Issues of Long-Term Cryogenic Propellant Storage in Microgravity

Modern multi-layer insulation (MLI) allows to sharply reduce the heat leak into cryogenic propellant storage tanks through the tank surface and, as a consequence, significantly extend the storage duration. In this situation the MLI penetrations, such as support struts, feed lines, etc., become one of the most significant challenges of the tanks heat management. This problem is especially acute for liquid hydrogen (LH2) storage, since currently no efficient cryocoolers exist that operate at very low LH2 temperatures (20K). Even small heat leaks under microgravity conditions and over the period of many months give rise to a complex slowly-developing, large-scale spatiotemporal physical phenomena in a multi-phase liquid-vapor mixture. These phenomena are not well-understood nor can be easily controlled. They can be of a potentially hazardous nature for long-term on-orbital cryogenic torage, propellant loading, tank chilldown, engine restart, and other in-space cryogenic fluid management operations. To support the engineering design solutions that would mitigate these effects a detailed physics-based analysis of heat transfer, vapor bubble formation, growth, motion, coalescence and collapse is required in the presence of stirring jets of different configurations and passive cooling devices such as MLI, thermodynamic vent system, and vapor-cooled shield. To develop physics-based models and correlations reliable for microgravity conditions and long-time scales there is a need for new fundamental data to be collected from on-orbit cryogenic storage experiments. Our report discusses some of these physical phenomena and the design requirements and future studies necessary for their mitigation. Special attention is payed to the phenomena occurring near MLI penetrations

Risk Assessment and Scaling for the SLS LH2 ET

In this report the main physics processes in LH2 tank during prepress and rocket flight are studied. The goal of this investigation is to analyze possible hazards and to make risk assessment in proposed LH2 tank designs for SLS with 5 engines (the situation with 4 engines is less critical). For analysis we use the multinode model (MNM) developed by us and presented in a separate report and also 3D ANSYS simulations. We carry out simulation and theoretical analysis the physics processes such as (i) accumulation of bubbles in LH2 during replenish stage and their collapsing in the liquid during the prepress; (ii) condensation-evaporation at the liquid-vapor interface and tank wall, (iv) heating the liquid near the interface and wall due to condensation and environment heat, (v) injection of hot He during prepress and of hot GH2 during flight, (vi) mixing and cooling of the injected gases due to heat transfer between the gases, liquid and the tank wall. We analyze the effects of these physical processes on the thermo- and fluid gas dynamics in the ullage and on the stratification of temperature in the liquid and assess the associated hazards. A special emphasize is put on the scaling predictions for the larger SLS LH2 tank

Chemical Kinetics of the TPS and Base Bleeding During Flight Test

The present research deals with thermal degradation of polyurethane foam (PUF) during flight test. Model of thermal decomposition was developed that accounts for polyurethane kinetics parameters extracted from thermogravimetric analyses and radial heat losses to the surrounding environment. The model predicts mass loss of foam, the temperature and kinetic of release of the exhaust gases and char as function of heat and radiation loads. When PUF is heated, urethane bond break into polyol and isocyanate. In the first stage, isocyanate pyrolyses and oxidizes. As a result, the thermo-char and oil droplets (yellow smoke) are released. In the second decomposition stage, pyrolysis and oxidization of liquid polyol occur. Next, the kinetics of chemical compound release and the information about the reactions occurring in the base area are coupled to the CFD simulations of the base flow in a single first stage motor vertically stacked vehicle configuration. The CFD simulations are performed to estimate the contribution of the hot out-gassing, chemical reactions, and char oxidation to the temperature rise of the base flow. The results of simulations are compared with the flight test data

Physics-Based Methods of Failure Analysis and Diagnostics in Human Space Flight

The Integrated Health Management (IHM) for the future aerospace systems requires to interface models of multiple subsystems in an efficient and accurate information environment at the earlier stages of system design. The complexity of modern aeronautic and aircraft systems (including e.g. the power distribution, flight control, solid and liquid motors) dictates employment of hybrid models and high-level reasoners for analysing mixed continuous and discrete information flow involving multiple modes of operation in uncertain environments, unknown state variables, heterogeneous software and hardware components. To provide the information link between key design/performance parameters and high-level reasoners we rely on development of multi-physics performance models, distributed sensors networks, and fault diagnostic and prognostic (FD&P) technologies in close collaboration with system designers. The main challenges of our research are related to the in-flight assessment of the structural stability, engine performance, and trajectory control. The main goal is to develop an intelligent IHM that not only enhances components and system reliability, but also provides a post-flight feedback helping to optimize design of the next generation of aerospace systems. Our efforts are concentrated on several directions of the research. One of the key components of our strategy is an innovative approach to the diagnostics/prognostics based on the real time dynamical inference (DI) technologies extended to encompass hybrid systems with hidden state trajectories. The major investments are into the multiphysics performance modelling that provides an access of the FD&P technologies to the main performance parameters of e.g. solid and liquid rocket motors and composite materials of the nozzle and case. Some of the recent results of our research are discussed in this chapter. We begin by introducing the problem of dynamical inference of stochastic nonlinear models and reviewing earlier results. Next, we present our analytical approach to the solution of this problem based on the path integral formulation. The resulting algorithm does not require an extensive global search for the model parameters, provides optimal compensation for the effects of dynamical noise, and is robust for a broad range of dynamical models. In the following Section the strengths of the algorithm are illustrated illustrated by inferring the parameters of the stochastic Lorenz system and comparing the results with those of earlier research. Next, we discuss a number of recent results in application to the development of the IHM for aerospace system. Firstly, we apply dynamical inference approach to a solution of classical three tank problems with mixed unknown continuous and binary parameters. The problem is considered in the context of ground support system for filling fuel tanks of liquid rocket motors. It is shown that the DI algorithm is well suited for successful solution of a hybrid version of this benchmark problem even in the presence of additional periodic and stochastic perturbation of unknown strength. Secondly, we illustrate our approach by its application to an analysis of the nozzle fault in a solid rocket motor (SRM). The internal ballistics of the SRM is modelled as a set of one-dimensional partial differential equations coupled to the dynamics of the propellant regression. In this example we are specifically focussed on the inference of discrete and continuous parameters of the nozzle blocking fault and on the possibility of an application of the DI algorithm to reducing the probability of "misses" of an on-board FD&P for SRM. In the next section re-contact problem caused by first stage/upper stage separation failure is discussed. The reaction forces imposed on the nozzle of the upper stage during the re-contact and their connection to the nozzle damage and to the thrust vector control (TVC) signal are obtained. It is shown that transient impact induced torquean be modelled as a response of an effective damped oscillator. A possible application of the DI algorithm to the inference of damage parameters and predicting fault dynamics ahead of time using the actuator signal is discussed. Finally, we formulate Bayesian inferential framework for development of the IHM system for in-flight structural health monitoring (SHM) of composite materials. We consider the signal generated by piezoelectric actuator mounted on composite structure generating elastic waves in it. The signal received by the sensor is than compared with the baseline signal. The possibility of damage inference is discussed in the context of development of the SHM

Case breach fault model and diagnostic for the solid rocket

A model of the case breach fault for solid rocket boosters (SRBs) that takes into account burning-through hole in propellant, insulator and metal layers of a rocket case is developed. Melting of the metal layer and an ablation of the insulator layer in the presence of hot gas flow through the hole are analyzed in detail. Dynamics of the lateral (side) thrust produced by the growing hole is calculated for typical parameters of the SRB. A problem of inference of the fault parameters from the measurements of the nominal values of stagnation pressure and thrust is formulated and solved in quasi-steady approximation. An application of the recently developed Bayesian framework for diagnostics and prognostics of the case breach fault that can cause loss of flight control is discussed

Explosion Hazard from a Propellant-Tank Breach in Liquid Hydrogen-Oxygen Rockets

An engineering risk assessment of the conditions for massive explosions of cryogenic liquid hydrogen-oxygen rockets during launch accidents is presented. The assessment is based on the analysis of the data of purposeful rupture experiments with liquid oxygen and hydrogen tanks and on an interpretation of these data via analytical semiquantitative estimates and numerical simulations of simplified models for the whole range of the physical phenomena governing the outcome of a propellant-tank breach. The following sequence of events is reconstructed: rupture of fuel tanks, escape of the fluids from the ruptured tanks, liquid film boiling, fragmentation of liquid flow, formation of aerosol oxygen and hydrogen clouds, mixing of the clouds, droplet evaporation, self-ignition of the aerosol clouds, and aerosol combustion. The power of the explosion is determined by a small fraction of the escaped cryogens that become well mixed within the aerosol cloud during the delay time between rupture and ignition. Several scenarios of cavitation-induced self-ignition of the cryogenic hydrogen/oxygen mixture are discussed. The explosion parameters in a particular accident are expected to be highly varied and unpredictable due to randomness of the processes of formation, mixing, and ignition of oxygen and hydrogen clouds. Under certain conditions rocket accidents may result in very strong explosions with blast pressures from a few atm up to 100 atm. The most dangerous situations and the foreseeable risks for space missions are uncovered