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In support of the U.S. Space Exploration Policy, focused cryogenic fluid management technology efforts are underway within the National Aeronautics and Space Administration. Under the auspices of the Exploration Technology Development Program, cryogenic fluid management technology efforts are being conducted by the Cryogenic Fluid Management Project. Cryogenic Fluid Management Project objectives are to develop storage, transfer, and handling technologies for cryogens to support high performance demands of lunar, and ultimately, Mars missions in the application areas of propulsion, surface systems, and Earth-based ground operations. The targeted use of cryogens and cryogenic technologies for these application areas is anticipated to significantly reduce propellant launch mass and required on-orbit margins, to reduce and even eliminate storage tank boil-off losses for long term missions, to economize ground pad storage and transfer operations, and to expand operational and architectural operations at destination. This paper organizes Cryogenic Fluid Management Project technology efforts according to Exploration Architecture target areas, and discusses the scope of trade studies, analytical modeling, and test efforts presently underway, as well as future plans, to address those target areas. The target areas are: liquid methane/liquid oxygen for propelling the Altair Lander Ascent Stage, liquid hydrogen/liquid oxygen for propelling the Altair Lander Descent Stage and Ares V Earth Departure Stage, liquefaction, zero boil-off, and propellant scavenging for Lunar Surface Systems, cold helium and zero boil-off technologies for Earth-Based Ground Operations, and architecture definition studies for long term storage and on-orbit transfer and pressurization of LH2, cryogenic Mars landing and ascent vehicles, and cryogenic production via in situ resource utilization on Mars.

A report discusses the development of a flexible thermal-insulation material for cryogenic tanks in next-generation spacecraft. This material is denoted Advanced Reusable All-temperature Multimode Insulation System (ARAMIS). The report begins by describing the need for ARAMIS and the technological challenges of developing a single material that is useable throughout the temperature range from storage of liquid hydrogen (20 K) to atmospheric-reentry heating (>2,000 K), has the requisite low thermal conductivity, resists condensation of moisture without need for a gas purge, and withstands reentry heating for a 400-mission lifetime. The report then discusses laboratory apparatuses for testing materials that have been and will be considered as candidates for the development of ARAMIS.

Recently, a great deal of attention has been focused on zero boil-off (ZBO) propellant storage as a means of minimizing the launch mass required for long-term exploration missions. A key component of ZBO systems is the cooler. Pulse tube coolers offer the advantage of zero moving mass at the cold head, and recent advances in lightweight, high efficiency cooler technology have paved the way for reliable liquid oxygen (LOx) temperature coolers to be developed which are suitable for flight ZBO systems. Liquid hydrogen (LH2) systems, however, are another matter. For ZBO liquid hydrogen systems, cooling powers of 1-5 watts are required at 20 K. The final development from tier for these coolers is to achieve high efficiency and reliability at lower operating temperatures. Most of the life-limiting issues of flight Stirling and pulse tube coolers are associated with contamination, drive mechanisms, and drive electronics. These problems are well in hand in the present generation coolers. The remaining efficiency and reliability issues reside with the low temperature regenerators. This paper will discuss advances to be made in regenerators for pulse tube LH2 ZBO coolers, present some historical background, and discuss recent progress in regenerator technology development using alloys of erbium.

Zero boil off (ZBO) cryogen storage using both cryocoolers and passive insulation technologies will enable long-term exploration missions by allowing designers to optimize tankage without the need for excess cryogen storage to account for boil off. Studies of ZBO (zero boil off) have been on-going in the USA for several years. More recently, a review of the needs of advanced space propulsion took place in Europe. This showed the interest of the European community in cryogenic propulsion for planetary missions as well as the use of liquid hydrogen for large power electric propulsion (manned Mars missions). Although natural boiling could be acceptable for single leg missions, passive insulation techniques yield roughly a I% per month cryogen loss and this would not be cost effective for robotic planetary missions involving storage times greater than one year. To make economic sense, long-term exploration missions require lower tank capacity and longer storage times. Recent advances in cryocooler technology, resulting in vast improvements in both cooler efficiency and reliability, make ZBO is a clear choice for planetary exploration missions. Other, more near term applications of ZBO include boil-off reduction or elimination applied to first and upper stages of future earth-to-orbit (ETO) launchers. This would extend launch windows and reduce infrastructure costs. Successors to vehicles like Ariane 5 could greatly benefit by implementing ZBO. Zero Boil Off will only be successful in ETO launcher applications if it makes economic sense to implement. The energy cost is only a fraction of the total cost of buying liquid cryogen, the rest being transportation and other overhead. Because of this, higher boiling point cryogens will benefit more from on-board liquefaction, thus reducing the infrastructure costs. Since hydrogen requires a liquefier with at least a 17% efficiency just to break even from a cost standpoint, one approach for implementing ZBO in upper stages would be to actively cool the shield in the hydrogen tank to reduce the parasitic losses. This would allow the use of less expensive, presently available coolers (80 K vs. 20 K) and potentially simplify the system by requiring only a single compressor on the pad amd a single disconnect line. The compressor could be a hefty commercial unit, with only the cold head requiring expensive flight development and qualification. While this is actually a reduced boil off configuration rather than a zero-boil off case, if the cryogen loss could be cut significantly, the increase in hold time and reduced need for draining and refilling the propellant tanks could meet the vehicle operations needs in the majority of instances.Bearing in mind the potential benefits of ZBO, NASA AMES and SNECMA Moteurs decided to exchange their technical views on the subject. This paper will present a preliminary analysis for a multi-mission module using a fairly low thrust cryogenic engine and ZBO during cruise. Initial mass is 5.5. tons (in ETO). The cryogenic engine will be used near each periapsis in order to minimize the AV requirement. The payload obtained by this propulsion system is compared to a classical storable bipropellant propulsion system for several cases (e. g. Mars lander, Jupiter orbiter, Saturn orbiter). For the Jupiter and Saturn cases, the power source could be an RTG or a large parabolic mirror illuminating a solar panel. It is shown -that - due to its much larger specific impulse - the cryogenic ZBO solution provides much higher payloads, especially for exploration missions involving landing on planets, asteroids, comets, or other celestial bodies.

The performance of cryogenic instruments is often a function of their operating temperature. Thus, designers of cryogenic instruments often are required to predict the operating temperature of each instrument they design. This requires accurate thermal models of cryogenic components which include the properties of the materials and assembly techniques used. When components are bolted or otherwise pressed together, a knowledge of the thermal performance of such joints are also needed. In some cases, the temperature drop across these joints represents a significant fraction of the total temperature difference between the instrument and its cooler. While extensive databases exist on the thermal properties of bulk materials, similar databases for pressed contacts do not. This has often lead to instrument designs that avoid pressed contacts or to the over-design of such joints at unnecessary expense. Although many people have made measurements of contact conductances at cryogenic temperatures, this data is often very narrow in scope and even more often it has not been published in an easily retrievable fashion, if published at all. This paper presents a summary of the limited pressed contact data available in the literature.

Current plans within NASA involve extending the human exploration of space from low earth orbit into the solar system, with the first human exploration of Mars presently planned in 2011. Integral to all hum Mars mission phases is cryogenic fluid management. Cryogenic fluids will be required both as propellant and for In-Situ Resource Utilization (ISRU). Without safe and efficient cryogen storage human Mars missions will not be possible. Effective control and handling of cryogenic fluids is the key to affordable Mars missions, and advancing active thermal control technology is synergistic with all of NASA's exploration initiatives and with existing and future instrument cooling programs, including MTPE and Origins. Present mission scenarios for human exploration require cryogenic propellant storage for up to 1700 days and for up to 60 metric tons. These requirements represent increases of an order of magnitude over previous storage masses and lifetimes. The key cryogenic terminology areas to be addressed in human Mars missions are long-term propellant storage, cryogenic refrigeration, cryogenic liquefaction, and zero gravity fluid management. Long-term storage for the thermal control of cryogenic propellants is best accomplished with a mix of passive and active technologies. Passive technologies such as advanced multilayer insulation (MLI) concepts will be combined with the development of active coolers (cryogenic refrigerators). Candidates for long-life active cooling applications include Reverse Turbo-Brayton, Stirling, and Pulse-Tube coolers. The integration of passive and active technologies will form a hybrid system optimized to minimize the launch mass while preserving the cryogenic propellants. Since cryogenic propellants are the largest mass that Mars missions must launch from earth, even a modest reduction in the percentage of propellant carried results in a significant weight saving. This paper will present a brief overview of cryogenic fluid management technology as it applies to the current human Mars mission scenarios.

Report describes study of thermal conductance of gold-plated copper, aluminum, brass, and stainless-steel contacts at temperatures from 1.6 to 4.2 K under applied forces of 22 to 670 N.

Large Dewars often use aluminum radiation shields and stainless steel vent lines. A simple, low cost method of making thermal contact between the shield and the line is to deform the shield around the line. A knowledge of the thermal conductance of such a joint is needed to thermally analyze the system. The thermal conductance of pressed metal contacts consisting of one aluminum and one stainless steel contact has been measured at 77 K, with applied forces from 8.9 N to 267 N. Both 5052 or 5083 aluminum were used as the upper contact. The lower contact was 304L stainless steel. The thermal conductance was found to be linear in temperature over the narrow temperature range of measurement. As the force was increased, the thermal conductance ranged from roughly 9 to 21 mW/K within a range of errors from 3% to 8%. Within the range of error no difference could be found between the using either of the aluminum alloys as the upper contact. Extrapolating the data to zero applied force does not result in zero thermal conductance. Possible causes of this anomalous effect are discussed.

The thermal conductance of pressed contacts which have been augmented with Indium foil or Apiezon-N (tm) grease was measured over the temperature range of 1.6 to 6.0 K, with applied forces from 22 N to 670 N. The sample pairs were fabricated from OFHC copper, 6061-T6 aluminum, free-machining brass, and 304 stainless steel. Although the thermal conductance was found to increase with increasing applied contact force, the force dependence was less than in earlier work. The addition of Indium foil or Apiezon-NT grease between the contact surfaces resulted in an improvement over uncoated surfaces ranging from a factor of approximately 3 for stainless steel to an order of magnitude for copper contacts.

The thermal conductance of gold plated OFHC copper, 6061-T6 aluminum, free-machining brass, and 304 stainless steel contacts has been measured over the temperature range of 1.6 to 4.2 K, with applied forces from 22 N to 670 N. The contact surfaces were prepared with a 0.8 micron lapped finish prior to gold coating. It was found that for all materials, except stainless steel, the thermal conductance was significantly improved as the result of gold coating the contact surfaces.

Tests were made in the 20 MW arc jet facility at the NASA ARC to determine the suitability of sapphire and fused silica as window materials for the Aeroassist Flight Experiment (AFE) entry vehicle. Twenty nine tests were made; 25 at a heating rate about 80 percent of that expected during the AFE entry and 4 at approximately the full, 100 percent AFE heating rate profile, that produces a temperature of about 2900 F on the surface of the tiles that protect the vehicle. These tests show that a conductively cooled window design using mechanical thermal contacts and sapphire is probably not practical. Cooling the window using mechanical thermal contacts produces thermal stresses in the sapphire that cause the window to crack. An insulated design using sapphire, that cools the window as little as possible, appears promising although some spectral data in the vacuum-ultra-violet (VUV) will be lost due to the high temperature reached by the sapphire. The surface of the insulated sapphire windows, tested at the 100 percent AFE heating rate, showed some slight ablation, and cracks appeared in two of three test windows. One small group of cracks were obviously caused by mechanical binding of the window in the assembly, which can be eliminated with improved design. Other cracks were long, straight, thin crystallographic cracks that have very little effect on the optical transmission of the window. Also, the windows did not fall apart along these crystallographic cracks when the windows were removed from their assemblies. Theoretical results from the thermal analysis computer program SINDA indicate that increasing the window thickness from 4 to 8 mm may enable surface ablation to be avoided. An insulated design using a fused silica window tested at the nominal AFE heating rate experienced severe ablation, thus fused silica is not considered to be an acceptable window material.

Two all-metal demountable cryogenic seals with an outside diameter of 36.6 mm, inside diameter of 27.2 mm, and thickness of 0.51 mm were leak-tested at room temperature (300 K), liquid nitrogen temperature (21 cycles at 77 K), liquid helium temperature (9 cycles at 4.2 K), and superfluid helium temperature (4 cycles at 1.6 K). Each seal was mounted and demounted for 13 cycles. Thickness measurements at 90 deg intervals along the circumference showed a maximum seal compression of 0.038 mm. Leak-rate measurements at all temperatures showed no detectable leak above the helium background level, typically 0.1 x 10(-9) std-cc/sec, during testing.

A concept is presented for a national cryogenic optics test facility capable of optical characterization of 1.25 m diameter optics having focal lengths up to 6.2 m at temperatures from 300 K to near 4 K. The facility will be comprised of a large Dewar with a phase shift interferometer, a two-stage vacuum system employing a turbomolecular pump, and an integral vibration isolation system. The entire facility will be housed in a concrete site with a massive floor to assist in reducing vibration during optical tests. By providing interchangeable sections, the overall height of the Dewar can be adjusted to provide for testing of shorter focal length optics. The background for the facility is discussed along with the facility location, and the requirements and the performance considerations which drive the Dewar design with respect to the vibration isolation system, vacuum system, and optical interferometry.

A concept is presented for a national cryogenic optics test facility capable of optical characterization of 1.25 m diameter optics having focal lengths up to 6.2 m at temperatures from 300 K to near 4 K. The facility will be comprised of a large Dewar with a phase shift interferometer, a two stage vacuum system employing a turbomolecular pump, and an integral vibration isolation system. The entire facility will be housed in a concrete site with a massive floor to assist in reducing vibration during optical tests. By providing interchangeable sections, the overall height of the Dewar can be adjusted to provide for testing of shorter focal length optics. The background for the facility is discussed along with the facility location, and the requirements and the performance considerations which drive the Dewar design with respect to the vibration isolation system, vacuum system, and optical interferometry.

Instrument measures thermal conductance of pressed contacts in liquid helium. Makes measurements automatically as function of force on pairs of brass samples having various surface finishes. Developed as part of effort to determine heat-transfer characteristics of bolted joints on cryogenically cooled focal planes in infrared equipment. Cylindrical chamber hangs from cover plate in bath of liquid helium. Inside chamber rocker arm applies controlled force to samples. Upper sample made slightly wider than lower one so two samples remain in complete contact even under slight lateral misalignment.