ALBERT

Description: Current reduced-order thermal model for cryogenic propellant tanks is based on correlations built for flat plates collected in the 1950's. The use of these correlations suffers from: inaccurate geometry representation; inaccurate gravity orientation; ambiguous length scale; and lack of detailed validation. The work presented under this task uses the first-principles based Computational Fluid Dynamics (CFD) technique to compute heat transfer from tank wall to the cryogenic fluids, and extracts and correlates the equivalent heat transfer coefficient to support reduced-order thermal model. The CFD tool was first validated against available experimental data and commonly used correlations for natural convection along a vertically heated wall. Good agreements between the present prediction and experimental data have been found for flows in laminar as well turbulent regimes. The convective heat transfer between tank wall and cryogenic propellant, and that between tank wall and ullage gas were then simulated. The results showed that commonly used heat transfer correlations for either vertical or horizontal plate over predict heat transfer rate for the cryogenic tank, in some cases by as much as one order of magnitude. A characteristic length scale has been defined that can correlate all heat transfer coefficients for different fill levels into a single curve. This curve can be used for the reduced-order heat transfer model analysis.

Description: The predicted slosh damping values from Loci-Stream-VOF agree with experimental data very well for all fill levels in the vicinity of the baffle. Grid refinement study is conducted and shows that the current predictions are grid independent. The increase of slosh damping due to the baffle is shown to arise from: a) surface breakup; b) cascade of energy from the low order slosh mode to higher modes; and c) recirculation inside liquid phase around baffle. The damping is a function of slosh amplitude, consistent with previous observation. Miles equation under predicts damping in the upper dome section.

Description: Propellant slosh is a potential source of disturbance critical to the stability of space vehicles. The slosh dynamics are typically represented by a mechanical model of a spring mass damper. This mechanical model is then included in the equation of motion of the entire vehicle for Guidance, Navigation and Control analysis. Our previous effort has demonstrated the soundness of a CFD approach in modeling the detailed fluid dynamics of tank slosh and the excellent accuracy in extracting mechanical properties (slosh natural frequency, slosh mass, and slosh mass center coordinates). For a practical partially-filled smooth wall propellant tank with a diameter of 1 meter, the damping ratio is as low as 0.0005 (or 0.05%). To accurately predict this very low damping value is a challenge for any CFD tool, as one must resolve a thin boundary layer near the wall and must minimize numerical damping. This work extends our previous effort to extract this challenging parameter from first principles: slosh damping for smooth wall and for ring baffle. First the experimental data correlated into the industry standard for smooth wall were used as the baseline validation. It is demonstrated that with proper grid resolution, CFD can indeed accurately predict low damping values from smooth walls for different tank sizes. The damping due to ring baffles at different depths from the free surface and for different sizes of tank was then simulated, and fairly good agreement with experimental correlation was observed. The study demonstrates that CFD technology can be applied to the design of future propellant tanks with complex configurations and with smooth walls or multiple baffles, where previous experimental data is not available.

Description: To meet the flight control damping requirement, baffles of various configurations have been devised to increase the natural viscous damping and decrease the magnitude of the slosh forces and torques. In the design of slosh baffles, the most widely used damping equation is the one derived by Miles, which is based on the experiments of Keulegan and Carpenter. This equation has been used in predicting damping of the baffled tanks in different diameters ranging from 12 to 112 inches. The analytical expression of Miles equation is easy to use, especially in the design of complex baffle system. Previous investigations revealed that some experiments had shown good agreements with the prediction method of Miles, whereas other experiments have shown significant deviations. For example, damping from Miles equation differs from experimental measurements by as much as 100 percent over a range of tank diameters from 12 to 112 inches, oscillation amplitudes from 0.1 to 1.5 baffle widths, and baffle depths of 0.3 to 0.5 tank radius. Previously, much of this difference has been attributed to experimental scatter. A systematical study is needed to understand the damping physics of baffled tanks, to identify the difference between Miles equation and experimental measurement, and to develop new semi-empirical relations to better represent the real damping physics. The approach of this study is to use CFD technology to shed light on the damping mechanisms of a baffled tank. First, a 1-D Navier-Stokes equation representing different length scales and time scales in the baffle damping physics is developed and analyzed. A well validated CFD solver, developed at NASA MSFC, Loci-STREAM-VOF, is applied to study vorticity field around the baffle and around the fluid interface to highlight the dissipation mechanisms at different slosh amplitudes. Previous measurement data are then used to validate the CFD damping results. The study found several critical parameters controlling fluid damping from a baffle: local slosh amplitude to baffle thickness (A/t), surface liquid depth to tank radius (h/R), local slosh amplitude to baffle width (A/W); and non-dimensional slosh frequency. The simulation highlights three significant damping regimes where different mechanisms dominate. The study proves that the previously found discrepancies between Miles equation and experimental measurement are not due to the measurement scatter, but rather due to different damping mechanisms at various slosh amplitudes. The limitations on the use of Miles equation are discussed based on the flow regime.

Description: The Miles equation has long been used to predict slosh damping in liquid propellant tanks due to ring baffles. The original work by Miles identifies defined limits to its range of application. Recent evaluations of the Space Launch System identified that the Core Stage baffle designs resulted in violating the limits of the application of the Miles equation. This paper describes the work conducted by NASA/MSFC to develop methods to predict slosh damping from ring baffles for conditions for which Miles equation is not applicable. For asymptotically small slosh amplitudes or conversely large baffle widths, an asymptotic expression for slosh damping was developed and calibrated using historical experimental sub-scale slosh damping data. For the parameter space that lies between region of applicability of the asymptotic expression and the Miles equation, Computational Fluid Dynamics simulations of slosh damping were used to develop an expression for slosh damping. The combined multi-regime slosh prediction methodology is shown to be smooth at regime boundaries and consistent with both sub-scale experimental slosh damping data and the results of validated Computational Fluid Dynamics predictions of slosh damping due to ring baffles.

Description: An experimental investigation was conducted on a scaled annular pogo accumulator for the Ares I Upper Stage. The test article was representative of the LO2 feedline and preliminary accumulator design, and included multiple designs of a perforated ring connecting the accumulator to the core feedline flow. The system was pulse tested in water over a range of pulse frequency and flow rates. Time dependent measurements of pressure at various locations in the test article were used to extract system compliance, inertance, and resistance. Preliminary results indicated a significant deviation from standard orifice flow theory and suggest a strong dependence on feedline average velocity. In addition, several CFD analyses were conducted to investigate the details of the time variant flow field. Both two-dimensional and three-dimensional simulations were performed with time varying boundary conditions used to represent system pulsing. The CFD results compared well with the sub-scale results and demonstrated the influence of feedline average velocity on the flow into and out of the accumulator. This paper presents updated results of the investigation including a parametric design space for determining resistance characteristics. Using the updated experimental results a new scaling relationship has been defined for shear flow over a cavity. A comparison of sub-scale and full scale CFD simulations provided early verification of the scaling of the fluid flowfield and resistance characteristics.

Description: Propellant tank slosh dynamics are typically represented by a mechanical model of spring mass damper. This mechanical model is then included in the equation of motion of the entire vehicle for Guidance, Navigation and Control (GN&C) analysis. For a partially-filled smooth wall propellant tank, the critical damping based on classical empirical correlation is as low as 0.05%. Due to this low value of damping, propellant slosh is potential sources of disturbance critical to the stability of launch and space vehicles. It is postulated that the commonly quoted slosh damping is valid only under the linear regime where the slosh amplitude is small. With the increase of slosh amplitude, the critical damping value should also increase. If this nonlinearity can be verified and validated, the slosh stability margin can be significantly improved, and the level of conservatism maintained in the GN&C analysis can be lessened. The purpose of this study is to explore and to quantify the dependence of slosh damping with slosh amplitude. Accurately predicting the extremely low damping value of a smooth wall tank is very challenging for any Computational Fluid Dynamics (CFD) tool. One must resolve thin boundary layers near the wall and limit numerical damping to minimum. This computational study demonstrates that with proper grid resolution, CFD can indeed accurately predict the low damping physics from smooth walls under the linear regime. Comparisons of extracted damping values with experimental data for different tank sizes show very good agreements. Numerical simulations confirm that slosh damping is indeed a function of slosh amplitude. When slosh amplitude is low, the damping ratio is essentially constant, which is consistent with the empirical correlation. Once the amplitude reaches a critical value, the damping ratio becomes a linearly increasing function of the slosh amplitude. A follow-on experiment validated the developed nonlinear damping relationship. This discovery can lead to significant savings by reducing the number and size of slosh baffles in liquid propellant tanks.

Description: Determination of slosh damping is a very challenging task as there is no analytical solution. The damping physics involves the vorticity dissipation which requires the full solution of the nonlinear Navier-Stokes equations. As a result, previous investigations were mainly carried out by extensive experiments. A systematical study is needed to understand the damping physics of baffled tanks, to identify the difference between the empirical Miles equation and experimental measurements, and to develop new semi-empirical relations to better represent the real damping physics. The approach of this study is to use Computational Fluid Dynamics (CFD) technology to shed light on the damping mechanisms of a baffled tank. First, a 1-D Navier-Stokes equation representing different length scales and time scales in the baffle damping physics is developed and analyzed. Loci-STREAM-VOF, a well validated CFD solver developed at NASA MSFC, is applied to study the vorticity field around a baffle and around the fluid-gas interface to highlight the dissipation mechanisms at different slosh amplitudes. Previous measurement data is then used to validate the CFD damping results. The study found several critical parameters controlling fluid damping from a baffle: local slosh amplitude to baffle thickness (A/t), surface liquid depth to tank radius (d/R), local slosh amplitude to baffle width (A/W); and non-dimensional slosh frequency. The simulation highlights three significant damping regimes where different mechanisms dominate. The study proves that the previously found discrepancies between Miles equation and experimental measurement are not due to the measurement scatter, but rather due to different damping mechanisms at various slosh amplitudes. The limitations on the use of Miles equation are discussed based on the flow regime.

Description: Propellant slosh is a potential source of disturbance that can significantly impact the stability of space vehicles. The slosh dynamics are typically represented by a mechanical model of a spring-mass-damper. This mechanical model is then included in the equation of motion of the entire vehicle for Guidance, Navigation and Control analysis. The typical parameters required by the mechanical model include natural frequency of the slosh, slosh mass, slosh mass center location, and the critical damping ratio. A fundamental study has been undertaken at NASA MSFC to understand the fluid damping physics from a ring baffle in the barrel section of a propellant tank. An asymptotic damping equation and CFD blended equation have been derived by NASA MSFC team to complement the popularly used Miles equation at different flow regimes. The new development has found success in providing a nonlinear damping model for the Space Launch System. The purpose of this study is to further extend the semi-empirical damping equations into the oblate spheroidal dome section of the propellant tanks. First, previous experimental data from the spherical baffled tank are collected and analyzed. Several methods of taking the dome curvature effect, including a generalized Miles equation, area projection method, and equalized fill height method, are assessed. CFD simulation is used to shed light on the interaction of vorticity around the baffle with the locally curved wall and liquid-gas interface. The final damping equation will be validated by a recent subscale test with an oblate spheroidal dome conducted at NASA MSFC.

Description: Fluid motion in a fuel tank produced during thrust oscillations can circulate sub-cooled hydrogen near the liquid-vapor interface resulting in increased condensation and ullage pressure collapse. The first objective of this study is to validate the capabilities of a Computational Fluid Dynamics (CFD) tool, CFD-ACE+, in modeling the fundamental interface transition physics occurring at the propellant surface. The second objective is to use the tool to assess the effects of thrust oscillations on surface dynamics. Our technical approach is to first verify the CFD code against known theoretical solutions, and then validate against existing experiments for small scale tanks and a range of transition regimes. A 2D axisymmetric, multi-phase model of gases, liquids, and solids is used to verify that CFD-ACE+ is capable of modeling fluid-structure interaction and system resonance in a typical thrust oscillation environment. Then, the 3D mode is studied with an assumed oscillatory body force to simulate the thrust oscillating effect. The study showed that CFD modeling can capture all of the transition physics from solid body motion to standing surface wave and to droplet ejection from liquid-gas interface. Unlike the analytical solutions established during the 1960 s, CFD modeling is not limited to the small amplitude regime. It can extend solutions to the nonlinear regime to determine the amplitude of surface waves after the onset of instability. The present simulation also demonstrated consistent trends from numerical experiments through variation of physical properties from low viscous fluid to high viscous fluids, and through variation of geometry and input forcing functions. A comparison of surface wave patterns under various forcing frequencies and amplitudes showed good agreement with experimental observations. It is concluded that thrust oscillations can cause droplet formation at the interface, which results in increased surface area and enhanced heat transfer between the liquid and gas phases as the ejected droplets travel well into the warmer gas region.