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NASA NTRS2013

Large-Scale Liquid Hydrogen Tank Rapid Chill and Fill Testing for the Advanced Shuttle Upper Stage Concept

Cryogenic upper stages in the Space Shuttle program were prohibited primarily due to a safety risk of a 'return to launch site' abort. An upper stage concept addressed this concern by proposing that the stage be launched empty and filled using shuttle external tank residuals after the atmospheric pressure could no longer sustain an explosion. However, only about 5 minutes was allowed for tank fill. Liquid hydrogen testing was conducted within a near-ambient environment using the multipurpose hydrogen test bed 638.5 ft3 (18m3) cylindrical tank with a spray bar mounted longitudinally inside. Although the tank was filled within 5 minutes, chilldown of the tank structure was incomplete, and excessive tank pressures occurred upon vent valve closure. Elevated tank wall temperatures below the liquid level were clearly characteristic of film boiling. The test results have substantial implications for on-orbit cryogen transfer since the formation of a vapor film would be much less inhibited due to the reduced gravity. However, the heavy tank walls could become an asset in normal gravity testing for on-orbit transfer, i.e., if film boiling in a nonflight weight tank can be inhibited in normal gravity, then analytical modeling anchored with the data could be applied to reduced gravity environments with increased confidence.

Flachbart, R. H.↗

NASA NTRS2014

Simulation for Prediction of Entry Article Demise (SPEAD): an Analysis Tool for Spacecraft Safety Analysis and Ascent/Reentry Risk Assessment

For the purpose of performing safety analysis and risk assessment for a probable offnominal suborbital/orbital atmospheric reentry resulting in vehicle breakup, a synthesis of trajectory propagation coupled with thermal analysis and the evaluation of node failure is required to predict the sequence of events, the timeline, and the progressive demise of spacecraft components. To provide this capability, the Simulation for Prediction of Entry Article Demise (SPEAD) analysis tool was developed. This report discusses the capabilities, modeling, and validation of the SPEAD analysis tool. SPEAD is applicable for Earth or Mars, with the option for 3 or 6 degrees-of-freedom (DOF) trajectory propagation. The atmosphere and aerodynamics data are supplied in tables, for linear interpolation of up to 4 independent variables. The gravitation model can include up to 20 zonal harmonic coefficients. The modeling of a single motor is available and can be adapted to multiple motors. For thermal analysis, the aerodynamic radiative and free-molecular/continuum convective heating, black-body radiative cooling, conductive heat transfer between adjacent nodes, and node ablation are modeled. In a 6- DOF simulation, the local convective heating on a node is a function of Mach, angle-ofattack, and sideslip angle, and is dependent on 1) the location of the node in the spacecraft and its orientation to the flow modeled by an exposure factor, and 2) the geometries of the spacecraft and the node modeled by a heating factor and convective area. Node failure is evaluated using criteria based on melting temperature, reference heat load, g-load, or a combination of the above. The failure of a liquid propellant tank is evaluated based on burnout flux from nucleate boiling or excess internal pressure. Following a component failure, updates are made as needed to the spacecraft mass and aerodynamic properties, nodal exposure and heating factors, and nodal convective and conductive areas. This allows the trajectory to be propagated seamlessly in a single run, inclusive of the trajectories of components that have separated from the spacecraft. The node ablation simulates the decreasing mass and convective/reference areas, and variable heating factor. A built-in database provides the thermo-mechanical properties of For the purpose of performing safety analysis and risk assessment for a probable offnominal suborbital/orbital atmospheric reentry resulting in vehicle breakup, a synthesis of trajectory propagation coupled with thermal analysis and the evaluation of node failure is required to predict the sequence of events, the timeline, and the progressive demise of spacecraft components. To provide this capability, the Simulation for Prediction of Entry Article Demise (SPEAD) analysis tool was developed. This report discusses the capabilities, modeling, and validation of the SPEAD analysis tool. SPEAD is applicable for Earth or Mars, with the option for 3 or 6 degrees-of-freedom (DOF) trajectory propagation. The atmosphere and aerodynamics data are supplied in tables, for linear interpolation of up to 4 independent variables. The gravitation model can include up to 20 zonal harmonic coefficients. The modeling of a single motor is available and can be adapted to multiple motors. For thermal analysis, the aerodynamic radiative and free-molecular/continuum convective heating, black-body radiative cooling, conductive heat transfer between adjacent nodes, and node ablation are modeled. In a 6- DOF simulation, the local convective heating on a node is a function of Mach, angle-ofattack, and sideslip angle, and is dependent on 1) the location of the node in the spacecraft and its orientation to the flow modeled by an exposure factor, and 2) the geometries of the spacecraft and the node modeled by a heating factor and convective area. Node failure is evaluated using criteria based on melting temperature, reference heat load, g-load, or a combination of the above. The failure of a liquid propellant tank is evaluated based on burnout flux from nucleate boiling or excess internal pressure. Following a component failure, updates are made as needed to the spacecraft mass and aerodynamic properties, nodal exposure and heating factors, and nodal convective and conductive areas. This allows the trajectory to be propagated seamlessly in a single run, inclusive of the trajectories of components that have separated from the spacecraft. The node ablation simulates the decreasing mass and convective/reference areas, and variable heating factor. A built-in database provides the thermo-mechanical properties of

Ling, Lisa↗

NASA NTRS2014

Flow Visualization of Liquid Hydrogen Line Chilldown Tests

We present experimental measurements of wall and fluid temperature during chill-down tests of a warm cryogenic line with liquid hydrogen. Synchronized video and fluid temperature measurements are used to interpret stream temperature profiles versus time. When cold liquid hydrogen starts to flow into the warm line, a sequence of flow regimes, spanning from all-vapor at the outset to bubbly with continuum liquid at the end can be observed at a location far downstream of the cold inlet. In this paper we propose interpretations to the observed flow regimes and fluid temperature histories for two chilldown methods, viz. trickle (i.e. continuous) flow and pulse flow. Calculations of heat flux from the wall to the fluid versus wall temperature indicate the presence of the transition/nucleate boiling regimes only. The present tests, run at typical Reynolds numbers of approx O(10 (exp 5)), are in sharp contrast to similar tests conducted at lower Reynolds numbers where a well-defined film boiling region is observed.

Line chill down↗

NASA NTRS2014

Insulation Test Cryostat with Lift Mechanism

A multi-purpose, cylindrical thermal insulation test apparatus is used for testing insulation materials and systems of materials using a liquid boil-off calorimeter system for absolute measurement of the effective thermal conductivity (k-value) and heat flux of a specimen material at a fixed environmental condition (cold-side temperature, warm-side temperature, vacuum pressure level, and residual gas composition). The apparatus includes an inner vessel for receiving a liquid with a normal boiling point below ambient temperature, such as liquid nitrogen, enclosed within a vacuum chamber. A cold mass assembly, including the upper and lower guard chambers and a middle test vessel, is suspended from a lid of the vacuum canister. Each of the three chambers is filled and vented through a single feedthrough. All fluid and instrumentation feedthroughs are mounted and suspended from a top domed lid to allow easy removal of the cold mass. A lift mechanism allows manipulation of the cold mass assembly and insulation test article.

Fesmire, James E.↗

NASA NTRS2015

Proof-of-Concept Experiments on a Gallium-Based Ignitron for Pulsed Power Applications

Ignitrons are electrical switching devices that operate at switching times that are on the order of microseconds, can conduct high currents of thousands of amps, and are capable of holding off tens of thousands of volts between pulses. They consist of a liquid metal pool within an evacuated tube that serves both the cathode and the source of atoms and electrons for an arc discharge. Facing the liquid metal pool is an anode suspended above the cathode, with a smaller ignitor electrode tip located just above the surface of the cathode. The ignitron can be charged to significant voltages, with a potential difference of thousands of volts between anode and cathode. When an ignition pulse is delivered from the ignitor electrode to the cathode, a small amount of the liquid metal is vaporized and subsequently ionized, with the high voltage between the anode and cathode causing the gas to bridge the gap between the two electrodes. The electrons and ions move rapidly towards the anode and cathode, respectively, with the ions liberating still more atoms from the liquid metal cathode surface as a high-current plasma arc discharge is rapidly established. This arc continues in a self-sustaining fashion until the potential difference between the anode and cathode drops below some critical value. Ignitrons have been used in a variety of pulsed power applications, including the railroad industry, industrial chemical processing, and high-power arc welding. In addition, they might prove useful in terrestrial power grid applications, serving as high-current fault switches, quickly shunting dangerous high-current or high-voltage spikes safely to ground. The motivation for this work stemmed from the fact that high-power, high-reliability, pulsed power devices like the ignitron have been used for ground testing in-space pulsed electric thruster technologies, and the continued use of ignitrons could prove advantageous to the future development and testing of such thrusters. Previous ignitron designs have used mercury as the liquid metal cathode, owing to its presence as a liquid at room temperatures and a vapor pressure of 10 Pa (75 mtorr) at room temperature. While these are favorable properties, there are obvious environmental and personal safety concerns with the storage, handling, and use of mercury and its compounds. The purpose of the present work was to fabricate and test an ignitron that used as its cathode an alternate liquid metal that was safe to handle and store. To that end, an ignitron test article that used liquid gallium as the cathode material was developed and tested. Gallium is a metal that has a melting temperature of 29.76 C, which is slightly above room temperature, and a boiling point of over 2,300 C at atmospheric pressure. This property makes gallium the element with the largest relative difference between melting and boiling points. Gallium has a limited role in biology, and when ingested, it will be subsequently processed by the body and expelled rather than accumulating to toxic levels. The next section of this Technical Memorandum (TM) provides background information on the development of mercury-based ignitrons, which serves as the starting point for the development of the gallium-based variant. Afterwards, the experimental hardware and setup used in proof-of-concept testing of a basic gallium ignitron are presented. Experimental data, consisting of discharge voltage and current waveforms as well as high-speed imaging of the gallium arc discharge in the gallium ignitron test article, are presented to demonstrate the efficacy of the concept. Discussion of the data and suggestions on improvements for future iterations of the design are presented in the final two sections of this TM.

Ali, H. K.↗

NASA NTRS2012

Design of Accumulators and Liquid/Gas Charging of Single Phase Mechanically Pumped Fluid Loop Heat Rejection Systems

For single phase mechanically pumped fluid loops used for thermal control of spacecraft, a gas charged accumulator is typically used to modulate pressures within the loop. This is needed to accommodate changes in the working fluid volume due to changes in the operating temperatures as the spacecraft encounters varying thermal environments during its mission. Overall, the three key requirements on the accumulator to maintain an appropriate pressure range throughout the mission are: accommodation of the volume change of the fluid due to temperature changes, avoidance of pump cavitation and prevention of boiling in the liquid. The sizing and design of such an accumulator requires very careful and accurate accounting of temperature distribution within each element of the working fluid for the entire range of conditions expected, accurate knowledge of volume of each fluid element, assessment of corresponding pressures needed to avoid boiling in the liquid, as well as the pressures needed to avoid cavitation in the pump. The appropriate liquid and accumulator strokes required to accommodate the liquid volume change, as well as the appropriate gas volumes, require proper sizing to ensure that the correct pressure range is maintained during the mission. Additionally, a very careful assessment of the process for charging both the gas side and the liquid side of the accumulator is required to properly position the bellows and pressurize the system to a level commensurate with requirements. To achieve the accurate sizing of the accumulator and the charging of the system, sophisticated EXCEL based spreadsheets were developed to rapidly come up with an accumulator design and the corresponding charging parameters. These spreadsheets have proven to be computationally fast and accurate tools for this purpose. This paper will describe the entire process of designing and charging the system, using a case study of the Mars Science Laboratory (MSL) fluid loops, which is en route to Mars for an August 2012 landing.

HRS↗

NASA NTRS2015

Cryogenic Orbital Testbed (CRYOTE) Ground Test Article, Final Report

Liquid propulsion has been used since Robert Goddard started developing a liquid oxygen (LO2) and gasoline powered rocket and fired it in 1923 (Ref. 1). In the following decades engineers settled on the combination of liquid hydrogen (LH2) and LO2 as the most efficient propellant combination for in-space travel. Due to their low temperatures (LH2 at 20 K and LO2 at 90 K), they require special handling and procedures. General Dynamics began developing LO2 and LH2 upper stages in 1956 in the form of Centaur, these efforts were soon funded by the Department of Defense in conjunction with NASA (beginning in 1958) (Ref. 2). Meanwhile NASA also worked with McDonnell Douglas to develop the SIV-B stage for the Saturn V rocket. In the subsequent years, the engineers were able to push the Centaur to up to 9 hr of orbital lifetime and the SIV-B to up to 6 hr. Due to venting the resultant boil-off from the high heat loads through the foam insulation on the upper stages, both vehicles remained in a settled configuration throughout the flights, thus the two phases of propellant (liquid and vapor) were separated at a known location. The one exception to this were the Titan/Centaur missions, which thanks to the lower boil-off using three layers of multilayer insulation (MLI), were able to coast unsettled for up to 5.25 hr during direct geosynchronous orbit insertion missions. In the years since there has been a continuous effort to extend the life of these upper stages from hours to days or even months.

Joule-Thompson Effect↗

NASA NTRS2016

Insulation Test Cryostat with Lift Mechanism

A multi-purpose, cylindrical thermal insulation test apparatus is used for testing insulation materials and systems of materials using a liquid boil-off calorimeter system for absolute measurement of the effective thermal conductivity (k-value) and heat flux of a specimen material at a fixed environmental condition (cold-side temperature, warm-side temperature, vacuum pressure level, and residual gas composition). An inner vessel receives liquid with a normal boiling point below ambient temperature, such as liquid nitrogen, enclosed within a vacuum chamber. A cold mass assembly, including upper and lower guard chambers and middle test vessel, is suspended from a lid of the vacuum canister. Each of the three chambers is filled and vented through a single feedthrough. All fluid and instrumentation feedthroughs are mounted and suspended from a top domed lid allowing easy removal of the cold mass. A lift mechanism allows manipulation of the cold mass assembly and insulation test article.

Fesmire, James E.↗

NASA NTRS2017

Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER)

Abstract: NASA is currently investigating methods to reduce the boil-off rate on large cryogenic upper stages. Two such methods to reduce the total heat load on existing upper stages are vapor cooling of the cryogenic tank support structure and integration of thick multilayer insulation systems to the upper stage of a launch vehicle. Previous efforts have flown a 2-layer MLI blanket and shown an improved thermal performance, and other efforts have ground-tested blankets up to 70 layers thick on tanks with diameters between 2 3 meters. However, thick multilayer insulation installation and testing in both thermal and structural modes has not been completed on a large scale tank. Similarly, multiple vapor cooled shields are common place on science payload helium dewars; however, minimal effort has gone into using boil-off to intercept heat on large structural surfaces associated with rocket stages. A majority of the vapor cooling effort focuses on metallic cylinders called skirts, which are the most common structural components for launch vehicles. In order to provide test data for comparison with analytical models, a 4 meter diameter test tank and assembly is currently being designed to include skirt structural systems with integral vapor cooling. In order to give a more representative result for actual applications, the technologies will be designed for an 8.4 m and scaled down to a 4 meter tank. In order to prove that the insulation system and vapor cooling attachment methods are structurally sound, acoustic testing will also be performed on the system. The test tank with insulation and vapor cooled shield installed will be tested thermally in the B2 test facility at NASAs Plum Brook Station both before and after being vibration tested at Plum Brooks Space Power Facility.

Johnson, Wesley↗

NASA NTRS2018

Validation of Heat Transfer Correlations in Line Chill-Down Tests of Cryogenic Fluid in SINDA/FLUINT

Line chill-down is an important process in cryogenic tank propellant management, storage, and usage Complex flow dynamics during these processes: boiling heat transfer (film, transition, and nucleate) Understanding boiling phenomena can lead to efficient line chill-down systems that use less propellant, propellant stored, reducing cost for space missions Line Chill-down heat transfer was modelled using SINDA/FLUINT version 5.8 (SF) Multiple chill-down tests were modelled using: heat transfer correlations readily available in SF using HTN/HTC TIES heat transfer empiricisms developed by the University of Florida (UF) based on a series of liquid nitrogen chill-down tests using SF HTU TIES Chill-down tests modelled: liquid nitrogen tests conducted by the University of Florida horizontal flow, upward flow, and downward flow (Reynolds Numbers ranging 850-231,000)liquid hydrogen tests conducted by NASA Glenn Research Center vertical upward flow (Reynolds Number range of 18,400 - 433,000)The flow rate was measured far downstream of the test section, near the system exit. Where to set the flow rate? SF was highly sensitive, and sometime unstable, setting the test flow rate downstream (the outlet) of the test section model and setting the test pressure upstream (the inlet) of the test section model higher flow rate oscillations at the entrance of the model's test section SF was more stable setting the test flow rate upstream (than the downstream flow rate set case)test pressure was used as an inlet (SF plenum) to set the thermodynamic state (temperature and quality) coming into the system setting the appropriate downstream pressure was the unknown. The pressure drops predicted by SF for the downstream set flow rate boundary condition were much smaller than test section measured pressure drops. The multiphase pressure drop correlations used internally in SF may need to be adjusted. Models with an upstream flow rate set assumed a pressure drop that was small

cryogenic modeling↗

NASA NTRS2020

Marshall Space Flight Center Faculty Fellowship Program

This paper presents a multi-node model of autogenous pressurization of liquid nitrogen in a flight tank using the Generalized Fluid System Simulation Program (GFSSP), a general purpose flow network code developed at NASA/Marshall Space Flight Center. This study considers two different models: (a) pressurization of the tank by nitrogen gas from a supply tank and (b) pressurization of the tank by using the boil-off propellant through an IVF (Integrated Vehicle Fluids) loop. The tank pressurization model considers two different liquid fill-levels of the tank (a) 75% and (b) 45%. Heat and mass transfer between the liquid and vapor has been modeled at the liquid vapor interface. Heat transfer between wall and vapor at the ullage has been accounted for by assuming heat transfer occurs by natural convection. The model also accounts for heat leak to the tank through the insulation and metal wall by heat conduction. The predicted pressures and temperatures are compared with the measured data and good agreement has been observed. In the second case, the tank is pressurized by using the boil-off fluid that recirculates through an IVF loop. Preliminary results from this model are also reported.

N.F. Six↗

NASA NTRSDate not supplied

SHIIVER Assemby Thermal Model Prediction for Transient Test Conditions

An integrated thermal model of the Structure Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER) was built in Thermal Desktop/Sinda-Fluint and used to predict thermal performance of the system with the technologies being tested from the eCryo project. The technologies tested include the vapor cooling of the structure using the boil-off and multilayer insulation (MLI) on the hydrogen tank. The thermal model is used to 1) understand system transient behaviors; 2) perform trade studies of different vapor-cooling designs; 3) define the test operations matrix, test procedures, and conditions; and 4) address thermal-related questions at different phases of SHIIVER project. Details of the thermal model are herein described, and results corresponding to the test operations are presented for four different configurations at different fill levels. The thermal performance of each configuration is predicted with the thermal model regarding the heat reduction and boil-off reduction by using vapor cooling and/or MLI on the structures attached to the hydrogen tank.

thermal modeling↗

NASA NTRSDate not supplied

CFD Modeling of Cryogenic Chilldown in a Complex Channel under Normal and Low Gravity Conditions

Future NASA architectures have baselined cryogenic propulsion systems as well as cryogenic fluid management to support lunar missions and ultimately to support future missions to Mars. These missions will require chilling hardware down prior to engine restart as well as chilling lines and tanks prior to transferring and refueling these propulsion elements in orbit. In lieu of expensive tests conducted on-orbit, accurate predictive computational models of these chilldown processes can be used to reduce system and propellant mass as well as mission risk. To gain confidence in these computational models, appropriate anchoring and validation to experimental data in a relevant environment needs to be performed. Recent ground and sub-orbital flight experiments conducted by the Japan Aerospace Exploration Agency (JAXA) investigated chilldown of a complex channel resembling a turbopump bearing cavity at low flow rates. This work presents Computational Fluid Dynamics (CFD) model development of the chilldown experiment employing two-phase flow boiling models available in commercial CFD software STAR-CCM+ using Volume of Fluid (VOF) and the traditional Euler-Euler multiphase flow solvers. Comparisons of the numerical and experimental results under normal and low-gravity conditions are presented. An assessment of solid wall temperatures and phase distribution yielded important insights into multiphase solver choice, dependence on gravity environment, and challenges associated with cryogenic flow boiling prediction and validation.

CFD↗

NASA NTRSDate not supplied

Designing the Imaging and Breadboard System for FBCE-TL Project

This presentation outlines the support work done on designing the imaging and breadboard system of the Transfer Line (TL) project, which is the third module for the Flow Boiling and Condensation Experiment (FBCE) operating in the Fluids Integrated Rack on-board the International Space Station (ISS). The goal of the FBCE is to serve as a facility for flow boiling and condensation investigating two-phase flow and heat transfer data in microgravity. The TL module aims use existing FBCE hardware to study cryogenic chilldown, a large component of cryogenic propellant tank transfer research. The TL test module will perform chilldown studies with normal-perfluorohexane (nPFH), a cryogenic simulant, flowing through a super-heated line, which is heated through the process of Joule-heating. SolidWorks and Creo were used to create electrically conductive pipe junctions that connect and seal several Indium Tin Oxide (ITO) coated sapphire tube sections together to allow for low leak probability fluid flow and circumferentially uniform electrical current density. It is necessary to understand and calculate the thermal expansion of the tubing sections such that the junctions would not leak at anticipated operating temperatures and pressures, would maintain electrical contact, and not crack the crystalline tubes. Optical imaging techniques were used to build an experimentally validated image remapping process for flight-like setups of cylindrical tubes. Then MATLAB was used to create an algorithm that distorts an image based on the refraction of light passing through the mediums we were imaging through to accurately visualize the cryogenic chilldown that is of scientific interest. This research will assist NASA to move forward with long-duration spaceflight missions where knowledge of efficient heat transfer processes becomes more critical.

imaging system↗

NASA NTRSDate not supplied

Experimental Studies on the Effect of Inlet Liquid Subcooling on the Chilldown Characteristics of Stainless Steel Tubes

Understanding transfer line chilldown process under microgravity is important for the efficient transfer of cryogenic propellants in space fuel depots to facilitate future long duration space missions. The present work is part of the ongoing efforts to develop and test a two-phase flow chilldown test section to study the complete chilldown process under sustained microgravity conditions onboard the International Space Station. In this study, ground-based chilldown experiments are carried out on a 60 cm long SS-316 test section with PF-5060 as the working fluid. The complete chilldown curve was obtained including the film, transition and nucleate boiling regimes along with the temperature transition points. The effect of inlet liquid subcooling on the behavior of the chilldown curves are presented. Further, the chilldown and heat flux curves are analyzed to obtain re-wetting/Leidenfrost and onset of nucleate boiling temperature transition points as well as the critical heat flux values. The effect of inlet liquid subcooling on regime-specific heat flux and heat transfer coefficients are also examined.

CFD↗

NASA NTRSDate not supplied

The ZBOT-NC Experiment - Effects of Non-Condensable Gases on Propellant Tank Pressurization and Pressure Control

Introduction Integral to all phases of NASA’s projected planetary expeditions is affordable and reliable cryogenic fluid storage for use in propellant or life support systems. It is greatly advantageous to develop innovative vent-less pressure control designs based on cooling/mixing of the bulk tank fluid to allow storage of the cryogenic fluid with zero or reduced boil-off. The presence of noncondensable gases, can interfere with the condensation at the interface impacting tank pressure control during subcooled jet mixing especially in microgravity. The Zero-Boil-Off Tank (ZBOT) Experiments are a series of small-scale experiments aboard the International Space Station (ISS) that use a transparent volatile simulant fluid in a transparent sealed tank to delineate various fundamental fluid flow, heat and mass transport, and phase change phenomena associated with storage tank pressurization and pressure control in microgravity. The ZBOT-1 experiment was performed on the ISS 2017-2018 timeframe and collected data to validate a state-of-the-art CFD model for tank pressurization and pressure control for a pure system. The ZBOT-NC Experiment is the second experiment in the series to be performed on the International Space Station (ISS) in 2025. Its goal is to investigate the effects of noncondensable gases on interfacial evaporation and condensation during self -pressurization and jet-mixing pressure control in microgravity for a two-component system. Materials & Methods In this work, we will describe the detailed features of the ZBOT-NC experimental hardware and Diagnostics that includes nonintrusive Quantum Dot Thermometry (QDT) for whole field temperature measurement. All microgravity pressurization and pressure control tests will be performed for both the pure and the two-components systems with Xenon and Neon as the two noncondensable gases spanning small and large molecular weights and sizes. The two-phase CFD model that is developed as part of the project will be also presented and discussed. Results Ground-based pressurization and jet mixing experiments and CFD simulation results are compared to each other to validate both the fidelity of the CFD model predictions and the accuracy of the QDT measurement. Model simulations for noncondensable gas effects will also be compared against large Cryogenic LH2-GHe experiments to indicate the noncondensable gas effects on tank pressure control during jet mixing in 1G. Finally, CFD results will be presented to predict the effects of the noncondensable gas during subcooled jet mixing during the ZBOT-NC in advance of the microgravity experiment in 2015.

Evaporation Condensation↗

NASA NTRSDate not supplied

Validation and Development of a Fast-Running CFD Model for the No-Vent Fill of Liquid Propellant Tank

Cryogenic fluids, while offering higher energy density than storable propellants, present several handling challenges, including gradual boil-off and tank self-pressurization. Transferring these propellants between tanks can be problematic, as the receiving tank's temperature and pressure often lead to flashing and rapid boil-off upon injection. The No-Vent Fill (NVF) technique mitigates these risks by preventing liquid fuel from being expelled overboard. By controlling tank pressure and ensuring appropriate condensation in the ullage region, the NVF process avoids exceeding vent pressure limits. In this study, Loci/STREAM-VOF simulations were compared with data from NASA K-site test runs on a 2.1 cubic meter tank with a bottom orifice under various no-vent fill conditions, including different wall temperatures, flow rates, and inlet liquid temperatures. The effort demonstrated that Loci/STREAM-VOF is capable of quantitatively capturing the important physics of NVF with submerged jets: (1) validation of the liquid-vapor interface turbulence velocity using previous experimental data showed good agreement at different fill levels; (2) validation of the CFD Stanton number for mass transfer provided an adequate mass transfer coefficient range; (3) consistent pressure agreements were found in the pressure history for both cold and warm conditions; and (4) the variations of final pressure with flow rate and inlet liquid temperature were well predicted by the CFD simulation. The application of NVF for low-gravity conditions will be studied in future work.

CFD↗

NASA NTRSDate not supplied

Validation and Development of a Fast-Running CFD Model for the No-Vent Fill of Liquid Propellant Tank

CFD↗