars Campaign construct, and will also facilitate the testing and demonstration of resource acquisition, processing, storage, and useage technologies that can play a role in later missions. This analysis has also led to the identification of several objectives that should be targeted during the missions building up to and including the initial crewed missions. These objectives are mapped to strategies for incorporating ISRU to support resource cycle closure and reduce mass requirements from Earth. This analysis has yielded engineering constraints, based on ISRU, that impact the evaluation of landing sites for missions to the surface of Mars. The terrain of a particular site must be sufficiently flat to permit ISRU systems, as well as ancillary systems such as power and propellant storage tanks, to be landed, moved into position, set up, and operated. Water must be accessible in a form that can be acquired via ISRU, in quantities that align with demands. The chosen method of acquiring and processing water should align with the available resources at a particular site, and that site must have sufficient quantities to meet the requirements (based on crew consumables and propellant demands). Lower altitude landing sites are preferred, as the increase in density can facilitate carbon dioxide acquisition from the atmosphere. Another preference is for sites with a greater ability to move regolith for civil engineering purposes; for example, this would be conducive to both bulk regolith uses (such as the manufacture of berms), and processed regolith uses (such as microwave sintering).

Evolvable Mars Campaign↗

Analysis of Launch Vehicle Liftoff Debris: Historical Perspective from Space Shuttle and Application to Artemis I

Human exploration-class launch vehicles are inherently prone to debris due to the extreme environments generated during pre-launch operations, liftoff, and flight. The use of cryogenic propellants often requires thermal protection system (TPS) coatings, typically foam, to maintain the propellant conditions in the tank and prevent an accumulation ice on the external surface of the vehicle. Some ice growth is to be expected at umbilical interfaces, vents, flanges, or brackets where it is difficult to apply TPS. This ice may come loose at any time due to wind on the launch pad, structural vibration and acoustics after rocket ignition, or aerodynamic forces during flight. This phenomena is especially apparent on vehicles with no TPS, such as the Saturn V rockets used in the Apollo Program, see Figure 1. During propellant tanking, the thermal contraction of the underlying substrate may generate cracks in the TPS (Figure 1). Chunks of TPS can release due to the expansion of ingested gas from cryopumping or from aerodynamic forces if the crack creates an offset surface. Most foams will also have a certain amount of “popcorning” where small pieces of foam will pop off during flight because of the differential between the static surface pressure and the pressure of the gas trapped in the foam cell structure. There are a number of other coating or closeout materials that may be shed from the vehicle and become debris. During pre-launch operations and liftoff, the vehicle may also be exposed to debris originating from the launch pad or ground support equipment. This debris is separate from foreign object debris, or FOD, which is not intended to be present and is strictly controlled through operations and maintenance procedures. In this case, debris is generated from hardware and materials that are necessary for launch and are subject to the intense vibration, acoustics, and direct plume impingement of the launch environment. Examples include ice from umbilicals, tape and tie wraps that protect cables, and rust or corrosion from the launch platform. While NASA has historically been aware of debris as a potential issue that could cause a failure resulting in loss of mission, loss of vehicle, or loss of crew, the likelihood and severity of that risk was not always well understood or given sufficient weight in program and flight decisions. After the Space Shuttle Columbia accident (STS-107), the investigation found that foam TPS debris shed from the external tank was the proximate cause of the damage to the orbiter wing. Six previous observations of debris released from the foam ramp that covered the bipod connecting the forward end of the orbiter to the external tank resulted in minor changes or were determined to be accepted flight risks. Two occurrences of bipod ramp foam loss were not identified until the STS-107 investigation. Despite the damage inflicted by these debris strikes, the Shuttle Program Requirements Control Board deemed the vehicle safe to fly. During the Return to Flight effort following the Columbia disaster, NASA Engineering developed a process for the assessment of debris transport, impact, and damage tolerance to support independent assessments of risk by NASA Safety and Mission Assurance (S&MA). Under this system, each element (vehicle or ground system) defines a catalog of all expected debris based on launch history, component testing, or analysis. Debris transport analysis (DTA) is conducted using the debris catalog characteristics and potential flow transport mechanisms (e.g., vehicle aerodynamics, gravity, wind, plume-driven). The predicted debris impact locations and velocities are provided to the hardware owners, who use available test data and analysis to determine whether each component can withstand the impacts. In cases where the element hardware may be severely damaged or fail, the options are to mitigate the debris source through some change in design or operation, or to work with S&MA to try to characterize the probability of the impact and damage for program risk acceptance. Because of the differences in debris characteristics and transport, the DTA has been divided between the Liftoff and Ascent regimes. The development and application of Liftoff DTA methodology from the Shuttle Program to the current Artemis Program is the subject of this paper. Liftoff DTA covers the time from the start of pre-launch operations at the launch pad, up until the vehicle clears the launch tower and there is no longer any interaction with ground systems. Debris transport during this period is broadly classified as either gravity, wind, and plume-entrained (GWPE) or plume driven (PD). GWPE debris is generally lower speed, travelling in a forward-to-aft direction. PD transport includes flow features from the rocket ignition transient, as well as plume impingement and recirculation that occur as the vehicle lifts off the launch platform. In these cases, the debris typically moves in an aft-to-forward direction at higher speeds. The applicable transport mechanisms must be considered for each piece of debris depending on the material, and release location and time. For example, rust or metallic debris from the tower could fall (GWPE) and impact the vehicle before landing on the launch platform deck where it could be also be transported by plume impingement (PD). However, falling ice (GWPE) from an umbilical is unlikely to survive impact with the vehicle or launch platform and be available for PD transport. Modeling of debris transport is accomplished using a set of DTA tools which simulate debris trajectories subject to a reference frame acceleration (i.e., gravity) and aerodynamic drag. Where the trajectory encounters a solid surface, the debris is allowed to rebound with a specified coefficient of restitution. The drag is calculated by interpolating the fluid state at each point in the debris trajectory from high-fidelity computational fluid dynamics (CFD) simulations of the launch vehicle and pad. The CFD data may either be static (steady state or time averaged), typically for GWPE transport, or dynamic (time-accurate) for PD flow features like the ignition transient. Examples of the CFD flow field solutions for the Space Launch System (SLS) rocket and launch pad are shown in Figure 2. Typical SLS debris trajectory predictions from DTA are illustrated in Figure 3. The final version of this paper will include a more detailed examination of the Liftoff DTA process developed during the Shuttle Program, and how it has been augmented and applied to the SLS rocket under the Artemis Program. Comparisons with debris observations from the Artemis I launch will demonstrate validation of the tools and methodology.

Debris↗

Nodal Modeling of Tank Pressurization and Draining using a Multi-Node-Ullage Approach

Pressurized expulsion tests of liquid methane were modeled by a nodal code using a multinode ullage approach. Generalized Fluid System Simulation Program (GFSSP), a finite volume based nodal code was used to model the expulsion of liquid methane from a 1.52-meter (5 ft) diameter spherical tank by pressurizing with helium and gaseous methane. The purpose of the model was to estimate the amount of pressurant required and amount of condensation and evaporation of methane during the operation. The ullage was discretized into multiple nodes and each fluid node was connected to solid nodes. Both the fluid and solid nodes grow as the tank drains. The heat and mass transfer between fluid and solid node in the tank ullage was computed. The heat and mass transfer between the bottom ullage node and the liquid methane was also computed. The model predictions were compared with data from twelve test cases. The predicted pressurant consumption for helium pressurization compares with test data with a Mean Absolute Percent Error (MAPE) of 3 %. For autogenous pressurization, where gaseous methane was used to pressurize liquid methane, the predicted pressurant consumption compares with a MAPE of 6%.

Cryogenic Propellant↗

Zero-Boiloff Cryogenic Storage Cryocooler Integration Test

Developments in NASA Glenn Research Center's Centaur work have led to an exciting new cryogenic storage concept being considered for future NASA space missions. With long-duration cryogenic storage, propellants will boil off because of the environmental heating of the tank. To accommodate these losses, extra propellant is required along with larger propellant tanks. Analyses of space transportation concepts show that spacetransfer cryogenic stages with the zero boiloff (ZBO) cryogenic storage concept reduce the stage mass for missions longer than approximately 45 days in low Earth orbit. The ZBO system consists of an active cryocooling system using a cryocooler in addition to traditional passive thermal insulation. Engineers at Glenn analyzed, designed, built, and bench tested a heat exchanger and integration hardware for a large-scale ZBO demonstration for the NASA Marshall Space Flight Center. The heat exchanger, which transfers the heat that enters the tank from the fluid to the cryocooler, must limit the temperature difference across it to limit the cryocooler size and power requirements. With a low temperature difference, the system efficiency is improved. For that temperature difference to be reduced, the thermal conductivity must be as high as possible at liquid hydrogen temperatures, around 25 K (-248 C). In addition, it is important for the heat exchanger to be welded to a stainless steel flange and have enough strength to accommodate piping stress. High-conductivity copper was selected and fabricated, then integrated with the stainless steel piping tee as shown in the cutaway representation. Literature showed that this conductivity might range from 2 to 100 W/cm/K but that is was likely to be around 13 W/cm/K. Unexpectedly, this conductivity was measured to be 23 W/cm/K, which limited the temperature increase along the heat exchanger to just 2 K. This limited temperature increase, compared with the predicted difference of 3.5 K, improves the overall system efficiency by 7.4 percent and limits the expected integration losses to a projected 4 percent with a flight design for liquid hydrogen storage. These results improve the cryocooler integration concept by allowing the cryocooler to operate at a lower input power, or by potentially permitting a smaller cryocooler to be selected.

Plachta, David W.↗

Investigating Dual Electrospinning as a Means of Enhancing Passive Thermal Control Coatings for Cryogenic Propellant Storage in Extraterrestrial Environments

Passive thermal control is necessary as space exploration becomes increasingly widespread. Materials with superior optical properties (high solar reflectance and infrared emittance) are critical for passive thermal control because they can reject most of the incident solar radiation and promote thermal emission from cryogenic propellant storage tanks, enabling the extraterrestrial storage of cryogens. We have demonstrated in previous studies that electrospun nanofibers exhibit exceptional optical properties, offering significant benefits for passive radiative cooling in space. Particularly, electrospun polyvinylidene fluoride-co-hexafluoropropylene PVDF-HFP nanofibers demonstrate exceptionally high solar reflectance (>99%) and strong thermal emittance (measured at ~300 K). However, they exhibit nanostructural changes in the presence of atomic oxygen, which is prevalent in Low Earth Orbit. This study focuses on creating a unique blend of polymeric (PVDF-HFP) and ceramic-based (silica) nanofibers by leveraging the chemical stability and atomic oxygen resistance of silica, using the dual electrospinning manufacturing method. This approach aims to preserve the structural properties of the polymeric counterpart without compromising its optical performance, thereby providing an innovative method for manufacturing environmentally resilient passive thermal control nanofibers with desirable optical and thermal control functionalities for extraterrestrial storage of cryogenic propellants.

Chieloka Ibekwe↗

Ultralight Linerless Composite Tanks for In-Space Applications

NASA missions are becoming increasingly more demanding of propulsion capability, driving the mass of propulsion systems higher, even as the science mass of electronics is reduced. Typically, the propulsion tank is the single largest highest dry mass item of an in-space propulsion system. Ultralight linerless composite tanks (ULLCTs) promise to achieve the efficiencies that will make future propulsion systems viable and minimize propulsion system mass growth. ULLCTS may offer up to a 25 percent weight reduction compared to conventional metal lined composite overwrapped tanks, allowing increased reactant storage and/or reduced launch mass. For successful design of such a tank, the composite shell itself is required to provide an integral impermeable barrier, in addition to carrying the pressure and environmental loads for in-space propulsion. Significant materials technologies are required to achieve the microcrack resistance of the composites in order to contain small molecule gases such as helium (He). The goal is to develop a material that can limit the leakage rate of gaseous He to 10(exp -4) scc/sec at 1% biaxial strain level. The current paper details an integrated systematic approach to developing novel composite materials that can meet such performance requirements. It also explains how micromechanical models and material testing can be combined to define material performance indicators critical for designing an ULLCT, such as the material's resistance to microcracking and permeability.

lightweight propellant tanks↗

Validation of Universal Cryogenic Flow Boiling Correlations in Thermal Desktop for Liquid Hydrogen

Developing accurate models of two-phase cryogenic flow will reduce risk and reduce margins for future NASA vehicles such as the Nuclear Thermal Propulsion (NTP) system. Currently there is a need for more accurate, direct cryogenic data-anchored models for various boiling and two-phase phenomena. The focus of the current work is on modeling steady state cryogenic flow boiling in the transfer line that connects a propellant storage tank to an engine or customer receiver tank. This paper presents Thermal Desktop model validation results against several historical liquid hydrogen (LH2) heated tube experiments that cover a wide range of inlet conditions, mass flux, and heat flux. New universal cryogenic flow boiling correlations were recently developed and anchored to the largest cryogenic flow boiling database assembled in the world to-date. The new universal correlations are patched together and implemented into Thermal Desktop to compare model performance against the built-in flow boiling correlations. Axial wall temperature predictions as a function of preponderant parameters like heat flux, mass flux, inlet pressure, inlet quality, tube diameter, etc. using the two sets of flow boiling correlations are compared against the experimental data. Overall, the Thermal Desktop model with the new universal cryogenic flow boiling correlations demonstrates an improvement in predictive performance over the Thermal Desktop model using built-in correlations for both wall temperature and location of critical heat flux compared to the data for LH2 flow boiling in heated tubes.

Cryogenic Propellant Transfer↗

Validation of Universal Cryogenic Flow Boiling Correlations in Thermal Desktop for Liquid Hydrogen

Developing accurate models of two-phase cryogenic flow will reduce risk and reduce margins for future NASA vehicles such as the Nuclear Thermal Propulsion (NTP) system. Currently there is a need for more accurate, direct cryogenic data-anchored models for various boiling and two-phase phenomena. The focus of the current work is on modeling steady state cryogenic flow boiling in the transfer line that connects a propellant storage tank to an engine or customer receiver tank. This paper presents Thermal Desktop model validation results against several historical liquid hydrogen (LH2) heated tube experiments that cover a wide range of inlet conditions, mass flux, and heat flux. New universal cryogenic flow boiling correlations were recently developed and anchored to the largest cryogenic flow boiling database assembled in the world to-date. The new universal correlations are patched together and implemented into Thermal Desktop to compare model performance against the built-in flow boiling correlations. Axial wall temperature predictions as a function of preponderant parameters like heat flux, mass flux, inlet pressure, inlet quality, tube diameter, etc. using the two sets of flow boiling correlations are compared against the experimental data. Overall, the Thermal Desktop model with the new universal cryogenic flow boiling correlations demonstrates an improvement in predictive performance over the Thermal Desktop model using built-in correlations for both wall temperature and location of critical heat flux compared to the data for LH2 flow boiling in heated tubes.

cryogenic propellant transfer↗