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NASA NTRS2012

SKYLAB II - Making a Deep Space Habitat from a Space Launch System Propellant Tank

Called a "House in Space," Skylab was an innovative program that used a converted Saturn V launch vehicle propellant tank as a space station habitat. It was launched in 1973 fully equipped with provisions for three separate missions of three astronauts each. The size and lift capability of the Saturn V enabled a large diameter habitat, solar telescope, multiple docking adaptor, and airlock to be placed on-orbit with a single launch. Today, the envisioned Space Launch System (SLS) offers similar size and lift capabilities that are ideally suited for a Skylab type mission. An envisioned Skylab II mission would employ the same propellant tank concept; however serve a different mission. In this case, the SLS upper stage hydrogen tank is used as a Deep Space Habitat (DSH) for NASA s planned missions to asteroids, Earth-Moon Lagrangian point and Mars.

Griffin, Brand N.↗
NASA NTRS2012

Validation of Slosh Model Parameters and Anti-Slosh Baffle Designs of Propellant Tanks by Using Lateral Slosh Testing

The slosh dynamics of propellant tanks can be represented by an equivalent mass-pendulum-dashpot mechanical model. The parameters of this equivalent model, identified as slosh mechanical model parameters, are slosh frequency, slosh mass, and pendulum hinge point location. They can be obtained by both analysis and testing for discrete fill levels. Anti-slosh baffles are usually needed in propellant tanks to control the movement of the fluid inside the tank. Lateral slosh testing, involving both random excitation testing and free-decay testing, are performed to validate the slosh mechanical model parameters and the damping added to the fluid by the anti-slosh baffles. Traditional modal analysis procedures were used to extract the parameters from the experimental data. Test setup of sub-scale tanks will be described. A comparison between experimental results and analysis will be presented.

Perez, Jose G.↗
NASA NTRS2012

Development of Non-Optimum Factors for Launch Vehicle Propellant Tank Bulkhead Weight Estimation

Non-optimum factors are used during aerospace conceptual and preliminary design to account for the increased weights of as-built structures due to future manufacturing and design details. Use of higher-fidelity non-optimum factors in these early stages of vehicle design can result in more accurate predictions of a concept s actual weights and performance. To help achieve this objective, non-optimum factors are calculated for the aluminum-alloy gores that compose the ogive and ellipsoidal bulkheads of the Space Shuttle Super-Lightweight Tank propellant tanks. Minimum values for actual gore skin thicknesses and weld land dimensions are extracted from selected production drawings, and are used to predict reference gore weights. These actual skin thicknesses are also compared to skin thicknesses predicted using classical structural mechanics and tank proof-test pressures. Both coarse and refined weights models are developed for the gores. The coarse model is based on the proof pressure-sized skin thicknesses, and the refined model uses the actual gore skin thicknesses and design detail dimensions. To determine the gore non-optimum factors, these reference weights are then compared to flight hardware weights reported in a mass properties database. When manufacturing tolerance weight estimates are taken into account, the gore non-optimum factors computed using the coarse weights model range from 1.28 to 2.76, with an average non-optimum factor of 1.90. Application of the refined weights model yields non-optimum factors between 1.00 and 1.50, with an average non-optimum factor of 1.14. To demonstrate their use, these calculated non-optimum factors are used to predict heavier, more realistic gore weights for a proposed heavy-lift launch vehicle s propellant tank bulkheads. These results indicate that relatively simple models can be developed to better estimate the actual weights of large structures for future launch vehicles.

Wu, K. Chauncey↗
NASA NTRS2013

Atmospheric Processing Module for Mars Propellant Production

The multi-NASA center Mars Atmosphere and Regolith COllector/PrOcessor for Lander Operations (MARCO POLO) project was established to build and demonstrate a methane/oxygen propellant production system in a Mars analog environment. Work at the Kennedy Space Center (KSC) Applied Chemistry Laboratory is focused on the Atmospheric Processing Module (APM). The purpose of the APM is to freeze carbon dioxide from a simulated Martian atmosphere containing the minor components nitrogen, argon, carbon monoxide, and water vapor at Martian pressures (approx.8 torr) by using dual cryocoolers with alternating cycles of freezing and sublimation. The resulting pressurized CO2 is fed to a methanation subsystem where it is catalytically combined with hydrogen in a Sabatier reactor supplied by the Johnson Space Center (JSC) to make methane and water vapor. We first used a simplified once-through setup and later employed a HiCO2 recycling system to improve process efficiency. This presentation and paper will cover (1) the design and selection of major hardware items, such as the cryocoolers, pumps, tanks, chillers, and membrane separators, (2) the determination of the optimal cold head design and flow rates needed to meet the collection requirement of 88 g CO2/hr for 14 hr, (3) the testing of the CO2 freezer subsystem, and (4) the integration and testing of the two subsystems to verify the desired production rate of 31.7 g CH4/hr and 71.3 g H2O/hr along with verification of their purity. The resulting 2.22 kg of CH4/O2 propellant per 14 hr day (including O2 from electrolysis of water recovered from regolith, which also supplies the H2 for methanation) is of the scale needed for a Mars Sample Return mission. In addition, the significance of the project to NASA's new Mars exploration plans will be discussed.

Muscatello, Anthony↗
NASA NTRS2013

Performance Gains of Propellant Management Devices for Liquid Hydrogen Depots

This paper presents background, experimental design, and preliminary experimental results for the liquid hydrogen bubble point tests conducted at the Cryogenic Components Cell 7 facility at the NASA Glenn Research Center in Cleveland, Ohio. The purpose of the test series was to investigate the parameters that affect liquid acquisition device (LAD) performance in a liquid hydrogen (LH2) propellant tank, to mitigate risk in the final design of the LAD for the Cryogenic Propellant Storage and Transfer Technology Demonstration Mission, and to provide insight into optimal LAD operation for future LH2 depots. Preliminary test results show an increase in performance and screen retention over the low reference LH2 bubble point value for a 325 2300 screen in three separate ways, thus improving fundamental LH2 LAD performance. By using a finer mesh screen, operating at a colder liquid temperature, and pressurizing with a noncondensible pressurant gas, a significant increase in margin is achieved in bubble point pressure for LH2 screen channel LADs.

Hartwig, Jason W.↗
NASA NTRS2013

An Electric Propulsion "Shepherd" for Active Debris Removal that Utilizes Ambient Gas as Propellant

There is a growing consensus among the space debris technical community that limiting the long ]term growth of debris in Low-Earth Orbit (LEO) requires that space users limit the accumulation of mass in orbit. This is partially accomplished by mitigation measures for current and future LEO systems, but there is now interest in removing mass that has already accumulated in LEO from more than 50 years of space activity (termed "Active Debris Removal", or ADR). Many ADR proposals face complex technical issues of how to grapple with uncooperative targets. Some researchers have suggested the use of conventional ion thrusters to gently "blow" on objects to gradually change their orbits, without ever having to come into physical contact with the target. The chief drawback with these methods is the cost per object removed. Typically, a space "tug" or an ion-drive "shepherd" can only remove a few objects per mission due to limited propellant. Unless a costeffective way that removes tens of objects per mission can be found, it is not clear that any of the ideas so far proposed will be economically viable. In this paper, a modified version of the ion-drive "shepherd" is proposed that uses ambient atmospheric gases in LEO as propellant for the ion drives. This method has the potential to greatly extend the operational lifetime of an ADR mission, as the only mission limit is the lifetime of the components of the satellite itself, not on its fuel supply. An ambient-gas ion-drive "shepherd" would the local atmospheric drag on an object by ionizing and accelerating the ambient gas the target would have encountered anyway, thereby hastening its decay. Also, the "shepherd" satellite itself has a great deal of flexibility to maneuver back to high altitude and rendezvous with its next target using the ion drive not limited by fuel supply. However, the amount of available ambient gas is closely tied to the altitude of the spacecraft. It may be possible to use a "hybrid" approach that supplements high-altitude ion-drive operations with stored gas, and transitions to ambient gas at lower altitudes. This paper will include realistic numbers on the estimated times needed to deorbit objects from different orbit regimes using drives that either partially or completely take advantage of ambient gas. It will conclude with recommendations on whether this is a viable candidate for future ADR efforts.

Matney, Mark J.↗
NASA NTRS2013

High Energy, Low Temperature Gelled Bi-propellant Formulation Preparation Method

A method for preparing a gelled liquid propane (GLP) composition comprises the introduction of liquid propane into an evacuated mixing vessel containing a gellant and mixing the liquid propane with the gellant. A bi-propellant system comprising GLP is particularly well-suited for outer planet missions greater than 3 AU from the sun and also functions in earth and near earth environments. Additives such as powders of boron, carbon, lithium, and/or aluminum can be added improve performance or enhance hypergolicity. The gelling agent can be silicon dioxide, clay, carbon, or organic or inorganic polymers. The bi-propellant system may be, but need not be, hypergolic.

DiSalvo, Roberto↗
NASA NTRS2013

An Electric Propulsion "Shepherd" for Active Debris Removal that Utilizes Ambient Gas as Propellant

There is a growing consensus among the space debris technical community that limiting the long-term growth of debris in Low-Earth Orbit (LEO) requires that space users limit the accumulation of mass in orbit. This is partially accomplished by mitigation measures for current and future LEO systems, but there is now interest in removing mass that has already accumulated in LEO from more than 50 years of space activity (termed "Active Debris Removal", or ADR). Many ADR proposals face complex technical issues of how to grapple with uncooperative targets. Some researchers have suggested the use of conventional ion thrusters to gently "blow" on objects to gradually change their orbits, without ever having to come into physical contact with the target. The chief drawback with these methods is the cost per object removed. Typically, a space "tug" or an ion-drive "shepherd" can only remove a few objects per mission due to limited propellant. Unless a cost-effective way that removes tens of objects per mission can be found, it is not clear that any of the ideas so far proposed will be economically viable. In this paper, a modified version of the ion-drive "shepherd" is proposed that uses ambient atmospheric gases in LEO as propellant for the ion drives. This method has the potential to greatly extend the operational lifetime of an ADR mission, as the only mission limit is the lifetime of the components of the satellite itself, not on its fuel supply. An ambient-gas ion-drive "shepherd" would enhance the local atmospheric drag on an object by ionizing and accelerating the ambient gas the target would have encountered anyway, thereby hastening its decay. Also, the "shepherd" satellite itself has a great deal of flexibility to maneuver back to high altitude and rendezvous with its next target using the ion drive not limited by fuel supply. However, the amount of available ambient gas is closely tied to the altitude of the spacecraft. It may be possible to use a "hybrid" approach that supplements high-altitude ion-drive operations with stored gas, and transitions to ambient gas at lower altitudes. This paper will include realistic numbers on the estimated times needed to deorbit objects from different orbit regimes using drives that either partially or completely take advantage of ambient gas. It will conclude with recommendations on whether this is a viable candidate for future ADR efforts.

Matney, Mark↗
NASA NTRS2013

Atmospheric Processing Module for Mars Propellant Production

The multi-NASA center Mars Atmosphere and Regolith COllector/PrOcessor for Lander Operations (MARCO POLO) project was established to build and demonstrate a methane/oxygen propellant production system in a Mars analog environment. Work at the Kennedy Space Center (KSC) Applied Chemistry Laboratory is focused on the Atmospheric Processing Module (APM). The purpose of the APM is to freeze carbon dioxide from a simulated Martian atmosphere containing the minor components nitrogen, argon, carbon monoxide, and water vapor at Martian pressures (~8 torr) by using dual cryocoolers with alternating cycles of freezing and sublimation. The resulting pressurized CO2 is fed to a methanation subsystem where it is catalytically combined with hydrogen in a Sabatier reactor supplied by the Johnson Space Center (JSC) to make methane and water vapor. We first used a simplified once-through setup and later employed a HiCO2 recycling system to improve process efficiency. This presentation and paper will cover (1) the design and selection of major hardware items, such as the cryocoolers, pumps, tanks, chillers, and membrane separators, (2) the determination of the optimal cold head design and flow rates needed to meet the collection requirement of 88 g CO2/hr for 14 hr, (3) the testing of the CO2 freezer subsystem, and (4) the integration and testing of the two subsystems to verify the desired production rate of 31.7 g CH4/hr and 71.3 g H20/hr along with verification of their purity. The resulting 2.22 kg of CH4/O2 propellant per 14 hr day (including O2 from electrolysis of water recovered from regolith, which also supplies the H2 for methanation) is of the scale needed for a Mars Sample Return mission. In addition, the significance of the project to NASA's new Mars exploration plans will be discussed.

Muscatello, Anthony↗
NASA NTRS2013

Implementation of Sub-Cooling of Cryogenic Propellants by Injection of Non-condensing Gas to the Generalized Fluid Systems Simulation Program (GFSSP)

Cryogenic propellants are readily heated when used. This poses a problem for rocket engine efficiency and effective boot-strapping of the engine, as seen in the "hot" LOX (Liquid Oxygen) problem on the S-1 stage of the Saturn vehicle. In order to remedy this issue, cryogenic fluids were found to be sub-cooled by injection of a warm non-condensing gas. Experimental results show that the mechanism behind the sub-cooling is evaporative cooling. It has been shown that a sub-cooled temperature difference of approximately 13 deg F below saturation temperature [1]. The phenomenon of sub-cooling of cryogenic propellants by a non-condensing gas is not readily available with the General Fluid System Simulation Program (GFSSP) [2]. GFSSP is a thermal-fluid program used to analyze a wide variety of systems that are directly impacted by thermodynamics and fluid mechanics. In order to model this phenomenon, additional capabilities had to be added to GFSSP in the form of a FORTRAN coded sub-routine to calculate the temperature of the sub-cooled fluid. Once this was accomplished, the sub-routine was implemented to a GFSSP model that was created to replicate an experiment that was conducted to validate the GFSSP results.

Huggett, Daniel J.↗
NASA NTRS2014

Propellant Handler's Ensemble (PHE) Aka Self-Contained Atmospheric Protective Ensemble (SCAPE), Ventilator Improvement Study Project

The overall objective for this project is to evaluate two candidate alternatives for the existing Propellant Handler's Ensemble (PHE) escape ventilator. The new candidate ventilators use newer technology with similar quantities of air at approximately half the weight of the current ventilator. Ventilators are typically used to ingress/egress a hazardous work area when hard line air is provided at the work area but the hose is not long enough to get the operator to and from the staging area to the work area. The intent of this test is to verify that the new ventilators perform as well as or better than the current ventilators in maintaining proper oxygen (O2) and carbon dioxide (CO2) levels in the PHE during a typical use for the rated time period (~10 minutes). We will evaluate two new units comparing them to the existing unit. Subjects will wear the Category I version of the Propellant Handler's Ensemble with the rear suit pouch snapped.

PHE↗
NASA NTRS2014

Iodine Hall Thruster Propellant Feed System for a CubeSat

The components required for an in-space iodine vapor-fed Hall effect thruster propellant management system are described. A laboratory apparatus was assembled and used to produce iodine vapor and control the flow through the application of heating to the propellant reservoir and through the adjustment of the opening in a proportional flow control valve. Changing of the reservoir temperature altered the flowrate on the timescale of minutes while adjustment of the proportional flow control valve changed the flowrate immediately without an overshoot or undershoot in flowrate with the requisite recovery time associated with thermal control systems. The flowrates tested spanned a range from 0-1.5 mg/s of iodine, which is sufficient to feed a 200-W Hall effect thruster.

Polzin, Kurt A.↗
NASA NTRS2015

Lattice Boltzmann Method for Spacecraft Propellant Slosh Simulation

A scalable computational approach to the simulation of propellant tank sloshing dynamics in microgravity is presented. In this work, we use the lattice Boltzmann equation (LBE) to approximate the behavior of two-phase, single-component isothermal flows at very low Bond numbers. Through the use of a non-ideal gas equation of state and a modified multiple relaxation time (MRT) collision operator, the proposed method can simulate thermodynamically consistent phase transitions at temperatures and density ratios consistent with typical spacecraft cryogenic propellants, for example, liquid oxygen. Determination of the tank forces and moments is based upon a novel approach that relies on the global momentum conservation of the closed fluid domain, and a parametric wall wetting model allows tuning of the free surface contact angle. Development of the interface is implicit and no interface tracking approach is required. A numerical example illustrates the method's application to prediction of bulk fluid behavior during a spacecraft ullage settling maneuver.

Orr, Jeb S.↗
NASA NTRS1942

Preliminary Results of Flight Tests of a Conventional Three-Blade Propeller at High Speeds

As part of the program of flight tests of airplane propellers to determine compressibility effects at high speeds, preliminary flights have been made with a conventional three-blade propeller (Hamilton Standard 3155-6) on a Bell YP-39 airplane. This preliminary report presents the high-speed data obtained thus far with a brief analysis of the results.

Vogeley, A. W.↗
NASA NTRS2016

The Effects of Reducing the Structural Mass of the Transit Habitat on the Cryogenic Propellant Required for a Human Phobos Mission

A technique for rapidly determining the relationship between the pressurized volume, structural mass and the cryogenic propellant required to be delivered to Earth orbit for a Mars Transit Habitat is provided. This technique is based on assumptions for the required delta-V's, the Exploration Upper Stage performance and the historical structural masses for human spacecraft from Mercury Program through the International Space Station. If the Mars Transit Habitat is constructed from aluminum, structural mass estimates based on the habitat pressurized volume are accurate to within 15%. Other structural material options for the Mars Transit Habitat are also evaluated. The results show that small, achievable reductions in the structural mass of the Transit Habitat can save tens of thousands of pounds of cryogenic propellant that need to be delivered to Earth orbit for a human Phobos Mission.

Zipay, John Joseph↗
NASA NTRS2015

Computational Fluid Dynamics Based Extraction of Heat Transfer Coefficient in Cryogenic Propellant Tanks

Current reduced-order thermal model for cryogenic propellant tanks is based on correlations built for flat plates collected in the 1950's. The use of these correlations suffers from: inaccurate geometry representation; inaccurate gravity orientation; ambiguous length scale; and lack of detailed validation. The work presented under this task uses the first-principles based Computational Fluid Dynamics (CFD) technique to compute heat transfer from tank wall to the cryogenic fluids, and extracts and correlates the equivalent heat transfer coefficient to support reduced-order thermal model. The CFD tool was first validated against available experimental data and commonly used correlations for natural convection along a vertically heated wall. Good agreements between the present prediction and experimental data have been found for flows in laminar as well turbulent regimes. The convective heat transfer between tank wall and cryogenic propellant, and that between tank wall and ullage gas were then simulated. The results showed that commonly used heat transfer correlations for either vertical or horizontal plate over predict heat transfer rate for the cryogenic tank, in some cases by as much as one order of magnitude. A characteristic length scale has been defined that can correlate all heat transfer coefficients for different fill levels into a single curve. This curve can be used for the reduced-order heat transfer model analysis.

Yang, H. Q.↗
NASA NTRS2015

CFD Extraction of Heat Transfer Coefficient in Cryogenic Propellant Tanks

Current reduced-order thermal model for cryogenic propellant tanks is based on correlations built for flat plates collected in the 1950's. The use of these correlations suffers from inaccurate geometry representation; inaccurate gravity orientation; ambiguous length scale; and lack of detailed validation. This study uses first-principles based CFD methodology to compute heat transfer from the tank wall to the cryogenic fluids and extracts and correlates the equivalent heat transfer coefficient to support reduced-order thermal model. The CFD tool was first validated against available experimental data and commonly used correlations for natural convection along a vertically heated wall. Good agreements between the present prediction and experimental data have been found for flows in laminar as well turbulent regimes. The convective heat transfer between the tank wall and cryogenic propellant, and that between the tank wall and ullage gas were then simulated. The results showed that the commonly used heat transfer correlations for either vertical or horizontal plate over-predict heat transfer rate for the cryogenic tank, in some cases by as much as one order of magnitude. A characteristic length scale has been defined that can correlate all heat transfer coefficients for different fill levels into a single curve. This curve can be used for the reduced-order heat transfer model analysis.

Yang, H. Q.↗
NASA NTRS2015

Propellant Feed System for Swirl-Coaxial Injection

A propellant feed system for swirl-coaxial injection of a liquid propellant includes a reservoir having a bottom plate and at least one tube originating in the bottom plate and extending therefrom. The tube has rectangular slits defined in and distributed tangentially and evenly about a portion of the tube that is disposed in the bottom plate. Drain holes are provided in the bottom plate and tunnels are defined in the bottom plate. Each tunnel fluidly couples one of the drain holes to a corresponding one of the rectangular slits. Each tunnel includes (i) a bend of at least 90.degree., and (ii) a straight portion leading to its corresponding rectangular slit wherein the straight portion is at least five times as long as a hydraulic diameter of the corresponding rectangular slit.

Reynolds, David Christopher↗