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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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At least 829 records · Page 46
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Space Launch System Core Stage Green Run Base Heating: Anomaly, Mitigation and Flight Redesign

The NASA Space Launch System (SLS) vehicle is composed of four RS-25 liquid oxygen and hydrogen rocket engines in the Core Stage (CS). The SLS Core Stage went through Green Run hotfire testing at NASA Stennis Space Center’s B-2 test facility in 2021. The main goal of this testing was to confirm Core Stage tanking, propulsion and thrust vector control systems operations and performance to verify with predicted models. Two hot-fire (HF) test sequences were performed with the first one (HF1) in January for a test duration of 70 seconds and the second (HF2) testing completed in March for a test duration of 500 seconds. This paper focuses on the base heating anomalies observed during HF1 and HF2 where an extensive fire was observed along the Core Stage base heat shield during test operations. This environment was not anticipated and led to extensive unplanned damage to the thermal protection system which was augmented for flight. Green Run observations also led to a reassessment of flight environments for Artemis I. This paper discusses the potential cause of the anomalies, the flow physics, the reconstructed base environments, and mitigation plans for HF2 and flight.

aerothermodynamics↗
NASA NTRS1991

Autogenous pressurization of cryogenic vessels using submerged vapor injection

Experimental results are reported for submerged injection pressurization and expulsion tests of a 4.89 cu m liquid hydrogen tank. The pressurant injector was positioned near the bottom of the test vessel to simulate liquid engulfment of the pressurant gas inlet; a condition that may occur in low-gravity conditions. Results indicate a substantial reduction in pressurization efficiency, with pressurant gas requirements approximately five times greater than ideal amounts. Consequently, submerged vapor injection should be avoided as a low-gravity autogenous pressurization method whenever possible. The work presented herein validates that pressurent requirements are accurately predicted by a homogeneous thermodynamic model when the submerged injection technique is employed.

Stochl, Robert J.↗
NASA NTRS1992

Acoustic and thermal testing of the Titan/Centaur upper stage

A new version of the Centaur high-energy upper stage is being produced by General Dynamics for the USAF/Martin Marietta Titan launch vehicle. The Titan/Centaur upper stage is subject to consecutive acoustic and thermal testing in General Dynamics' Acoustic and Thermal Test Facility (ATTF). All data is acquired and processed digitally using the high-speed data acquisition system located in the ATTF. Processed data from over 250 sensors measuring acceleration, temperature, and sound pressure level is made available to the test team in minutes for use in making real-time test decisions. These tests represent the first consecutive large-scale environmental tests conducted on a complete, pressure stabilized, cryogenically tanked space launch vehicle. Some of the unique challenges involved in testing the Titan/Centaur and how these challenges were met using the ATTF are described.

Gehringer, Mark↗
NASA NTRS1991

Autogenous pressurization of cryogenic vessels using submerged vapor injection

Experimental results are reported for submerged injection pressurization and expulsion tests of a 4.89 cu m liquid hydrogen tank. The pressurant injector was positioned near the bottom of the test vessel to simulate liquid engulfment of the pressurant gas inlet, a condition that may occur in low-gravity conditions. Results indicate a substantial reduction in pressurization efficiency with pressurant gas requirements approximately five times greater than ideal amounts. Consequently, submerged vapor injection should be avoided as a low-gravity autogenous pressurization method whenever possible. The work presented herein validates that pressurant requirements are accurately predicted by a homogeneous thermodynamic model when the submerged injection technique is employed.

Stochl, Robert J.↗
NASA NTRS2007

Simulation of Foam Divot Weight on External Tank Utilizing Least Squares and Neural Network Methods

Simulation of divot weight in the insulating foam, associated with the external tank of the U.S. space shuttle, has been evaluated using least squares and neural network concepts. The simulation required models based on fundamental considerations that can be used to predict under what conditions voids form, the size of the voids, and subsequent divot ejection mechanisms. The quadratic neural networks were found to be satisfactory for the simulation of foam divot weight in various tests associated with the external tank. Both linear least squares method and the nonlinear neural network predicted identical results.

Chamis, Christos C.↗
NASA NTRS1991

Ground testing on the nonvented fill method of orbital propellant transfer: Results of initial test series

The results are presented of a series of no-vent fill experiments conducted on a 175 cu ft flightweight hydrogen tank. The experiments consisted of the nonvented fill of the tankage with liquid hydrogen using two different inlet systems (top spray, and bottom spray) at different tank initial conditions and inflow rates. Nine tests were completed of which six filled in excess of 94 percent. The experiments demonstrated a consistent and repeatable ability to fill the tank in excess of 94 percent using the nonvented fill technique. Ninety-four percent was established as the high level cutoff due to requirements for some tank ullage to prevent rapid tank pressure rise which occurs in a tank filled entirely with liquid. The best fill was terminated at 94 percent full with a tank internal pressure less than 26 psia. Although the baseline initial tank wall temperature criteria was that all portions of the tank wall be less than 40 R, fills were achieved with initial wall temperatures as high as 227 R.

Chato, David J.↗
NASA NTRS1991

Ground testing of the nonvented fill method of orbital propellant transfer - Results of initial test series

The results are presented of a series of no-vent fill experiments conducted on a 175 cu ft flightweight hydrogen tank. The experiments consisted of the nonvented fill of the tankage with liquid hydrogen using two different inlet systems (top spray, and bottom spray) at different tank initial conditions and inflow rates. Nine tests were completed of which six filled in exceess of 94 percent. The experiments demonstrated a consistent and repeatable ability to fill the tank in excess of 94 percent using the nonvented fill technique. Ninety-four percent was established as the high level cutoff due to requirements for some tank ullage to prevent rapid tank pressure rise which occurs in a tank filled entirely with liquid. The best fill was terminated at 94 percent full with a tank internal pressure less than 26 psia. Although the baseline initial tank wall temperature criteria was that all portions of the tank wall be less than 40 R, fills were achieved with initial wall temperatures as high as 227R.

Chato, David J.↗
DOE OSTI2023

Hanford Double Shell Waste Tank Corrosion Studies (Final Report)

For fiscal year (FY) 2022, the Savannah River National Laboratory (SRNL) focused on two experimental tasks related to Hanford Double Shell Tank (DST) chemistry and integrity. The first task focused on understanding risk of corrosion due to formation of either continuous layers or discrete patches of solids on the tanks' inner sidewalls and bottoms. The tank bottom solids contact corrosion testing focused on studying the effects of forming a dry adherent solids layer on a carbon steel substrate. Long-term exposure tests and electrochemical tests were performed to investigate the effect of drying (i.e., removing water) from the solids phase. The second task focused on corrosion of the exterior of the secondary liner. In previous years, vapor corrosion inhibitors (VCIs) were investigated as a means of mitigating corrosion of the exterior of the secondary liner. During FY22 the utilization of nitrogen was explored as a means of corrosion mitigation. The corrosion test results with nitrogen were compared with the corrosion mitigation performance of the VCIs.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Design, dynamic modeling and wave basin verification of a Hybrid Wave–Current Energy Converter

Massive and high-density Marine and Hydrokinetic (MHK) energy is contained in the ocean, including waves, tidal streams, and ocean currents. Traditional MHK energy converters harvest energy from only a single MHK energy source, which does not fully exploit the energy potential that co-exists in multiple forms of MHK energy in the ocean. This paper presents the design and dynamics of a Hybrid Wave–Current Energy Converter (HWCEC) that can simultaneously convert both wave and current energy to electricity with a single Power Take-off (PTO) through the engagement and disengagement of the three one-way clutches. The critical design parameters are analyzed through modeling and simulation, including the transmission ratios, the electrical impedance, and the turbine-heave plate distance. Water basin tests in a wave–current tank were conducted, which shows the prototyped HWCEC can improve the electric power output by 38%–71% for regular waves and 79% for irregular waves, while providing a 70% reduction of the Peak to Average Ratio (PAR) of power compared to the baseline Wave Energy Converter (WEC). Here we further analyze the occurring percentages of the instant power of both WEC and HWCEC in irregular wave tests, shedding new insight on how HWCEC reduces the PAR.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2000

X-33, Stepping Stone ot Low Cost Access to Space

In response to the Access to Space Study, which was conducted in 1993 through the Office of Space Systems Development, an advanced technology Reusable Launch Vehicle (RLV) was selected for demonstration. The X-33 was advanced as an demonstration project, to build and test a 53-percent scale prototype of an operational RLV, it would also demonstrate new technologies which would be required to assure the operation of the new RLV. This presentation reviews the progress of the X-33 development and supporting sites. The X-33 design has been completed and fabrication and assembly is progressing well. The X-33 launch site has been completed. The first LH2 tank and engine is in testing. This will lead to the full scale development of VentureStar(tm).

Naftel, J. Chris↗
NASA NTRS1999

Propellant Densification for Launch Vehicles: Simulation and Testing 1999

One of the many key technologies required to make single-stage to orbit an actuality, the technology of sub-cooling cryogenic propellants below their normal saturation temperatures and thereby making them more dense, is unquestionably on its way towards full and practical realization. The technology of Propellant Densification has been the subject of an extensive research and development program overseen by Lockheed Martin Michoud Space Systems and NASA Glenn Research Center over the past several years. This paper presents a status report of this research and development. Specifically examined within this paper is the status of the current and continuing efforts on the mathematical simulation of the in-tank propellant densification process currently baselined for the Lockheed Martin VentureStar Reusable Launch Vehicle (RLV). Keys to this modeling effort are an understanding and quantification of the effects of thermal stratification and the ability to capture the complex and unique multiple section tank geometries being proposed for future launch vehicles. A simulation that properly captures these phenomena has been developed by Lockheed Martin. Also discussed is the significant test program that has been undertaken in coordination with NASA Glenn Research Center. In this testing, the liquid hydrogen recirculation and densification process was simulated and the thermal stratification of the densified propellant was recorded throughout the tank. This testing marks the first time that such a process has been carried out within a multiple-lobe, flight-similar tank. The results from this testing have gone a long way towards grounding the mathematical models and towards demonstrating the readiness of the technology for near-term use. A further and even more ambitious test program examining the production and utilization of densified propellants is being planned for late-autumn 1999. An overview of these plans is presented.

Knowles, Timothy E.↗
NASA NTRS1974

Design manual: Oxygen Thermal Test Article (OTTA)

The characteristics of a cryogenic tank for storing liquid hydrogen, nitrogen, oxygen, methane, or helium for an extended period of time with minimum losses are discussed. A description of the tank and control module, assembly drawings and details of major subassemblies, specific requirements controlling development of the system, thermal concept considerations, thermal analysis methods, and a record of test results are provided. The oxygen thermal test article thermal protection system has proven that the insulation system for cryogenic vessels is effective.

Chronic, W. L.↗
NASA NTRS2009

Synergistic Development, Test, and Qualification Approaches for the Ares I and V Launch Vehicles

The U.S. National Aeronautics and Space Administration is designing and developing the Ares I and Ares V launch vehicles for access to the International Space Station (ISS) and human exploration of the Moon. The Ares I consists of a first stage reusable five-segment solid rocket booster, a upper stage using a J-2X engine derived from heritage experience (Saturn and Space Shuttle External Tank programs), and the Orion crew exploration vehicle (CEV). The Ares V is designed to minimize the development and overall life-cycle costs by leveraging off of the Ares I design. The Ares V consists of two boosters, a core stage, an earth departure stage (EDS), and a shroud. The core stage and EDS use LH2/LO2 propellants, metallic propellant tanks, and composite dry structures. The core stage has six RS-68B upgraded Delta IV engines while the EDS uses a J-2X engine for second stage ascent and trans-lunar injection (TLI) burn. System and propulsion tests and qualification approaches for Ares V elements are being considered as follow-on extensions of the Ares I development program. Following Ares I IOC, testing will be conducted to verify the J-2X engine's orbital restart and TLI burn capability. The Ares I upper stage operation will be demonstrated through integrated stage development and acceptance testing. The EDS will undergo similar development and acceptance testing with additional testing to verify aspects of cryogenic propellant management, operation of sub-systems in a space simulation environment, and orbital re-start of the main propulsion system. RS-68B certification testing will be conducted along with integrated core stage development and acceptance testing. Structural testing of the Ares V EDS and core stage propellant tanks will be conducted similar to the Ares I upper stage. The structural qualification testing may be accomplished with separate propellant tank test articles. Structural development and qualification testing of the dry structure will be pursued as part of the design and development process. Especially critical is the development test program for the composite structures. The Ares V payload shroud will undergo acoustic, vibration, structural qualification, and deployment testing in a space simulation environment. Similar to Ares I, requirements for full-scale structural dynamic testing are being studied. Both Ares I and Ares V include validation flight testing as part of the qualification programs.

Cockrell, Charles E.↗
DOE OSTI2020

Progress on Advancing the Robotic Air-slot Volumetric Inspection System (RAVIS) for Hanford Under-tank Inspection - 20519

The 27 in-service double-shell tank (DST) systems at Hanford provide interim storage for nearly 56 million gallons of nuclear and hazardous chemical legacy waste. The safe and reliable storage of the waste is critical to the site's extended cleanup mission. While in service, the leak integrity of the DSTs must be demonstrated to satisfy the Washington Administrative Code, inform decisions on tank management, and gauge fitness for continued service beyond originally intended design lives. The carbon steel plates and welds that comprise DST primary tank sidewalls and lower knuckles are routinely 'sampled' for volumetric non-destructive testing using ultrasonic inspection technology to determine whether corrosion pitting, cracking, or general corrosion are occurring that could compromise tank leak integrity. However, the carbon steel plates and welds that comprise the bottoms of primary tanks have not been thoroughly inspected since the DSTs were constructed (i.e., since 1968-1986) due to limited physical access to the exterior tank bottoms. The Robotic Air-slot Volumetric Inspection System, or 'RAVIS,' is being engineered to overcome the challenge of tank bottom in-service inspection. The system will be deployed under primary tanks within the small cooling channels/air-slots in the refractory pads upon which the tanks rest and will use ultrasonic guided wave inspection technology to volumetrically inspect physically inaccessible regions that make up ∼90% of a tank bottom, as well as regions that are physically accessible from the air-slots but comprise only ∼10% of a tank bottom. This paper describes the air-slot sensor and robotic deployment system and focuses on the testing approach and methods that are being applied to support (1) design feedback and performance acceptance (requirement verification) and (2) performance repeatability/reliability assessments (qualification) to ensure the RAVIS is prepared for successful inservice inspections of primary tank bottoms. Test progress made against the test plan, the results of 2019 testing, and the future outlook are included. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1981

Systems engineering challenges of the Space Shuttle

Problems encountered during the Space Shuttle's development that were due to the unique configuration of the vehicle are discussed. While conventional rocket space vehicles have been symmetric, greatly simplifying the analysis and integration of constituent elements, the Space Shuttle's combination of a winged orbiter with side-mounted solid rocket boosters and a large propellant tank presented a more complex system for the analysis and testing of ascent flight control, propulsion system, aerothermodynamics and structural dynamics. Attention is given first and second stage flight operations, return-to-launch-site, abort-once-around and abort-to-orbit mission modes, propulsion system and propulsion test development, and the aerothermodynamics of the external propellant tank and Orbiter.

Day, L. E.↗
NASA NTRS2010

Computational Fluid Dynamics (CFD) Simulations of Jet Mixing in Tanks of Different Scales

For long-duration in-space storage of cryogenic propellants, an axial jet mixer is one concept for controlling tank pressure and reducing thermal stratification. Extensive ground-test data from the 1960s to the present exist for tank diameters of 10 ft or less. The design of axial jet mixers for tanks on the order of 30 ft diameter, such as those planned for the Ares V Earth Departure Stage (EDS) LH2 tank, will require scaling of available experimental data from much smaller tanks, as well designing for microgravity effects. This study will assess the ability for Computational Fluid Dynamics (CFD) to handle a change of scale of this magnitude by performing simulations of existing ground-based axial jet mixing experiments at two tank sizes differing by a factor of ten. Simulations of several axial jet configurations for an Ares V scale EDS LH2 tank during low Earth orbit (LEO) coast are evaluated and selected results are also presented. Data from jet mixing experiments performed in the 1960s by General Dynamics with water at two tank sizes (1 and 10 ft diameter) are used to evaluate CFD accuracy. Jet nozzle diameters ranged from 0.032 to 0.25 in. for the 1 ft diameter tank experiments and from 0.625 to 0.875 in. for the 10 ft diameter tank experiments. Thermally stratified layers were created in both tanks prior to turning on the jet mixer. Jet mixer efficiency was determined by monitoring the temperatures on thermocouple rakes in the tanks to time when the stratified layer was mixed out. Dye was frequently injected into the stratified tank and its penetration recorded. There were no velocities or turbulence quantities available in the experimental data. A commercially available, time accurate, multi-dimensional CFD code with free surface tracking (FLOW-3D from Flow Science, Inc.) is used for the simulations presented. Comparisons are made between computed temperatures at various axial locations in the tank at different times and those observed experimentally. The affect of various modeling parameters on the agreement obtained are assessed.

Breisacher, Kevin↗
NASA NTRS2010

Glass Bubbles Insulation for Liquid Hydrogen Storage Tanks

A full-scale field application of glass bubbles insulation has been demonstrated in a 218,000 L liquid hydrogen storage tank. This work is the evolution of extensive materials testing, laboratory scale testing, and system studies leading to the use of glass bubbles insulation as a cost efficient and high performance alternative in cryogenic storage tanks of any size. The tank utilized is part of a rocket propulsion test complex at the NASA Stennis Space Center and is a 1960's vintage spherical double wall tank with an evacuated annulus. The original perlite that was removed from the annulus was in pristine condition and showed no signs of deterioration or compaction. Test results show a significant reduction in liquid hydrogen boiloff when compared to recent baseline data prior to removal of the perlite insulation. The data also validates the previous laboratory scale testing (1000 L) and full-scale numerical modeling (3,200,000 L) of boiloff in spherical cryogenic storage tanks. The performance of the tank will continue to be monitored during operation of the tank over the coming years.

Glass bubble↗