Development of a hybrid screen channel liquid acquisition device for reliable microgravity transfer of cryogenic fluids

Refueling spacecraft in orbit offers potential benefits to future extended duration missions including increased spacecraft payload capacity and reduced launch cost. However, a key challenge for refueling cryogenic propellants in microgravity conditions is the acquisition of vapor-free liquid propellants from an in-orbit supply tank. This is especially true when the required liquid flow rate is high but residual liquid in the tank must be minimal. Vane-type Propellant Management Devices (PMDs) excel in stabilizing and distributing liquid, but are more susceptible to gas ingestion, and generally only perform well at lower flow rates and/or under favorable acceleration gradients. Screen channel PMDs do not stabilize and distribute the liquid as well, but are less susceptible to gas ingestion, and perform well at higher flow rates and/or under adverse accelerations. Screened channel LADs appear to hold many advantages for a flight cryogenic system with high demand flow rate, however there are currently no flight cryogenic fluid-based screen channel LADs. To address this need, Creare has been working with NASA Glenn to develop a hybrid Liquid Acquisition Device (LAD) for cryogenic propellants consisting of screened channels with attached guide vanes, and a screened sump. Creare's design forms the flow channel from screen material itself, allowing much higher acquisition surface area per unit volume as compared to existing designs. The screened channel LAD and screened sump are assembled by Creare's advanced laser welding processes to reliably maintain the pore structure of the screen adjacent to the bonding joints. After completing a series of fabrication trials to validate the reliability and repeatability of the approach, a prototype screen channel was fabricated, and its performance was characterized in LN2 outflow. Results were found to be consistent with single-phase CFD predictions of this geometry for a partially exposed screen channel. Two-phase CFD analysis was conducted to evaluate the performance of the guide vanes in favorably distributing liquid to enhance expulsion efficiency. Preliminary structural analysis was performed on representative geometry for the LAD assembly to assess stresses of the under 5 g acceleration. Using this screen channel geometry and overall design approach, Creare assembled a laboratory-scale hybrid LAD with four parallel gallery arms, a screened sump, and guide vanes. The assembly has been installed in a large dewar for preliminary evaluation in LN2. This unit is planned for delivery to NASA for follow-on investigations using liquid hydrogen.

Automated summary

Refueling spacecraft in orbit has the potential to increase payload capacity and reduce launch costs, but the challenge of acquiring vapor-free liquid propellants in microgravity conditions remains. Vane-type Propellant Management Devices (PMDs) excel in stabilizing and distributing liquid, while screen channel PMDs are less susceptible to gas ingestion and perform well at higher flow rates and adverse accelerations. To meet this need, Creare has developed a hybrid Liquid Acquisition Device (LAD) consisting of screened channels with guide vanes and a screened sump, providing a higher acquisition surface area per unit volume compared to existing designs.