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The demonstration of a unique liquid hydrogen (LH2) storage and feed system concept for solar thermal upper stage was cooperatively accomplished by a Boeing/NASA Marshall Space Flight Center team. The strategy was to balance thermodynamic venting with the engine thrusting timeline during a representative 30-day mission, thereby, assuring no vent losses. Using a 2 cubic m (71 cubic ft) LH2 tank, proof-of-concept testing consisted of an engineering checkout followed by a 30-day mission simulation. The data were used to anchor a combination of standard analyses and computational fluid dynamics (CFD) modeling. Dependence on orbital testing has been incrementally reduced as CFD codes, combined with standard modeling, continue to be challenged with test data such as this.

A computational fluid dynamics (CFD) model is developed to simulate pressure control of an ellipsoidal-shaped liquid hydrogen tank under external heating in low gravity. Pressure control is provided by an axial jet thermodynamic vent system (TVS) centered within the vessel that injects cooler liquid into the tank, mixing the contents and reducing tank pressure. The two-phase cryogenic tank model considers liquid hydrogen in its own vapor with liquid density varying with temperature only and a fully compressible ullage. The axisymmetric model is developed using a custom version of the commercially available FLOW-3D software and simulates low gravity extrapolations of engineering checkout tests performed at Marshall Space Flight Center in 1999 in support of the Solar Thermal Upper Stage Technology Demonstrator (STUSTD) program. Model results illustrate that stable low gravity liquid-gas interfaces are maintained during all phases of the pressure control cycle. Steady and relatively smooth ullage pressurization rates are predicted. This work advances current low gravity CFD modeling capabilities for cryogenic pressure control and aids the development of a low cost CFD-based design process for space hardware.

A computational fluid dynamics (CFD) model is developed to simulate pressure control of an ellipsoidal-shaped liquid hydrogen tank under external heating in normal gravity. Pressure control is provided by an axial jet thermodynamic vent system (TVS) centered within the vessel that injects cooler liquid into the tank, mixing the contents and reducing tank pressure. The two-phase cryogenic tank model considers liquid hydrogen in its own vapor with liquid density varying with temperature only and a fully compressible ullage. The axisymmetric model is developed using a custom version of the commercially available FLOW-31) software. Quantitative model validation is ,provided by engineering checkout tests performed at Marshall Space Flight Center in 1999 in support of the Solar Thermal Upper Stage_ Technology Demonstrator (STUSTD) program. The engineering checkout tests provide cryogenic tank self-pressurization test data at various heat leaks and tank fill levels. The predicted self-pressurization rates, ullage and liquid temperatures at discrete locations within the STUSTD tank are in good agreement with test data. The work presented here advances current CFD modeling capabilities for cryogenic pressure control and helps develop a low cost CFD-based design process for space hardware.

A computational fluid dynamics (CFD) model is developed for the Saturn S-IVB liquid hydrogen (LH2) tank to simulate the 1966 AS-203 flight experiment. This significant experiment is the only known, adequately-instrumented, low-gravity, cryogenic self pressurization test that is well suited for CFD model validation. A 4000-cell, axisymmetric model predicts motion of the LH2 surface including boil-off and thermal stratification in the liquid and gas phases. The model is based on a modified version of the commercially available FLOW3D software. During the experiment, heat enters the LH2 tank through the tank forward dome, side wall, aft dome, and common bulkhead. In both model and test the liquid and gases thermally stratify in the low-gravity natural convection environment. LH2 boils at the free surface which in turn increases the pressure within the tank during the 5360 second experiment. The Saturn S-IVB tank model is shown to accurately simulate the self pressurization and thermal stratification in the 1966 AS-203 test. The average predicted pressurization rate is within 4% of the pressure rise rate suggested by test data. Ullage temperature results are also in good agreement with the test where the model predicts an ullage temperature rise rate within 6% of the measured data. The model is based on first principles only and includes no adjustments to bring the predictions closer to the test data. Although quantitative model validation is achieved or one specific case, a significant step is taken towards demonstrating general use of CFD for low-gravity cryogenic fluid modeling.

A liquid propellant management device for placement in a liquid storage tank adjacent an outlet of the storage tank to substantially reduce or eliminate the formation of a dip and vortex in the liquid of the tank, as well as prevent vapor ingestion into the outlet, as the liquid drains out through the outlet. The liquid propellant management device has a first member adapted to suppress the formation of a vortex of a liquid exiting the storage tank. A plate is affixed generally perpendicular to the first member, wherein the plate is adapted to suppress vapor ingestion into the outlet by reducing a dip in a surface level of the liquid leaving the tank. A second member is affixed to the second side of the plate. The second member ensures that the plate is wet with liquid and assists in positioning bubbles away from the outlet.

The low gravity liquid level sensor rake measures the liquid surface height of propellant in a propellant tank used in launch and spacecraft vehicles. The device reduces the tendency of the liquid propellant to adhere to the sensor elements after the bulk liquid level has dropped below a given sensor element thereby reducing the probability of a false liquid level measurement. The liquid level sensor rake has a mast attached internal to a propellant tank with an end attached adjacent the tank outlet. Multiple sensor elements that have an arm and a sensor attached at a free end thereof are attached to the mast at locations selected for sensing the presence or absence of the liquid. The sensor elements when attached to the mast have a generally horizontal arm and a generally vertical sensor.

Flame spread over thin paper samples in low-speed concurrent flow is experimentally investigated in a 5.18 s drop tower. In the experiment, the oxygen molar percentage is varied from 30% down to the flame extinction limits and the forced flow velocity from 5.29 cm/s down to the quenching limits. Motion pictures are taken to observe flame shape, color, size, and spread rates. These quantities are compared with a theoretical model describing concurrent flame spread over thin solids in low-speed flows. The paper also discusses the similarity and difference between concurrent-flow and opposed-flow flame spread in microgravity and between low-speed and high-speed concurrent-flow flame spread. Finally the limitations of using a drop tower for flame spread research is assessed.

In reduced gravity, the combustion of solid fuel in low-speed flow can be studied. The flame behavior in this low-speed regime will fill a void in our understanding of the flow effect on combustion. In addition, it is important for spacecraft fire safety considerations. In this work, modeling and experimental work on low-speed forced-concurrent-flow flame spread are carried out. In addition, experiments on reduced-gravity buoyant-flow flame spread are performed.