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Insulation Systems
16th Thermal and Fluids Analysis Workshop
Orlando, Florida
August 9, 2005
James E. Fesmire
Stan D. Augustynowicz
Cryogenics Test Laboratory
NASA Kennedy Space Center
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Outline
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Introduction
Part 1, Materials
Part 2, Testing
Part 3, Applications
Conclusion
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INTRODUCTION
Energy density
Refrigeration
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Food
Health and medicine
Energy
Transportation
Manufacturing
Research
Aerospace
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Spaceport facilities
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Space exploration
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In-space depots
Moon base
Mars base
Other destinations
Mass-efficient storage
and transfer of cryogens
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Industry
Hydrogen Transportation
Superconducting Power
Processes & Applications
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PART 1
MATERIALS
Background
Historical perspective
DArsonval in 1887 to Peterson in 1951
WW II to H2 bomb to Apollo
Conventional materials
Novel materials
Aerogels to sol-gel aerogels
Composites old and composites new
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New Materials
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Performance
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1. Thermal Conductivity
k-value
Real systems with large temperature differences
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koafi
Often one order of magnitude (or more!) higher than
reported ideal or laboratory k-values
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0.1
10
100
1000
10000
100000
1000000
Representative k-values
Material and Density
Vacuum, polished surfaces
HV
<10-4 torr
SV
1 torr
0.5 to 5
NV
760 torr
18.7
2
14
22
PU foam, 32 kg/m3
21
33
16
32
1.1
5.4
11
0.6
3.4
12
0.09
10
~24
0.09
1.6
14
Boundary temperatures of approx. 293 K and 77 K; residual gas is nitrogen; k-value in mW/m-K.
100
10
G la ss B u b b les, C 1 3 7
P erlite P ow der, 9 pcf
A erog el B ea d s, C 1 3 4
0.1
0.01
0.1
10
100
1000
10000
100000
1000000
1000
Boundary temperatures
are approximately 293
K and 77 K. Residual
gas is nitrogen.
100
10
H e a t F lu x , C 1 3 7
T o t a l H e a t, C 1 3 7
1
0 .1
10
100
1000
10000
C o ld V a c u u m P r e s s u re C V P (m illito rr )
100000
1000000
2. Vacuum Level
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3. Density
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4. Cost
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Aerogel Materials
LIGHTER THAN AIR?
Aerogel Basics
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Commercial products,
Aspen Aerogels, Inc.
catalyst
Si(OH)4 + (m+n) EtOH
hydrolysis
catalyst
condensation
Autoclave System
ks
BULK DENSITY
kg
PARTICLE LOADING
kr
SURFACE AREA
q = kA
kt
Total
ks
T
L
kg
Solid
Gas
Conduction Conduction
kr
Radiation
Waterglass
Sol
Hydrogel
Silation
Aerogel
PART 2
TESTING
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Comparison of Insulation
Test Methods
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Boundary
Temp Range
(K)
k-value
Heat Flux
Range
Range
(mW/m-K) (W/m2)
Method
Type
Sample
ASTM
C518
Comparative, Heat
Flow Meter
273 to 383
5 to 500
---
ASTM
C177
Absolute, Guarded
Hot Plate
Flat, disk
Small
93 to 773
14 to 2000
---
ASTM
C745
Absolute, Boiloff
Calorimeter
Flat, disk
Large
250/670 and
20/300
---
0.3 to 30
Cylindrical
Large
77 to 300
0.03 to 30
0.8 to 120
Large
77 to 350
0.1 to 50
2 to 400
Large
77 to 350
0.5 to 80
6 to 900
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Description of Cryostats
Cryostat-2
Cryostat-4
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Cryostat-1
Cryostat-2
Cryostat-4
Performance Characterization
of Perforated MLI Blankets
Experimental apparatus
350
RT D1
RT D2
RT D3
RT D5
RT D6
RT D7
RT D8
RT D9
RT D10
RT D11
RT D12
RT D13
RT D14
RT D15
RT D16
T C1
T C2
T C3
T C4
T C5
T C6
T C7
T C8
CVP1
0.1
300
CVP (microns)
Temperatute (K)
250
200
150
100
50
0.01
0
10
11 12
13 14
time (h)
15 16
17 18 19 20 21 22 23 24 25 26 27
1.1
P3, Manifold
P5, Lower
0.9
P4, Upper
Pressure (psig)
0.8
P6, Test
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0
10
11 12
13 14
time (h)
15 16
17 18 19
20 21
22 23
24 25
26 27
0.3
Flow
400
300
0.2
200
0.1
100
0.0
19
20
21
22
23
time (h)
24
25
26
27
100
10
0.1
Kaganer, MLI
C108, 40 layers MLI
C123, 60 layers MLI
C135, Perforated MLI Blanket
0.01
0.01
0.1
10
100
1000
10000
100000
1000000
270
Layer 20
Layer 15
230
Temperature (K)
Layer 10
Layer 5
190
150
1 millitorr, Test 3
5 millitorr, Test 9
10 millitorr, Test 4
110
Layer 1
70
0.0
Layer 0, CBT
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
Thickness (mm)
4.5
5.0
5.5
6.0
6.5
7.0
PART 3
APPLICATIONS
Main Categories
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Examples
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New Applications
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CONCLUSION
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Materials Tested
Multilayer insulation
(MLI), various types
Aluminum foil and
fiberglass paper
Polyester nonwovens
Polyurethane foam
Aerogel powder
Aerogel beads
Aerogel blankets
Glass microspheres
Polyimide
microspheres
Polyimide foams
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Layered composite
insulation (LCI)
Aluminized Mylar
and polyester fabric
Syntactic foam
composites
Micro fiberglass
Perlite powder
Modular cryogenic
insulation (MCI)
Various composite
insulation systems
Polystyrene
And many others!
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Selected References