Papers by James E Fesmire
NASA has completed a series of tests at the Kennedy Space Center to demonstrate the capability of... more NASA has completed a series of tests at the Kennedy Space Center to demonstrate the capability of using integrated refrigeration and storage (IRAS) to remove energy from a liquid hydrogen (LH2) tank and control the state of the propellant. A primary test objective was the keeping and storing of the liquid in a zero boil-off state, so that the total heat leak entering the tank is removed by a cryogenic refrigerator with an internal heat exchanger. The LH2 is therefore stored and kept with zero losses for an indefinite period of time. The LH2 tank is a horizontal cylindrical geometry with a vacuum-jacketed, multilayer insulation system and a capacity of 125,000 liters. The closed-loop helium refrigeration system was a Linde LR1620 capable of 390W cooling at 20K (without any liquid nitrogen pre-cooling). Three different control methods were used to obtain zero boil-off: temperature control of the helium refrigerant, refrigerator control using the tank pressure sensor, and duty cycling (on/off) of the refrigerator as needed. Summarized are the IRAS design approach, zero boil-off control methods, and results of the series of zero boil-off tests.
The heat transfer between room temperature and 80 K is controlled using various insulating materi... more The heat transfer between room temperature and 80 K is controlled using various insulating material combinations. The modes of heat transfer are well established to be conduction and thermal radiation when in a vacuum. Multi-Layer Insulation (MLI) in a vacuum has long been the best approach. Typically this layered system is applied to the cold surface. This paper investigates the application of MLI to both the cold and warm surface to see whether there is a significant difference. In addition if MLI is on the warm surface, the cold side of the MLI may be below the critical temperature of some high temperature superconducting (HTS) materials. It has been proposed that HTS materials can serve to block thermal radiation. An experiment is conducted to measure this effect. Boil-off calorimetry is the method of measuring the heat transfer.
The main penetrations (supports and piping) through multilayer insulation systems for cryogenic t... more The main penetrations (supports and piping) through multilayer insulation systems for cryogenic tanks have been previously addressed by heat flow measurements. Smaller penetrations due to fasteners and attachments are now experimentally investigated. The use of small pins or plastic garment tag fasteners to ease the handling and construction of multilayer insulation (MLI) blankets goes back many years. While it has long been understood that penetrations and other discontinuities degrade the performance of the MLI blanket, quantification of this degradation has generally been lumped into gross performance multipliers (often called degradation factors or scale factors). Small penetrations contribute both solid conduction and radiation heat transfer paths through the blanket. The conduction is down the stem of the structural element itself while the radiation is through the hole formed during installation of the pin or fastener. Analytical models were developed in conjunction with MLI perforation theory and Fourier's Law. Results of the analytical models are compared to experimental testing performed on a 10 layer MLI blanket with approximately 50 small plastic pins penetrating the test specimen. The pins were installed at ~76-mm spacing inches in both directions to minimize the compounding of thermal effects due to localized compression or lateral heat transfer. The testing was performed using a liquid nitrogen boil-off calorimeter (Cryostat-100) with the standard boundary temperatures of 293 K and 78 K. Results show that the added radiation through the holes is much more significant than the conduction down the fastener. The results are shown to be in agreement with radiation theory for perforated films.
Systematic review is given of development of novel heat switches at cryogenic temperatures that a... more Systematic review is given of development of novel heat switches at cryogenic temperatures that alternatively provide high thermal connection or ideal thermal isolation to the cold mass. These cryogenic heat switches are widely applied in a variety of unique superconducting systems and critical space applications. The following types of heat switch devices are discussed: 1) magnetic levitation suspension, 2) shape memory alloys, 3) differential thermal expansion, 4) helium or hydrogen gap-gap, 5) superconducting, 6) piezoelectric, 7) cryogenic diode, 8) magneto-resistive, and 9) mechanical demountable connections. Advantages and limitations of different cryogenic heat switches are examined along with the outlook for future thermal management solutions in materials and cryogenic designs.
Recent demonstration of advanced liquid hydrogen storage techniques using Integrated Refrigeratio... more Recent demonstration of advanced liquid hydrogen storage techniques using Integrated Refrigeration and Storage technology at NASA Kennedy Space Center led to the production of large quantities of densified liquid and slush hydrogen in a 125,000 L tank. Production of densified hydrogen was performed at three different liquid levels and LH2 temperatures were measured by twenty silicon diode temperature sensors. Overall densification performance of the system is explored, and solid mass fractions are calculated. Experimental data reveal hydrogen temperatures dropped well below the triple point during testing, and were continuing to trend downward prior to system shutdown. Sub-triple point temperatures were seen to evolve in a time dependent manner along the length of the horizontal, cylindrical vessel. The phenomenon, observed at two fill levels, is detailed herein. The implications of using IRAS for energy storage, propellant densification, and future cryofuel systems are discussed. 1. Introduction Fluid-based fuels and/or oxidizers are routinely stored on-board vehicles of various types in order to provide chemical potential for an engine. In the vast majority of these applications the fluids are stored in a liquid state due to the significantly larger stored energy capacity compared to the gaseous phase, and can be kept at much lower pressures, avoiding the need for heavy pressure vessels. In either case, the key point is that the fluid acts as an energy carrier, therefore, the denser the fluid the greater the energy stored in a given volume. This is especially important in applications where the transportation of energy in fluid form is the express purpose, such as in ocean-going and roadable tankers. The term " densification " refers to the process of thermodynamically manipulating a fluid with the intent of increasing its density above that of a typical reference value, thereby increasing its energy storage potential. Reference values usually correspond to atmospheric conditions (temperature, pressure, or both), and in the case of cryogenic propellants such as liquid hydrogen (LH2), liquid methane or liquefied natural gas (LNG), and liquid oxygen (LOX), the reference density is that realized at the normal boiling point (NBP); i.e. when the fluid is completely saturated at atmospheric pressure. Historically, the maximum attainable cryofuel density has corresponded to the NBP storage condition. This constraint has been an important driver for the design of any application that utilizes cryogenic propellants, most notably chemical combustion-powered launch vehicles, by effectively dictating the required tank volumes. Therefore, increasing the density of the propellants can have a substantial effect on the overall vehicle design and/or performance. This is especially true for rockets
Thermal conductivity of low-density materials in thermal insulation systems varies dramatically w... more Thermal conductivity of low-density materials in thermal insulation systems varies dramatically with the environment: cold vacuum pressure, residual gas composition, and boundary temperatures. Using a reference material of aerogel composite blanket (reinforcement fibers surrounded by silica aerogel), an experimental basis for the physical heat transmission model of aerogel composites and other low-density, porous materials is suggested. Cryogenic-vacuum testing between the boundary temperatures of 78 K and 293 K is performed using a one meter cylindrical, absolute heat flow calorimeter with an aerogel blanket specimen exposed to different gas environments of nitrogen, helium, argon, or CO2. Cold vacuum pressures include the full range from 1x10-5 torr to 760 torr. The soft vacuum region, from about 0.1 torr to 10 torr, is complex and difficult to model because all modes of heat transfer – solid conduction, radiation, gas conduction, and convection – are significant contributors to the total heat flow. Therefore, the soft vacuum tests are emphasized for both heat transfer analysis and practical thermal data. Results for the aerogel composite blanket are analyzed and compared to data for its component materials. With the new thermal conductivity data, future applications of aerogel-based insulation systems are also surveyed. These include Mars exploration and surface systems in the 5 torr CO2 environment, field joints for vacuum-jacketed cryogenic piping systems, common bulkhead panels for cryogenic tanks on space launch vehicles, and liquid hydrogen cryofuel systems with helium purged conduits or enclosures.
AIAA SPACE 2008 Conference & Exposition, 2008
AIP Conference Proceedings, 2003
An energy efficient, cost effective cryogenic distribution system (up to several miles) has been ... more An energy efficient, cost effective cryogenic distribution system (up to several miles) has been identified as important for spaceport and in-space cryogenic systems. The conduction heat loss from the supports that connect the lines cold mass to the warm support structure is ultimately the most serious heat leak after thermal radiation has been minimized. The use of magnetic levitation by permanent magnets and high temperature superconductors provides support without mechanical contact and thus, the conduction part of the heat leak can be reduced to zero. A stop structure is carefully designed to hold the center tube when the system is warm. The novel design will provide the potential of extending many missions by saving cryogens, or reducing the overall launch mass to accomplish a given mission.
Cryogenics, 2012
Spray-on foam insulation (SOFI) has been developed for use on the cryogenic tanks of space launch... more Spray-on foam insulation (SOFI) has been developed for use on the cryogenic tanks of space launch vehicles beginning in the 1960s with the Apollo program. The use of SOFI was further developed for the Space Shuttle program. The External Tank (ET) of the Space Shuttle, consisting of a forward liquid oxygen tank in line with an aft liquid hydrogen tank, requires thermal insulation over its outer surface to prevent ice formation and avoid in-flight damage to the ceramic tile thermal protection system on the adjacent Orbiter. The insulation also provides system control and stability throughout the lengthy process of cooldown, loading, and replenishing the tank. There are two main types of SOFI used on the ET: acreage (with the rind) and closeout (machined surface). The thermal performance of the seemingly simple SOFI system is a complex array of many variables starting with the large temperature difference of 200-260 K through the typical 25-mm thickness. Environmental factors include air temperature and humidity, wind speed, solar exposure, and aging or weathering history. Additional factors include manufacturing details, launch processing operations, and number of cryogenic thermal cycles. The study of the cryogenic thermal performance of SOFI under large temperature differentials is the subject of this article. The amount of moisture taken into the foam during the cold soak phase, termed Cryogenic Moisture Uptake, must also be considered. The heat leakage rates through these foams were measured under representative conditions using laboratory standard liquid nitrogen boiloff apparatus. Test articles included baseline, aged, and weathered specimens. Testing was performed over the entire pressure range from high vacuum to ambient pressure. Values for apparent thermal conductivity and heat flux were calculated and compared with prior data. As the prior data of record was obtained for small temperature differentials on non-weathered foams, analysis of the different methods is provided. Recent advancements and applications of SOFI systems on future launch vehicles and spacecraft are also addressed.
AIP Conference Proceedings, 2006
In a conventional vacuum-jacketed cryogen transfer line, the major heat transfer is dominated by ... more In a conventional vacuum-jacketed cryogen transfer line, the major heat transfer is dominated by two modes: i) radiation between the warm outer pipe and the cold inner pipe and ii) thermal conduction through support members and penetrations. Magnetic levitation makes it possible to eliminate the conduction portion by use of non-contact support, consisting of high temperature superconductor (HTS) and permanent
AIP Conference Proceedings, 2004
An energy efficient, cost effective cryogenic distribution system (up to several miles) is crucia... more An energy efficient, cost effective cryogenic distribution system (up to several miles) is crucial for spaceport and in-space cryogenic systems. The conduction heat loss from the supports that connect the cold inner lines to the warm support structure is ultimately the most serious heat leak after thermal radiation has been minimized. The use of magnetic levitation by permanent magnets and
IEEE Transactions on Appiled Superconductivity, 2005
An innovative six-meter long prototype of the magnetic levitation suspended cryogen transfer line... more An innovative six-meter long prototype of the magnetic levitation suspended cryogen transfer line has design, constructed and tested to demo potentials of extending many missions by saving cryogens, or reducing the overall launch mass to accomplish a given mission. The use of magnetic levitation by permanent magnets (PM) and high temperature superconductors (HTS) provides support without mechanical contact and thus,
Cryogenics, 2006
An energy efficient cryogenic transfer line with magnetic suspension has been prototyped and cryo... more An energy efficient cryogenic transfer line with magnetic suspension has been prototyped and cryogenically tested. The prototype transfer line exhibits cryogen saving potential of 30-35% in its suspension state as compared to its solid support state. Key technologies developed include novel magnetic levitation using multiple-pole high temperature superconductor (HTS) and rare earth permanent-magnet (PM) elements and a smart cryogenic actuator as the warm support structure. These technologies have vast applications in extremely low thermal leak cryogenic storage/delivery containers, superconducting magnetic bearings, smart thermal switches, etc. This paper reviews the development work and discusses future applications of established technologies.
Journal of Spacecraft and Rockets, 2012
AIP Conference Proceedings, 2002
Flexible, vacuum-insulated transfer lines for low-temperature applications have higher thermal lo... more Flexible, vacuum-insulated transfer lines for low-temperature applications have higher thermal losses than comparable rigid lines. Typical flexible piping construction uses corrugated tubes, inner and outer, with a multilayer insulation (MLI) system in the annular space. Experiments on vacuum insulation systems in a flexible geometry were conducted at the Cryogenics Test Laboratory of NASA Kennedy Space Center. The effects of bending were simulated by causing the inner tube to be eccentric with the outer tube. The effects of spacers were simulated in a controlled way by inserting spacer tubes for the length of the cylindrical test articles. Two material systems, standard MLI and a layered composite insulation (LCI), were tested under the full range of vacuum levels using a liquid nitrogen boiloff calorimeter to determine the apparent thermal conductivity (k-value). The results indicate that the flexible piping under simulated bending conditions significantly degrades the thermal performance of the insulation system. These data are compared to standard MLI for both straight and flexible piping configurations. The definition of an overall k-value for actual field installations (k oa fi) is described for use in design and analysis of cryogenic piping systems.
AIP Conference Proceedings, 2006
AIP Conference Proceedings, 2004
ABSTRACT
AIP Conference Proceedings, 2002
An investigation of the use of aerogel beads as thermal insulation for cryogenic applications was... more An investigation of the use of aerogel beads as thermal insulation for cryogenic applications was conducted at the Cryogenics Test Laboratory of NASA Kennedy Space Center. Steady-state liquid nitrogen boiloff methods were used to characterize the thermal performance of aerogel beads in comparison with conventional insulation products such as perlite powder and multilayer insulation (MLI). Aerogel beads produced by Cabot Corporation have a bulk density below 100 kilograms per cubic meter (kg/m 3 ) and a mean particle diameter of 1 millimeter (mm). The apparent thermal conductivity values of the bulk material have been determined under steady-state conditions at boundary temperatures of approximately 293 and 77 kelvin (K) and at various cold vacuum pressures (CVP). Vacuum levels ranged from 10' 5 torr to 760 torr. All test articles were made in a cylindrical configuration with a typical insulation thickness of 25 mm. Temperature profiles through the thickness of the test specimens were also measured. The results showed the performance of the aerogel beads was significantly better than the conventional materials in both soft-vacuum (1 to 10 torr) and no-vacuum (760 torr) ranges. Opacified aerogel beads performed better than perlite powder under high-vacuum conditions. Further studies for material optimization and system application are in progress.
AIP Conference Proceedings, 2006
ABSTRACT
AIP Conference Proceedings, 2004
ABSTRACT
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Papers by James E Fesmire