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NASA NTRSDate not supplied

A Simplified Model of VIPER Thermal Management System. Part II: Integrated Vehicle

NASA’s Volatiles Investigating Polar Exploration Rover (VIPER) thermal management system (TMS) relies on four loop heat pipes (LHPs) to transport electronic waste heat to the vehicle cooling radiative surface and avoid overheating. The TMS has also ten constant conductance heat pipes (CCHPs) dedicated to balance the thermal load within the internal environment where the avionics boxes are mounted, also called warm electronic box (WEB), and to transport the heat from two of the science payload instruments. The TMS also uses two thermal straps to thermally link the batteries to the WEB. These thermal components, in addition to heaters, thermostat, multi-layer insulation (MLIs), and isolators forms the core of the VIPER TMS. The complex heat transport balance managed by the TMS is challenging to characterize and model. The more fidelity and granularity of a model, the more costly the computational resources needed and the longer the simulation and modeling time. When the priority is to provide quick but reliable assessments of the thermal performance or real time thermal feedback for training of console operators, simplified modeling tools are needed. To satisfy that need, this paper describes the effort to develop and correlate a model of VIPER TMS based on control volume approach. The correlation effort in particular focuses on hibernation, cold thermal balance, and hot thermal balance data from the integrated vehicle thermal vacuum (TVAC) test. Thus, the correlated model captures the heat leaks during hibernations and the performance at two extremes, bounding, operating scenarios.

Loop Heat Pipe↗

NASA NTRSDate not supplied

A Simplified Model of VIPER Thermal Management System. Part II: Integrated Vehicle

Thermal Modeling↗

NASA NTRS1992

Thermal issues at the SSC

A variety of heat transfer problems arise in the design of the Superconducting Super Collider (SSC). One class of problems is to minimize heat leak from the ambient to the SSC rings, since the rings contain superconducting magnets maintained at a temperature of 4 K. Another arises from the need to dump the beam of protrons (traveling around the SSC rings) on to absorbers during an abort of the collider. Yet another category of problems is the cooling of equipment to dissipate the heat generated during operation. An overview of these problems and sample heat transfer results are given in this paper.

Ranganathan, Raj P.↗

NASA NTRS1991

Test program, helium II orbital resupply coupling

The full scope of this program was to have included development tests, design and production of custom test equipment and acceptance and qualification testing of prototype and protoflight coupling hardware. This program was performed by Ball Aerospace Systems Division, Boulder, Colorado until its premature termination in May 1991. Development tests were performed on cryogenic face seals and flow control devices at superfluid helium (He II) conditions. Special equipment was developed to allow quantified leak detection at large leak rates up to 8.4 x 10(exp -4) SCCS. Two major fixtures were developed and characterized: The Cryogenic Test Fixture (CTF) and the Thermal Mismatch Fixture (Glovebox). The CTF allows the coupling hardware to be filled with liquid nitrogen (LN2), liquid helium (LHe) or sub-cooled liquid helium when hardware flow control valves are either open or closed. Heat leak measurements, internal and external helium leakage measurements, cryogenic proof pressure tests and external load applications are performed in this fixture. Special reusable MLI closures were developed to provide repeatable installations in the CTF. The Thermal Mismatch Fixture allows all design configurations of coupling hardware to be engaged and disengaged while measuring applied forces and torques. Any two hardware components may be individually thermally preconditioned within the range of 117 deg K to 350 deg K prior to engage/disengage cycling. This verifies dimensional compatibility and operation when thermally mismatched. A clean, dry GN2 atmosphere is maintained in the fixture at all times. The first shipset of hardware was received, inspected and cycled at room temperature just prior to program termination.

Hyatt, William S.↗

NASA NTRS2011

Power Distribution for Cryogenic Instruments at 6-40K The James Webb Space Telescope Case

The Integrated Science Instrument Module (ISIM) of the James Webb Space Telescope (JWST) operates its instruments passively cooled at around 40 Kelvin (K), with a warm Instrument Electronic Compartment (IEC) at 300K attached to it. From the warm electronics all secondary signal and power harnesses have to bridge this 300-40K temperature difference and minimize the power dissipation and parasitic heat leak into the cold region. After an introduction of the ISIM with its instruments, the IEC with the electronics, and the harness architecture with a special radiator, this paper elaborates on the cryogenic wire selection and tests performed to establish current de-rating rules for different wire types. Finally failure modes are analyzed for critical instrument interfaces that could inject excessive currents and heat into the harness and cold side, and several solutions for the removal of such failures are presented.

Rumler, Peter↗

NASA NTRS1989

An adiabatic demagnetization refrigerator for SIRTF

An adiabatic demagnetization refrigerator (ADR) has been proposed to cool bolometric infrared detectors on the multiband imaging photometer of the Space Infrared Telescope Facility (SIRTF). One such refrigerator has been built which uses a ferric ammonium alum salt pill suspended by nylon threads in a 3-T solenoid. The resonant modes of this suspension are above 100 Hz. The heat leak to the salt pill is less than 0.5 microW. The system has a hold time at 0.1K of more than 12 h. The cold stage temperature is regulated with a feedback loop that controls the magnetic field. A second, similar refrigerator is being built at a SIRTF prototype to fly on a ballon-borne telescope. It will use a ferromagnetic shield. The possibility of using a high-Tc solenoid-actuated heat switch is also discussed.

Timbie, P. T.↗

NASA NTRS1999

Flight Testing of a Cryogenic Capillary Pumped Loop

Future space-based cryogenic systems will require enhanced integration flexibility, lower weight reduced parasitic penalties, better vibration isolation, and a variety of other improvements to meet performance goals. Additionally, there is an increasing need to locate cooling sources remotely from cooled components. In the past flexible conductive links were used and worked well in most cases. However, as the transport lengths increase, conductive couplings become heavier and less effective, and must be replaced by higher performance systems. One available option, which can meet many of these future requirements, is the cryogenic capillary pumped loop (CCPL). The development of the CCPL technology started in 1992, following the success of the room temperature CPLS. The extrapolation of CCPL technology to cryogenic temperatures offers many performance benefits, which are not currently within the reach of traditional heat pipes or conductive links. Specific advantages of the CCPL technology pertaining to cryocooler integration include: (1) greater capillary pumping pressure for improved ground testability; (2) improved mechanical isolation; (3) faster diode shutdown and lower reverse heat leaks; (4) tighter control of detector temperature; (5) variable or fixed conductance operation; and (6) ease of integration due to their flexibility. The applications of CCPL technology are numerous. Military and commercial applications include surveillance satellites, earth observing satellites, deep space observation systems, medical devices, and many other cryogenic systems. Over the past few years, several breadboard and prototype CCPLs have been built and ground tested. A prototype CCPL has demonstrated successful operation between 80K and 110K with heat loads between O.5W and 12W using nitrogen as the working fluid, and 35K and 40K with head loads of 0.25W to 3.5W using neon. In order to verify CCPL performance in a microgravity environment, a flight unit, CCPL-5, was tested onboard the Space Shuttle STS-95 in October of 1998 as part of the CRYOTSU Flight Experiment. This flight was the first in-space demonstration of the CCPL. The CCPL-5 utilized nitrogen as the working fluid and operated between 75K and 110K. Flight results indicated excellent performance of the CCPL-5 under zero-G environment The CCPL could start from a supercritical condition in all tests, and the loop operating temperature could be tightly controlled regardless of changes in the heat load and/or the sink temperature. In addition, the loop demonstrated successful operation with a heat load of 0.5W as well as with parasitic heat loads alone. There were no noticeable differences between zero-G and one-G operation.

Ku, Jentung↗

NASA NTRS2007

Capillary Liquid Acquisition Device Heat Entrapment

Cryogenic liquid acquisition devices (LADs) for space-based propulsion interface directly with the feed system, which can be a significant heat leak source. Further, the accumulation of thermal energy within LAD channels can lead to the loss of subcooled propellant conditions and result in feed system cavitation during propellant outflow. Therefore, the fundamental question addressed by this program was: To what degree is natural convection in a cryogenic liquid constrained by the capillary screen meshes envisioned for LADs? Testing was first conducted with water as the test fluid, followed by LN2 tests. In either case, the basic experimental approach was to heat the bottom of a cylindrical column of test fluid to establish stratification patterns measured by temperature sensors located above and below a horizontal screen barrier position. Experimentation was performed without barriers, with screens, and with a solid barrier. The two screen meshes tested were those typically used by LAD designers, 200x1400 and 325x2300, both with Twill Dutch Weave. Upon consideration of both the water and LN2 data, it was concluded that heat transfer across the screen meshes was dependent upon barrier thermal conductivity and that the capillary screen meshes were impervious to natural convection currents.

Bolshinskiy, L. G.↗

NASA NTRS2007

Cryogenic Capillary Screen Heat Entrapment

Cryogenic liquid acquisition devices (LADs) for space-based propulsion interface directly with the feed system, which can be a significant heat leak source. Further, the accumulation of thermal energy within LAD channels can lead to the loss of sub-cooled propellant conditions and result in feed system cavitation during propellant outflow. Therefore, the fundamental question addressed by this program was: "To what degree is natural convection in a cryogenic liquid constrained by the capillary screen meshes envisioned for LADs.?"Testing was first conducted with water as the test fluid, followed by LN2 tests. In either case, the basic experimental approach was to heat the bottom of a cylindrical column of test fluid to establish stratification patterns measured by temperature sensors located above and below a horizontal screen barrier position. Experimentation was performed without barriers, with screens, and with a solid barrier. The two screen meshes tested were those typically used by LAD designers, "200x1400" and "325x2300", both with Twill Dutch Weave. Upon consideration of both the water and LN2 data it was concluded that heat transfer across the screen meshes was dependent upon barrier thermal conductivity and that the capillary screen meshes were impervious to natural convection currents.

Bolshinskiy, L.G.↗

NASA NTRS1984

Evaluation of propellant tank insulation concepts for low-thrust chemical propulsion systems

An analytical evaluation of cryogenic propellant tank insulations for liquid oxygen/liquid hydrogen low-thrust 2224N (500 lbf) propulsion systems (LTPS) was conducted. The insulation studied consisted of combinations of N2-purged foam and multilayer insulation (MLI) as well as He-purged MLI-only. Heat leak and payload performance predictions were made for three Shuttle-launched LTPS designed for Shuttle bay packaged payload densities of 56 kg/cu m, 40 kg/cu m and 24 kg/cu m. Foam/MLI insulations were found to increase LTPS payload delivery capability when compared with He-purged MLI-only. An additional benefit of foam/MLI was reduced operational complexity because Orbiter cargo bay N2 purge gas could be used for MLI purging. Maximum payload mass benefit occurred when an enhanced convection, rather than natural convection, heat transfer was specified for the insulation purge enclosure. The enhanced convection environment allowed minimum insulation thickness to be used for the foam/MLI interface temperature selected to correspond to the moisture dew point in the N2 purge gas. Experimental verification of foam/MLI benefits was recommended. A conservative program cost estimate for testing a MLI-foam insulated tank was 2.1 million dollars. It was noted this cost could be reduced significantly without increasing program risk.

Kramer, T.↗

NASA NTRS1994

Experimental Investigation of Jet-Induced Mixing of a Large Liquid Hydrogen Storage Tank

Experiments have been conducted to investigate the effect of fluid mixing on the depressurization of a large liquid hydrogen storage tank. The test tank is approximately ellipsoidal, having a volume of 4.89 m(exp 3) and an average wall heat flux of 4.2 W/m(exp 2) due to external heat input. A mixer unit was installed near the bottom of the tank to generate an upward directed axial jet flow normal to the liquid-vapor interface. Mixing tests were initiated after achieving thermally stratified conditions in the tank either by the introduction of hydrogen gas into the tank or by self-pressurization due to ambient heat leak through the tank wall. The subcooled liquid jet directed towards the liquid-vapor interface by the mixer induced vapor condensation and caused a reduction in tank pressure. Tests were conducted at two jet submergence depths for jet Reynolds numbers from 80,000 to 495,000 and Richardson numbers from 0.014 to 0.52. Results show that the rate of tank pressure change is controlled by the competing effects of subcooled jet flow and the free convection boundary layer flow due to external tank wall heating. It is shown that existing correlations for mixing time and vapor condensation rate based on small scale tanks may not be applicable to large scale liquid hydrogen systems.

Lin, C. S.↗

NASA NTRS1984

Evaluation of propellent tank insulation concepts for low-thrust chemical propulsion systems: Executive summary

Cryogenic propellant tank insulations or liquid oxygen/liquid hydrogen low-thrust 2224N (500 lbf) propulsion systems (LTPS) were assessed. The insulation studied consisted of combinations of N2-purged foam and multilayer insulation (MLI) as well as He-purged MLI-only. Heat leak and payload performance predictions were made for three shuttle-launched LTPS designed for shuttle bay packaged payload densities of 56 kg cu/m (3.5 lbm/cu ft), 40 kg/cu m (2.5 lbm/cu ft) and 24 kg/cu m (1.5 lbm/cu ft). Foam/MLI insulations were found to increase LTPS payload delivery capability when compared with He-purged MLI-only. An additional benefit of foam/MLI was reduced operational complexity because orbiter cargo bay N2 purge gas could be used for MLI purging. Maximum payload mass benefit occurred when an enhanced convection, rather than natural convection, heat transfer was specified for the insulation purge enclosure. The enhanced convection environment allowed minimum insulation thickness to be used for the foam/MLI interface temperature selected to correspond to the moisture dew point in the N2 purge gas. Experimental verification of foam/MLI benefits was recommended. A conservative program cost estimate for testing a MLI-foam insulated tank was 2.1 million dollars. This cost could be reduced significantly without increasing program risk.

Kramer, T.↗

NASA NTRS2007

Thermodynamic Vent System Performance Testing with Subcooled Liquid Methane and Gaseous Helium Pressurant

Due to its high specific impulse and favorable thermal properties for storage, liquid methane (LCH4) is being considered as a candidate propellant for exploration architectures. In order to gain an -understanding of any unique considerations involving micro-gravity pressure control with LCH4, testing was conducted at the Marshall Space Flight Center using the Multipurpose Hydrogen Test Bed (MHTB) to evaluate the performance of a spray-bar thermodynamic vent system (TVS) with subcooled LCH4 and gaseous helium (GHe) pressurant. Thirteen days of testing were performed in November 2006, with total tank heat leak conditions of about 715 W and 420 W at a fill level of approximately 90%. The TVS system was used to subcool the LCH4 to a liquid saturation pressure of approximately 55.2 kPa before the tank was pressurized with GHe to a total pressure of 165.5 kPa. A total of 23 TVS cycles were completed. The TVS successfully controlled the ullage pressure within a prescribed control band but did not maintain a stable liquid saturation pressure. This was likely. due to a TVS design not optimized for this particular propellant and test conditions, and possibly due to a large artificially induced heat input directly into the liquid. The capability to reduce liquid saturation pressure as well as maintain it within a prescribed control band, demonstrated that the TVS could be used to seek and maintain a desired liquid inlet temperature for an engine (at a cost of propellant lost through the TVS vent). One special test was conducted at the conclusion of the planned test activities. Reduction of the tank ullage pressure by opening the Joule-Thomson valve (JT) without operating the pump was attempted. The JT remained open for over 9300 seconds, resulting in an ullage pressure reduction of 30 kPa. The special test demonstrated the feasibility of using the JT valve for limited ullage pressure reduction in the event of a pump failure.

Flachbart, R. H.↗

NASA NTRS1984

Advanced passive radiator for spaceborne cryogenic cooling

A novel design to improve the cooling capability of spaceborne cryogenic passive radiators is described. The design is based on the use of lightweight angled radiation shields, low-conductance structural supports, and a separate detachable launch-support system to reduce the parasitic heat leaks from the warm spacecraft to the cold radiator. The effectiveness of this design is demonstrated by thermal-vacuum-chamber experiments which indicate that the angled-radiation-shield assembly has an effective emittance that is an order of magnitude lower than that of the best multilayer insulation used in flight. Performance predictions based on the experiments and analytical model indicate that an advanced passive-radiator design based on this technology would be between 10 and 57% of the size and 10 and 36% of the mass of the best state-of-the-art passive radiators and would make lower temperatures (< 60 K) and larger heat loads practical. The cooling requirements of many new spaceborne instruments could be accommodated by application of this new passive-radiator design.

Steven Bard↗

NASA NTRS2024

Exploration Extravehicular Mobility Unit (xEMU) Chamber B Thermal Vacuum “Suit 2” Pressure Garment System Test Article Results

NASA’s Exploration Extravehicular Mobility Unit (xEMU) is the government reference next-generation spacesuit design and is engineered to protect astronauts from extreme lunar environmental temperatures. To evaluate the xEMU hardware thermal requirements, the xEMU Testing Team invented, designed, and executed a dual-suit, uncrewed thermal vacuum (TVAC) test at Johnson Space Center’s (JSC) Chamber B. This paper details the test results from the “Suit 2” Pressure Garment System (PGS) test article. The primary objective of the “Suit 2” PGS test article was to evaluate system-level suit heat leak and Environmental Protection Garment (EPG) thermal performance. Eleven unique thermal profiles were tested including both cold and hot environmental cases over the course of five continuous days of testing. The radiative thermal environment was controlled through exposure to liquid-nitrogen shrouds on the chamber walls and a heater cage surrounding the test article. This paper will principally focus on system-level thermal results from the “Suit 2” PGS test article. This paper will examine data collected from one-hundred and seventy thermocouples located in critical locations inside and outside of the suit, as well as seven resistance thermometers (RTDs) for calorimetry to determine total heat flux in and out of the suit. The test data will be compared against the system-level PGS thermal models for model validation. To conclude, this paper will address knowledge gaps presented by unmanned xPGS thermal vacuum testing and the current state of lunar xPGS thermal modeling and testing.

xEMU↗

NASA NTRS2003

Surface-Micromachined Planar Arrays of Thermopiles

Planar two-dimensional arrays of thermopiles intended for use as thermal-imaging detectors are to be fabricated by a process that includes surface micromachining. These thermopile arrays are designed to perform better than do prior two-dimensional thermopile arrays. The lower performance of prior two-dimensional thermopile arrays is attributed to the following causes: The thermopiles are made from low-performance thermoelectric materials. The devices contain dielectric supporting structures, the thermal conductances of which give rise to parasitic losses of heat from detectors to substrates. The bulk-micromachining processes sometimes used to remove substrate material under the pixels, making it difficult to incorporate low-noise readout electronic circuitry. The thermoelectric lines are on the same level as the infrared absorbers, thereby reducing fill factor. The improved pixel design of a thermopile array of the type under development is expected to afford enhanced performance by virtue of the following combination of features: Surface-micromachined detectors are thermally isolated through suspension above readout circuitry. The thermopiles are made of such high-performance thermoelectric materials as Bi-Te and Bi-Sb-Te alloys. Pixel structures are supported only by the thermoelectric materials: there are no supporting dielectric structures that could leak heat by conduction to the substrate.

Foote, Marc C.↗

NASA NTRS2018

Large Scale Cryogenic Storage with Active Refrigeration

Storage and transfer of cryogenic liquefied gases on volume scales from under 10 liters for lab use, up to hundreds of millions of liters for industrial applications is of paramount importance across a vast range of industries. Traditionally, these commodities have been stored at or near the normal boiling point due to relative ease of operation and safety-related considerations; however, this also means that some percentage will always be lost due to environmental heat leaking into the vessel and causing boil-off. These losses become more concerning as scales increase, and are of particular importance for high-cost commodities such helium and hydrogen. Additionally, the normal boiling point marks the highest liquid density achievable; which becomes a strong driver of end-use system designs such as space launch vehicles. Recent development and testing of an Integrated Refrigeration and Storage (IRAS) system for liquid hydrogen has proven that next generation cryogenic storage operations such as zero boil-off and densification are feasible on a large scale. This IRAS system married an 850 Watt at 20 Kelvin reverse-Brayton cycle commercial cryogenic refrigerator with a 125,000 liter LH2 storage tank via and internal tubular heat exchanger. This allowed heat to be removed directly from the hydrogen, and by extension, provided a means to control the bulk thermodynamic state. Zero boil-off, in-situ liquefaction, and densification down to the triple point was performed during testing, and data such as fluid temperature profiles and tank pressure were gathered. Details regarding the design, setup, and testing of the IRAS system are discussed herein, and the data used to anchor various physics models created to predict the behavior of the system during transient and steady state operation. It is hoped that these efforts will provide a useful basis for the design and implementation of future large scale IRAS systems across numerous industries.

Swanger, Adam M.↗

NASA NTRS1961

ANALYSIS OF CRYOGENIC PROPELLANT FEED SYSTEMS FOR ELECTROTHERMAL ENGINES.

An analytical investigation was made of the problems associated with the long-term storage and control of flow of cryogenic propellants for electrothermal engines. Storage of 35 to 174 pounds of propellant for three years is made difficult by the high ratio of surface area to storage tank volume, and the resulting high rate of heat leak. Vented and non-vented storage, storage as high pressure gas, and the use of refrigeration were considered. Recommended storage methods are: for ethane and ammonia vented storage - by venting propellant stored in excess of mission requirements; for hydrogen and helium - by non-vented storage of cold supercritical vapor; and for methane by storage as a non-vented two-phase mixture. The optimum propellant density in the storage tank and optimum insulation thickness were also determined. Design charts were developed for hydrogen and helium, for estimating the maximum pressure expected in non-vented storage tanks, as function of mission requirements. Separation of the constituent phases of liquid-vapor mixtures is achieved by throttling the two-phase mixture to a lower pressure (and temperature) and vaporizing the liquid in the mixture by heat exchange with the contents of the storage tank. The time limitations for continuous use of this method are discussed. Linde super insulations SI-44 or SI -91 are recommended for insulation. Precooling the insulation to temperatures below the steady state level with cold helium vapor before or during fueling of the storage tank eliminates the flow of heat to the tank contents during countdown and take-off. The masses, sizes, and power requirements of the recommended systems are low. The controls are simple and reliable. From the equations and charts in this report the components of the system for a particular mission can be sized. Recommendations are given for experimental work required for the development and testing of such components.

ELECTROTHERMAL ENGINE↗