Below Ambient and Cryogenic Thermal Testing

Methods and apparatus for the testing of below-ambient temperature thermal insulation systems have been developed based on boiloff calorimetry. Boiloff calorimetry provides a direct measure of heat flow for below-ambient temperature conditions. The effective thermal conductivity (ke) and heat flux (q) of a test specimen are calculated for a fixed environmental condition (warm boundary temperature; cold boundary temperature; ambient or vacuum pressure). Through its heat of vaporization, liquid nitrogen (LN2) serves as the energy meter. Different apparatus have been built for flat-plate, cylindrical, and pipeline test specimens. Boundary temperatures can range from 353 K down to 77 K (80 C to -196 C). By interposing different insulation layers on the cold boundary, the cryogenic boiloff method is suitable for a wide range of below-ambient temperature applications. A cylindrical apparatus, Cryostat-100, as well as the pipeline test apparatus, Cryostat-P100, are thermally guarded and directly measure absolute thermal performance in watts. Pipe insulation systems can be mechanical, double-walled, or vacuum-jacketed including materials such as foams, cellular glass, aerogel blankets, clam-shell panels, and multilayer insulation. Two test pipelines, 12-meter-long, are mounted between two cold box assemblies. The test pipeline diameter is from 25-mm to 76-mm while the maximum outside diameter including insulation is up to 204-mm. The cold pipe tester design and test methods are discussed, as well as results for select thermal insulation materials. Progress toward a comparative type, bench-top cold pipe tester (Cryostat-P200) is also discussed

Aerogel-Based Insulation Materials for Cryogenic Applications

Many different aerogel-based materials are now being used in thermal insulation systems for cryogenic applications. These materials include flexible composite blankets, bulk-fill particles, and polymer composites in both evacuated and non-evacuated environments. In ambient environments, aerogels provide superior thermal performance compared to conventional polymeric foam and cellular glass insulations while offering unique advantages in avoiding problems with weathering, moisture, and mechanical damage. Aerogels are also used as spacer materials in multilayer insulation systems. These layered systems provide combined structural-thermal capability for cryogenic systems in either vacuum-jacketed or externally-applied insulation designs. Test data (effective thermal conductivity) include a wide range of both commercial and experimental aerogel materials. Testing was performed using laboratory cryostats and standard methods including full range vacuum (from ambient pressure to high vacuum) and boundary temperatures 293 K and 78 K. Examples of aerogel-based insulation systems are given for both evacuated and non-evacuated applications

Thermal insulation testing method and apparatus

A test apparatus and method of its use for evaluating various performance aspects of a test specimen is disclosed. A chamber within a housing contains a cold mass tank with a contact surface in contact with a first surface of a test specimen. The first surface of the test specimen is spaced from the second surface of the test specimen by a thickness. The second surface of the test specimen is maintained at a desired warm temperature. The first surface is maintained at a constant temperature by a liquid disposed within the cold mass tank. A boil-off flow rate of the gas is monitored and provided to a processor along with the temperature of the first and second surfaces of the test specimen. The processor calculates thermal insulation values of the test specimen including comparative values for heat flux and apparent thermal conductivity (k-value). The test specimen may be placed in any vacuum pressure level ranging from about 0.01 millitorr to 1,000,000 millitorr with different residual gases as desired. The test specimen may be placed under a mechanical load with the cold mass tank and another factors may be imposed upon the test specimen so as to simulate the actual use conditions

THERMAL INSULATION SYSTEMS

Thermal insulation systems and with methods of their production. The thermal insulation systems incorporate at least one reflection layer and at least one spacer layer in an alternating pattern. Each spacer layer includes a fill layer and a carrier layer. The fill layer may be separate from the carrier layer, or it may be a part of the carrier layer, i.e., mechanically injected into the carrier layer or chemically formed in the carrier layer. Fill layers contain a powder having a high surface area and low bulk density. Movement of powder within a fill layer is restricted by electrostatic effects with the reflection layer combined with the presence of a carrier layer, or by containing the powder in the carrier layer. The powder in the spacer layer may be compressed from its bulk density. The thermal insulation systems may further contain an outer casing. Thermal insulation systems may further include strips and seams to form a matrix of sections. Such sections serve to limit loss of powder from a fill layer to a single section and reduce heat losses along the reflection layer

Thermal Performance of Low Layer Density Multilayer Insu1ation Using Liquid Nitrogen

In order to support long duration cryogenic propellant storage, the Cryogenic Fluid Management (CFM) Project of the Exploration Technology Development Program (ETDP) is investigating the long duration storage propertie$ of liquid methane on the lunar surface. The Methane Lunar Surface Thermal Control (MLSTC) testing is using a tank of the approximate dimensions of the Altair ascent tanks inside of a vacuum chamber to simulate the environment in low earth orbit and on the lunar surface. The thermal performance testing of multilayer insulation (MLI) coupons that are fabricated identically to the tank applied insulation is necessary to understand the performance of the blankets and to be able to predict the performance of the insulation prior to testing. This coupon testing was completed in Cryostat-100 at the Cryogenics Test Laboratory. The results showed the properties of the insulation as a function of layer density, number of layers, and warm boundary temperature. These results aid in the understanding of the performance parameters o fMLI and help to complete the body of literature on the topic

Apparatus for Testing Flat Specimens of Thermal Insulation

An apparatus has been developed to implement an improved method of testing flat-plate specimens of thermal-insulation materials for cryogenic application. The method includes testing under realistic use conditions that could include vacuum and mechanical loading at a pressure up to 70 psi (=0.48 MPa). The apparatus can accommodate a rigid or flexible specimen having thickness up to 1.25 in. (=3.2 cm) and diameters between 6 and 10 in. (about 15.2 and 25.4 cm, respectively). Typical test conditions include boundary temperatures between 77 K and 373 K and vacuum/interstitial gas filling at a pressure between 10(exp -6) torr (=1.3 x 10(exp -4) Pa) and 760 torr (atmospheric pressure =0.1 MPa). The interstitial gas could be N2, He, CO2, or any other suitable gas to which the insulation is expected to be exposed in use. Relative to prior apparatuses and testing methods, this apparatus and the testing method that it implements offer advantages of relative simplicity and ease of use. The basic principle of operation of the apparatus is that of boil-off calorimetry, using liquid nitrogen or any other suitable liquid that boils at a desired temperature below ambient temperature. Comparative rates of flow of heat through the thicknesses of the specimens (heat-leak rates) and apparent-thermal-conductivity values are obtained from tests of specimens. Absolute values of heat-leak rates and apparent thermal conductivities are computed from a combination of (1) the aforementioned comparative values and (2) calibration factors obtained by testing reference specimens of materials that have known thermal-insulation properties. The apparatus includes a full complement of temperature sensors, a vacuum pump and chamber, a monitoring and control system, and tools and fixtures that enable rapid and reliable installation and removal of specimens. A specimen is installed at the bottom of the vacuum chamber, and a cold-mass assembly that includes a tank is lowered into position above and around the specimen (see figure). A spring-based compensating fixture helps to ensure adequate thermal contact with possibly irregular specimen surfaces. For a high-compression test, the springs can be replaced with spacers. A flat circular load cell at the bottom of the chamber measures the compressive load on the specimen. Once the desired compressive-load, temperature, and vacuum/gas-filling conditions are established, testing begins. During a test, all measurements are recorded by use of a portable data-acquisition system and a computer. The total heat-leak rate is measured and calculated as the boil-off flow rate multiplied by the latent heat of vaporization. The parasitic heat leak (to the side of the specimen and to the top and side of the cold-mass tank) is reduced to a small fraction of the total heat leak by use of a combination of multilayer-insulation (MLI) shield rings, reflective film, a fiberglass/epoxy centering ring, and a bulk fill of aerogel beads. This combination eliminates the need for a cryogenic guard chamber used in a typical prior apparatus to reduce the parasitic heat leak

Improved Thermal-Insulation Systems for Low Temperatures

Improved thermal-insulation materials and structures and the techniques for manufacturing them are undergoing development for use in low-temperature applications. Examples of low-temperature equipment for which these thermal insulation systems could provide improved energy efficiency include storage tanks for cryogens, superconducting electric-power-transmission equipment, containers for transport of food and other perishable commodities, and cold boxes for low-temperature industrial processes. These systems could also be used to insulate piping used to transfer cryogens and other fluids, such as liquefied natural gas, refrigerants, chilled water, crude oil, or low-pressure steam. The present thermal-insulation systems are layer composites based partly on the older class of thermal-insulation systems denoted generally as multilayer insulation (MLI). A typical MLI structure includes an evacuated jacket, within which many layers of radiation shields are stacked or wrapped close together. Low-thermal-conductivity spacers are typically placed between the reflection layers to keep them from touching. MLI can work very well when a high vacuum level (less than 10(exp-4) torr) is maintained and utmost care is taken during installation, but its thermal performance deteriorates sharply as the pressure in the evacuated space rises into the soft vacuum range [pressures greater than 0.1 torr (greater than 13 Pa)]. In addition, the thermal performance of MLI is extremely sensitive to mechanical compression and edge effects and can easily decrease from one to two orders of magnitude from its ideal value even when the MLI is kept under high vacuum condition. The present thermal-insulation systems are designed to perform well under soft vacuum level, in particular the range of 1 to 10 torr. They are also designed with larger interlayer spacings to reduce vulnerability to compression (and consequent heat leak) caused by installation and use. The superiority of these systems is the synergistic effect of improvements in materials, design, and manufacture

Energy Efficient Storage and Transfer of Cryogens

Cryogenics is globally linked to energy generation, storage, and usage. Thermal insulation systems research and development is an enabling part of NASA's technology goals for Space Launch and Exploration. New thermal testing methodologies and materials are being transferred to industry for a wide range of commercial applications

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

Guarded Flat Plate Cryogenic Test Apparatus and Calorimeter (C-600)

A test apparatus for thermal energy measurement of disk-shaped test specimens has a cold mass assembly locatable within a sealable chamber with a guard vessel having a guard chamber to receive a liquid fluid and a bottom surface to contact a cold side of a test specimen, and a test vessel having a test chamber to receive a liquid fluid and encompassed on one side by a center portion of the bottom surface shared with the guard vessel. A lateral wall assembly of the test vessel is closed by a vessel top, the lateral wall assembly comprising an outer wall and an inner wall having opposing surfaces that define a thermal break including a condensable vapor pocket to inhibit heat transfer through the lateral wall from the guard vessel to the test vessel. A warm boundary temperature surface is in thermal communication with a lower surface of the test specimen