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The instruments of the Space Infrared Telescope Facility (SIRTF) are cooled directly by liquid helium, while the optical system is cooled by helium vapor. The greater the power dissipation into the liquid helium, the more vapor is produced, and the colder the telescope. Observations at shorter wavelengths do not require telescope temperatures as low as those required at longer wavelengths. By taking advantage of this, it may be possible to extend the helium and mission lifetime by 10% or even 20%.
The concept of using liquid nitrogen to cool the test gas of a wind tunnel to cryogenic temperatures lead to the achievement of very high Reynolds number flows in relatively small transonic tunnels. The economical operation of liquid nitrogen cooled cryogenic tunnels is critically dependent on fast and accurate control of the tunnel variables. The control problem of a continuous flow fan driven cryogenic tunnel was addressed, first by developing a lumped multivariable mathematical model of a tunnel and validating the model by reconciling the responses of the Langley 0.3 m transonic cryogenic tunnel to the responses of the mathematical model on a simulator. Finally, the development of laws for the closed loop control of the tunnel pressure and temperature and the successful implementation of a control system for the 0.3 m transonic cryogenic tunnel based on these laws are presented.
Experiments with two electrohydrodynamic heat pipes are reported. Both devices employ an electromechanical flow structure for axial liquid flow and a capillary wicking structure for (1) collection of condensed liquid at the cooled end and (2) distribution of this liquid at the heated end. One device has circumferential grooving for the capillary structure and the other has feltmetal wicking. The experiments successfully demonstrate the electrohydrodynamic heat pipe concept. Compatibility of the two circumferential wick structures with an axial electromechanical flow structure is also demonstrated. A significant mismatch of the capillary groove and electrohydrodynamic pumping capabilities results in severe hydrodynamic burn-out limiting in the first heat pipe. Both devices have very poor over-all thermal conductances of the order of 1-2 W/deg C, reflecting the generally poor heat-transfer properties of the dielectric working fluids required in electrohydrodynamic heat pipes.
Rocket engines using high pressure liquid oxygen (LOX) and kerosene (RP-1) as the propellants have been considered for future launch vehicle propulsion. Generally, in regeneratively cooled engines, the fuel is used to cool the combustion chamber. However, hydrocarbons such as RP-1 are limited in their cooling capability at high temperatures and pressures. Therefore, LOX is being considered as an alternative coolant. However, there has been concern as to the effect on the integrity of the chamber liner if oxygen leaks into the combustion zone through fatigue cracks that may develop between the cooling passages and the hot-gas side wall. To address this concern, an investigation was previously conducted with simulated fatigue cracks upstream of the thrust chamber throat. When these chambers were tested, an unexpected melting in the throat region developed which was not in line with the simulated fatigue cracks. The current experimental program was conducted in order to determine the cause for the failure in the earlier thrust chambers and to further investigate the effects of cracks in the thrust chamber liner upstream of the throat. The thrust chambers were tested at oxygen-to-fuel mixture ratios from 1.5 to 2.86 at a nominal chamber pressure of 8.6 MPa. As a result of the test series, the reason for the failure occurring in the earlier work was determined to be injector anomalies. The LOX leaking through the simulated fatigue cracks did not affect the integrity of the chambers.
Rocket engines using high pressure liquid oxygen (LOX) and kerosene (RP-1) as the propellants have been considered for future launch vehicle propulsion. Generaly, in regeneratively cooled engines, thefuel is used to cool the combustion chamber. However, hydrocarbons such as RP-1 are limited in their cooling capability at high temperatures and pressures. Therefore, LOX is being considered as an alternative coolant. However, there has been concern as to the effect on the integrity of the chamber liner if oxygen leaks into the combustion zone through fatigue cracks that may develop between the cooling passages and the hot-gas side wall. To address this concern, an investigation was previously conducted with simulated fatigue cracks upstream of the thrust chamber throat. When these chambers were tested, an unexpected melting in the throat region developed which was not in line with the simulated fatigue cracks. The current experimental program was conducted in order to determine the cause for the failure in the earlier thrust chambers and to further investigate the effects of cracks in the thrust chamber liner upstream of the throat. The thrust chambers were tested at oxygen-to-fuel mixture ratios from 1.5 to 2.86 at a nominal chamber pressure of 8.6 MPa. As a result of the test series, the reason for the failure occurring in the earlier work was determined to be injector anomalies. The LOX leaking through the simulated fatigue cracks did not affect the integrity of the chambers.
Cooling systems for liquid propellant rocket engines operating at high chamber pressures
This technical memorandum describes models and calculational procedures to fully characterize the nuclear island of power sources for nuclear electric propulsion. Two computer codes were written: one for the gas-cooled NERVA derivative reactor and the other for liquid metal-cooled fuel pin reactors. These codes are going to be interfaced by NASA with the balance of plant in order to make scoping calculations for mission analysis.
A previous system study identified significant increases in range and number of urban air mobility (UAM) missions by replacing the all battery power system of a notional UAM vehicle with an advanced diesel hybrid using conventional diesel or liquid natural gas (LNG) fuels (at constant vehicle design gross weight). Some benefits were realized using the LNG's cryogenic properties to reduce some electrical component losses and cooling requirements. Significant questions were raised concerning volume and thermal management considerations for all studied systems. The notional, baseline vehicle was a hybrid helicopter / airplane design capable of vertical take-off and landing (VTOL), balancing high cruise efficiency with reasonable hover capability. A subsequent power system assessment using the same notional vehicle and mission was performed that identified increased volume and power requirements for the active cooling required. The cooling airflow could also generate additional drag on the vehicle during operation. For the notional vehicle studied, the additional volume identified by the subsequent study would not affect vehicle mold line and therefore drag. However, the additional drag from cooling airflow and the power to circulate it as needed would impact power system and vehicle mission performance. Vehicle and mission models were updated and rerun. Updated results still indicated significant benefits in range and number of UAM missions, but reduced the benefit by 12-15%. Hold time for the hybrid systems also generally increased a few minutes because of reduced power available for charging from the power for required cooling flows. Vehicle weights, thermal loads, and cooling airflows from the updated analyses were similar to previous results.
The Long-Baseline Neutrino Facility (LBNF) is providing a helium cryogenic system to support the superconducting solenoid magnet of the System for on-Axis Neutrino Detection (SAND) for the Deep Underground Neutrino Experiment (DUNE) Near Site at Fermilab in Batavia, IL. The design started in 2020 and construction is set to begin in the mid 2020‘s.The helium cryogenic system primarily consists of a helium refrigerator system, distribution valve boxes, vacuum-jacketed helium and nitrogen transfer lines, warm gaseous helium transfer system, instruments and control system, and gaseous helium storage tanks. It is designed to provide supercritical helium at around 3 bara and 5 K with expansion from 3 to 1.2 bara in the SAND cryostat and 70K forced cold gas helium to cool the thermal shields of the SAND cryostat. The SAND superconductive magnet is indirectly cooled through a liquid helium thermosiphon cycle. A pair of 3 kA leads is cooled by the gas helium vaporized from the liquid helium reservoir in the cryostat turret. The helium system will share the liquid nitrogen tank and liquid nitrogen phase separator with the Near Site Liquid Argon system. The helium recycle compressor system, GHe tanks and LN2 tank will be located on the Surface. The cryogenic facilities including refrigerator cold box, valve boxes and LN2 phase separator will be located on the shaft cryo-mezzanine in the underground cavern. The shaft connecting surface and cavern is more than 60 meter deep. The helium vacuum-jacketed transfer line between the cold box and the SAND magnet is more than 50 meter long. This paper presents the preliminary design of the helium cryogenic system including the design scheme, process flow diagram, heat load estimates, layout plan and so on.
Unsteady wake effect, with and without trailing edge ejection, on detailed heat transfer coefficient and film cooling effectiveness distributions is presented for a downstream film-cooled gas turbine blade. Tests were performed on a five-blade linear cascade at an exit Reynolds number of 5.3 x 10(exp 5). Upstream unsteady wakes were simulated using a spoke-wheel type wake generator. Coolant blowing ratio was varied from 0.4 to 1.2; air and CO2 were used as coolants to simulate different density ratios. Surface heat transfer and film effectiveness distributions were obtained using a transient liquid crystal technique; coolant temperature profiles were determined with a cold wire technique. Results show that Nusselt numbers for a film cooled blade are much higher compared to a blade without film injection. Unsteady wake slightly enhances Nusselt numbers but significantly reduces film effectiveness versus no wake cases. Nusselt numbers increase only slic,htly but film cooling, effectiveness increases significantly with increasing, blowing ratio. Higher density coolant (CO2) provides higher effectiveness at higher blowing ratios (M = 1.2) whereas lower density coolant (Air) provides higher 0 effectiveness at lower blowing ratios (M = 0.8). Trailing edge ejection generally has more effect on film effectiveness than on the heat transfer, typically reducing film effectiveness and enhancing heat transfer. Similar data is also presented for a film cooled cylindrical leading edge model.
In the 1970s, the U.S. Nuclear Regulatory Commission (NRC) issued Regulatory Guide (RG) 1.87 (Rev 1, June 1975) to provide interim licensing guidelines to aid applicants in implementing the 10 CFR Part 50 requirements with respect to American Society of Mechanical Engineers (ASME) Boiler Pressure and Vessel Code (BPVC) Class 1 components operating at elevated temperatures for high-temperature gas-cooled reactors, liquid-metal fast-breeder reactors, and gas-cooled fast-breeder reactors. RG 1.87 referenced ASME Code Case 1592 for materials and design and Code Cases 1593, 1594, 1595, and 1596 for fabrication and installation, examination, testing, and overpressure protection, respectively.
Jet impingement cooling of a hypersonic airfoil leading edge is experimentally investigated using thermochromic liquid crystals (TLCS) to measure surface temperature. The experiment uses computer data acquisition with digital imaging of the TLCs to determine heat transfer coefficients during a transient experiment. The data reduction relies on analysis of a coupled transient conduction - convection heat transfer problem that characterizes the experiment. The recovery temperature of the jet is accounted for by running two experiments with different heating rates, thereby generating a second equation that is used to solve for the recovery temperature. The resulting solution requires a complicated numerical iteration that is handled by a computer. Because the computational data reduction method is complex, special attention is paid to error assessment. The error analysis considers random and systematic errors generated by the instrumentation along with errors generated by the approximate nature of the numerical methods. Results of the error analysis show that the experimentally determined heat transfer coefficients are accurate to within 15%. The error analysis also shows that the recovery temperature data may be in error by more than 50%. The results show that the recovery temperature data is only reliable when the recovery temperature of the jet is greater than 5 C, i.e. the jet velocity is in excess of 100 m/s. Parameters that were investigated include nozzle width, distance from the nozzle exit to the airfoil surface, and jet velocity. Heat transfer data is presented in graphical and tabular forms. An engineering analysis of hypersonic airfoil leading edge cooling is performed using the results from these experiments. Several suggestions for the improvement of the experimental technique are discussed.
A number of future space missions require liquid helium for cooling scientific payloads. These missions will require the long term storage and resupply of liquid helium at temperatures of 1.4 - 2.1 Kelvin. In addition, some of the proposed instruments will require refrigeration to temperatures as low as 50 mK. A variety of liquid helium based refrigerator systems could provide this subkelvin cooling. The status of helium storage and refrigeration technologies and of several alternative technologies is presented here along with areas where further research and development are needed. (Helium resupply technologies are the topic of another presentation at this symposium). The technologies covered include passive and dynamic liquid helium storage, alternatives to liquid helium storage, He -3 refrigerators, He -3/He -4 dilution refrigerators, and alternative sub-kelvin coolers.
This paper presents a comparison of reactor and power conversion design options for 50 kWe class lunar and Mars surface power applications with scaling from 25 to 200 kWe. Design concepts and integration approaches are provided for three reactor-converter combinations: gas-cooled Brayton, liquid-metal Stirling, and liquid-metal thermoelectric. The study examines the mass and performance of low temperature, stainless steel based reactors and higher temperature refractory reactors. The preferred system implementation approach uses crew-assisted assembly and in-situ radiation shielding via installation of the reactor in an excavated hole. As an alternative, self-deployable system concepts that use earth-delivered, on-board radiation shielding are evaluated. The analyses indicate that among the 50 kWe stainless steel reactor options, the liquid-metal Stirling system provides the lowest mass at about 5300 kg followed by the gas-cooled Brayton at 5700 kg and the liquid-metal thermoelectric at 8400 kg. The use of a higher temperature, refractory reactor favors the gas-cooled Brayton option with a system mass of about 4200 kg as compared to the Stirling and thermoelectric options at 4700 and 5600 kg, respectively. The self-deployed concepts with on-board shielding result in a factor of two system mass increase as compared to the in-situ shielded concepts.
A NASA team is developing a test article for the purpose of demonstrating the long duration storage of liquid hydrogen utilizing passive Cryogenic Fluid Management and cryocoolers via a two-stage active cooling approach. Funded by NASA’s Technology Demonstration Mission Program and managed by the Cryogenic Fluid Management Portfolio Project, the team is leveraging demonstrations conducted under pervious NASA activities to develop a fully integrated test article that will demonstrate the zero boil-off storage of liquid hydrogen. This paper discusses the previous activities being leveraged from NASA’s Cryogenic Propellant Storage and Transfer project, the test article design and build, hardware and instrumentation selections, control methodology, and the planned primary and secondary test objectives. The test article assembly and demonstration are both to be conducted in the East Test Area at NASA Marshall Space Flight Center and are currently scheduled for Fiscal Year 2024.
Yttrium hydride is an excellent solid neutron moderator material for high temperature nuclear reactor applications due to its high hydrogen density and exceptional hydride stability at high temperatures. Despite these attractive characteristics, the details of how hydrogen behaves within yttrium hydride while temperature gradients exist are still not well understood. The evolution of the hydrogen composition profile resulting from a temperature gradient requires knowledge of hydrogen’s heat of transport, a critical parameter that has not yet been measured for this material. In this work, we perform hydride redistribution, hydrogen dissociation, and hydrogen leakage calculations while varying the Soret heat of transport of hydrogen in yttrium hydride to elucidate the sensitivity of hydride stability under temperature gradients to this parameter. This study analyzes hydride stability of a hypothetical uranium-yttrium hydride nuclear fuel design during operation of a high temperature liquid metal-cooled nuclear reactor. Assuming U-YH x could be fabricated in a physically stabilized manner, this fuel system can likely maintain hydride stability while operating at very high power densities and temperatures. We find that even though the hydrogen dissociation pressure in the gas gap does vary by several percent as the heat of transport temperature parameter is varied, the hydrogen content in the U-YH x fuel meat is relatively insensitive to this parameter over the course of a high burnup fuel cycle; this is due to yttrium hydride’s excellent hydrogen retention under the high temperature conditions considered here. Here, this suggests that hydride stability analyses are insensitive to the value of the Soret heat of transport in U-YH x under steady state liquid metal-cooled reactor conditions. However, the susceptibility to internal gas overpressurization-induced stress-rupture of the cladding during a high temperature transient is more sensitive to this parameter due to the non-linear dependence of hydrogen gas dissociation pressure vs. composition and temperature.
Capabilities of the Plant Dynamics Code (PDC) have been extended to allow steady-state and transient simulation of graphite-cooled reactors with direct helium Brayton cycle. On the cycle side, the most significant code modification is the addition of helium properties, in the format required by the code’s equations. Since the code was already formulated to handle more complex real gas properties, adding helium as working fluid that behaves like ideal gas was fairly straightforward. A reactor module was added to PDC to simulate a reactor cooled by the working fluid of the Brayton cycle. Two options are supported: channel type, typical for graphite gas-cooled reactors, and pin type, typical for light-water and liquid metal-cooled reactors. The reactor module is an extension of the electrical heater model and simulates heat deposition in the fuel and transfer of this heat from the fuel to the coolant through the matrix and tube materials. The new reactor module becomes the third option in PDC for modeling heat addition to the cycle, besides previously modeled heat addition heat exchanger and electrical heater. In addition to those changes, other minor code modifications and improvements were introduced during the work of expanding PDC to modeling of gas-cooled reactors. These modifications are summarized in the last chapter of this report.