VERIFICATIONS OF THE DIAPHRAGM TANK FOR HIGH TEST PEROXIDE

Transcription

1 VERIFICATIONS OF THE DIAPHRAGM TANK FOR HIGH TEST PEROXIDE T.C. Kuo 1, C.K. Pai 1, H. J. Liu 1, and K. Y. Chen 2 1 National Space Organization, 2 National Chung-Shan Institute of Science and Technology ABSTRACT National Space Organization (NSPO) has initiated a self-reliant development project on the satellite green propulsion system by using the so-called High-Test Peroxide (HTP) as the propellant of the propulsion system, and is planned to carry out the flight tests through the second launch of the FORMOSAT-7/ COSMIC-2 program. A two-liter diaphragm type propellant tank with the loading capacity of one-liter HTP is developing under a joint cooperation project between NSPO and National Chung-Shan Institute of Science and Technology (NCSIST). Two engineering qualification models (EQM) were designed, manufactured, and tested for ensuring their availabilities for the satellite mission. This study will summarize the verification-related works for the development of the diaphragm type tank. KEYWORDS:Satellite propulsion system, RCS, Hydrogen peroxide, Diaphragm Tank, Green propellant 1. INTRODUCTION Satellite propulsion system, or named as Reaction Control System (RCS), is usually used for providing the power to perform the operations of orbit correction, transfer and maintenance (Larson, 1992). The monopropellant systems use single chemical materials; most well- known one is hydrazine, decomposing at the catalyst bed, and the exothermic reaction producing high temperature has to generate the anticipated thrust. The research on the green propellant as the on board propulsion system for satellite is becoming more and more popular in the past decades. low-toxic (green) mono-propellants come to be an alternative option for traditional hydrazine- based fuel (Spores et al. 2013, Anflo et al. 2007, Anflo et al. 2010, and Dinardi et al. 2012). Recent years, HTP is one of the alternative propellant, which is also characterized as ITAR-free, nontoxic, easy to produce, and low cost for components development and manufacturing, as well as the assembly of the system. To bring to the practical applications of the HTP propulsion system, thruster assemblies and additional modification or re-design of the flow control parts, that may be compatible with the HTP propellant is required. The on-board HTP storage tank is one of the major components for such a system. (Neumaier et al. 2012, Musker et al 2016, Rønningen et al. 2016, Krogstie et al. 2016, Lin 2016, Lestrade et al. 2016, Angelo 2016, A1

2 and Kuo et al. 2016) Solli et.al(2016) has developed the raw material encoded AA6000 series for the tank shell structures, which are made by cold impact extrusion and the basis material is an aluminum sheet, and are accompany with the Viton-based diaphragm. They conducted performance and pressure tests to verified the functionalities. NSPO has been performing components development for HTP propulsion systems, including the propellant tank.(tseng et al. 2016) The progresses of development, verification and current status of the HTP diaphragm type storage tank will be summarize in this paper. 2. DESIGN 2.1 Functional Principle The tank functional principle is utilizing Positive Expulsion Diaphragm (PED) technology to drive the propellant flowing into the downstream fuel supply system. The tanks should provide expulsion efficiency of greater than 95% Internal Leakage: 3 scc/h Ghe Pressure Cycle Life: 25 cycles to MEOP and 5 cycles to proof pressure. Expulsion Cycle Life: 25 cycles Operating Temperature (with Fuel): 0 50 C. Operating Temperature (w/o Fuel): C. 2.3 Tanks Development Three types of tanks have been developed: Bladder type tank proto model: Bladder type tank engineering qualification model (encoded as EQM I), and Diaphragm type tank engineering qualification model (encoded as EQM II). The out-looking of these three type was shown in Figure Specifications (a) (b) The primary specifications of the tank are shown as follows: Dry Mass: 1.6 kg Fuel loading: 1.38 kg HTP ( 90%) Internal volume: 2 liters Maximum Effective Operating Pressure (MEOP): 25 bar Acceptance Proof Pressure: 37.5 bar (SF: 1.5) Burst Pressure: 50 bar (SF: 2.0) External Leakage: 1.0E-5 scc/s GHe (c) Figure 1 (a) Bladder type proto model, (b) Bladder type tank EQM I and (C) Diaphragm type tank EQM II. A2

3 3. MATERIALS COMPATIBILITY TEST The hydrogen peroxide may contact with the FKM robber and the tank shell inner surface. For the bladder type, the concerns of material compatibility issues is relatively simple than the diaphragm type tanks, and only FKMs and HTP tests are required. However, the issues on manufacturing have arisen and cannot well solved at the end, the development bladder type were stopped till EQM I. The diaphragm type tanks (EQM II) are composed tank shell of Zr 702 alloy and diaphragm is made of one of the two FKM formulas. EQM II tanks are composed by five parts: bottom shell, middle shell, top shell, integration interface, and FKM diaphragm. The bottom shell and diaphragm will contact with HTP; the middle shell clamp the diaphragm interface with the bottom shell; and then the top shell comprise the space for pressurant (gaseous nitrogen, GN 2 ). Laser weld processes were perform to assembly the tank shells. Figure 2 shows the pass of laser weld on the tank. Table 1 shows results of the compatibility tests. Two FKM formulas with ingredient adjustment for meet the meet the low temperature requirements (encoded LTFKM01 and LTFKM02) were tested, and the HTP concertation change is acceptable. Zr 702 alloys and Aluminum 1070 has been tested, and shows excellent compatibility with HTP. For easy assembling the tank, Zr 702 material is chosen for manufacturing the tank shell. 4. ASSEMBLY Figure 2 The Pass of Laser Weld on EQM II SN02 Tank Shell While complete the welding processes, the carbon fibers over-wrapped outside the tank shell are applied. The last step of assembly is Formula/ Material Table 1 Code The Test Data for Material Compatibility Checks Beginning H 2 O 2 (wt%) Temperature/ Duration Gravimetric AOL(%) Concentration AOL(%) Post Test H 2 O 2 (wt%) Blank /7days LTFKM01 LT01CP /7days LT01CP /7days Blank /7days LTFKM02 LT02CP /7days LT02CP /7days Blank /7days Zr 702 Zr /7days Al 1070 Al /7days A3

4 Figure 3 The EQM II Verification Test Plan to integrated the aluminum integration interface to the dedicated position and fixed by another carbon fiber over-wrapped process. Table 2 summarized the mass properties for the two EQM II models. Table 2 The Mass Properties for EQM II Parts / Descriptions EQM II EQM II SN-01 SN-02 EQMII-Bottom Shell EQMII-Middle Shell EQMII-Top Shell Integration I/F FKM Diaphragm Total Mass [g] cycle life tests; To ensure both the external and internal leakage rate meeting the requirement through the test history; To check the expulsion cycles To check if both EQM II may pass the thermal, vacuum and vibration environments; 4. Environmental and Functional Tests The objectives for the propellant tanks EQM II testing are described as follows: To verify the expulsion efficiency is greater than 95%; To measure the internal volume; To ensure the models will pass the pressure Figure 4 Vibration Test Configuration A4

5 The verification test plan for EQM II models is shown in Fig. 3. Figure 4 shows the vibration (sine and random) tests and the shock test (a) (b) Figure 6 Thermal Cycling Test: (a) Test Article in the Thermal Cycling Chamber (SN01 and SN02), and (b) the Test Result (SN02) The test results of the random vibration and the thermal cycling are shown in Fig. 5 and Fig. 6, respectively. Figure 5 Results for Random Vibration Tests: (a) out-of-plane, and (b) In-Plane. The expulsion cycles tests are conducted by utilizing a the test model that is identical with the EQM II configuration, but is made by different material (SUS 316L). Expulsion efficiency measured the water draining out of the tank shell for each cycle test. Both the expulsion efficiency and the cycle life are satisfying the specifications described in section of 2.2. Table 3 summarized the leakage measurement for both EQM II Models. A5

6 Table 3 External and Internal Leakage Measurement Results EQM II SN01 External Leak@ Liquid Side External Leak@ Gas Side Internal Leak MEOP 1 PROOF MEOP 2 MEOP 1 PROOF MEOP 2 2 barg 4 barg Post Assembly 1.13E E E E E E E-03 Post Vibration E E E E E E-02 Post TC 6.36E E E E E E E E-02 Post TV 6.36E E E E E E E E-02 Pre Burst 6.36E E E E E E E E-02 Post Burst 6.36E E E E+00 EQM II SN02 External Leak@ Liquid Side External Leak@ Gas Side Internal MEOP 1 PROOF MEOP 2 MEOP 1 PROOF MEOP 2 2 barg 4 barg Post Assembly 4.68E E E E E E E-03 Post Vibration 3.63E E E E E E E E-04 Post TC 1.84E E E E E E E E-03 Post TV 1.27E E E E E E E E-04 Pre Burst 5.22E E E E E E E E-03 The external leakage measurements at the post assembly for both tank models may interfered by a large background gaseous helium concentration, and result in inappropriate data. As remove the root causes of the mistake, the data obtained at the post vibration, post thermal cycling, thermal vacuum, and pre burst pressure are not vary obviously, and located around the order of under 10-3 ~10-1 scc/hr (10-7 ~10-5 scc/s). The diaphragm internal leak measurements are performed for both SN01 and SN02. All test data meet the test requirement. It should remarked that only SN01 was inserted to the burst pressure test, and the internal leak is growth sharply after the qualification test. It means while the EQM II diaphragm submitted to the burst test, some damage might be occurred at the membrane. 5. Conclusions Several aspects can be concluded for the current HTP tanks as follow: Two EQM II diaphragm type propellant tanks were designed, manufactured, assembled and tested. Current design may meet the vibration and thermal environments requirement. The expulsion efficiency meets requirement. The welding processes are sufficient for the external leakage requirement. The diaphragm internal leak is acceptable under normal operation conditions, and may be causing minor ruptures as performing the burst test. Several treatment to the tank design and hardware development in the future may be specified as follow: Reduce the mass by way of shrinking the tank shell thickness, and minimizing the shell parts. Redesign the diaphragm shape to enhance A6

7 the expulsion efficiency. Conduct comprehensive compatibility test by storing HTP in the well manufactured model. Remove the carbon fiber over-wrapped design. It may be not necessary for current application and pressure levels. 6. REFERENCES 1. Larson W. J. and Wertz J. R. 1992, Space Mission Analysis and Design. Microcosm, Inc. Second Edition, pp Spores R. A., Masse R. and, Kimbrel S GPIM AF-M315E Propulsion System. 49th AIAA/ASME/SAE/ASEE Joint Propulsion Conference & Exhibit July 2013, San Jose, California American, AIAA Anflo K., Bergman G., Hasanof T., Kuzavas L., Thormaehlen P., and Astrand B Flight Demonstration of New Thrusters and Green Propellant Thechology on the PRISMA Satellite. 21th Annual AIAA/USU Conference on Small Satellite, SSC07-X-2, Anflo K., Crowe B. and Persson M , The First In-Space Demonstration of A Green Propulsion System, 24th Annual AIAA/USU Conference on Small Satellite, SSC10-XI-2, Dinardi A. and Persson M High Performance Green Propulsion (HPGP): A Flight-Proven Capability and Cost Game-Changer for Small and Secondary Satellite. 26th Annual AIAA/USU Conference on Small Satellite, SSC12-III-6, Neumaier W. W., Weels M., Brinkley A., and Talty T Development of a 90% Hydroden Peroxide ono-propellant Propulsion System for the Warm Gas Test Article. 48 th AIAA/ASME/SAE/ASEE Joint Propulsion Conference & Exhibit., 30 July 01 August, 2012, Atlanta, Georgia. 7. Musker A. J., Ryan J., Florczuk W., Sobczak K., Kaniewski D., Rarata., Leininger S. and Christ P. 2016, Realistic Testing of PX1 Catalyst Using Near-Anhydrous Hydrogen Peroxide. Space Propulsion 2-6 May 2016, Rome, Italy. 8. Rønningen J.-E., Kolsgaard A., Husdal J., Haugen K. L., Rudi S., Stenseth A., Hegre J. S., Øye I Development of a high-performance hydrogen peroxide monopropellant thruster for launcher applications. Space Propulsion 2-6 May 2016, Rome, Italy. 9. Krogstie L., Kolsgaard A., Smestad E., Rudi S., Husdal J., Hegre J. S., Rønningen J.-E., Verberne O Pyroshock Testing of High-Strength Hydrogen Peroxide. Space Propulsion 2-6 May 2016, Rome, Italy. 10. Lin Q Research on 1N Monopropellant Thruster Using Hydrogen Peroxide for Small Satellites. Space Propulsion 2-6 May 2016, Rome, Italy. 11. Lestrade J.-Y., Prévot P., Messineo J., Anthoine J., Casu S. and Geiger B Development of a Catalyst Highly Concentrated Hydrogen Peroxide. Space Propulsion 2-6 May 2016, Rome, Italy. 12. Angelo P Design and Testing of a 98% H2O2 Pulsed Thruster. Space Propulsion 2-6 May 2016, Rome, Italy. 13. Kuo T.C., Tseng K.C., Liu H.J. and Pai C.K Development of a Satellite-Level Propulsion System by Using Hydrogen Peroxide Propellant Space Propulsion 2-6 May 2016, Rome, Italy. 14. Solli L., Rønninge J. E., Rudi S., Husdal J., Skoglund A., Hegre J. S., and Kolsgaard A Development of a Propellant Tank for Hydrogen Peroxide for Launcher Applications. Space Propulsion 2-6 May 2016, Rome, Italy. 15. Tseng K. C., Liu H. J., Pai C. K., Kuo T. C. and Chan Y. A Development of Satellite Propulsion Components for Hydrogen Peroxide Propellant. Space Propulsion 2-6 May 2016, Rome, Italy. A7

8 VERIFICATIONS OF THE DIAPHRAGM TANK FOR HIGH TEST PEROXIDE T.C. Kuo 1, C.K. Pai 1, H. J. Liu 1, and K. Y. Chen 2 1 National Space Organization, 2 National Chung Shan Institute of Science and Technology HTP Propellant Tank Vibration Tests EQM I EQMII (Bladder Type) (Diaphragm Type) Tank Assembly Thermal Cycle/Vacuum Tests Verification Test Plan External/Internal Leak Test