Demisable fuel supply system

A demisable fuel supply system for a satellite includes a pressurized aluminum alloy tank with an aluminum alloy propellant management device therein. The propellant management device (PMD) can have any capillary action surface tension fluid transport features known in the art. Selected inner surfaces of the tank and the PMD are covered with a plasma powder sprayed titanium based coating to guarantee propellant wettability and corrosion resistance of the fuel supply system.

BACKGROUND

Satellite fuel tanks are complex devices that use various means to deliver fuel to propulsion systems of the space craft. In a zero or low gravity environment, separating the liquids from pressurizing gases in order to deliver them in sufficient quantities to support mission requirements is difficult. Often, this process is performed with a propellant management device (PMD) that utilizes surface tension and capillary action to transport the liquid fuel. It is imperative that the tank and PMD materials are compatible and wettable with the liquid fuel chemicals such as hydrazine. It is known in the art that materials such as titanium and titanium alloys are used for this purpose because of their high chemical compatibility and wettability with hydrazine and other propellants and oxidizers used to fuel satellites.

One requirement for low earth orbiting (LEO) satellites is the ability to retain enough fuel for a final de-orbit maneuver at end of life. The purpose of this activity is to position the space craft in a controlled re-entry trajectory that allows it to fall into the ocean, thereby reducing the loss of life and property should the debris fall into a populated area. Unfortunately, the amount of fuel needed for this final action could otherwise enable the space craft to remain functional for a period of up to several years if the end of mission re-entry were uncontrolled. Uncontrolled re-entry requirements are that all but a negligible portion of the space craft burn up (demise) during re-entry.

Designs for demise programs have emphasized replacing components fabricated from higher melting point materials such as steels and titanium with lower melting material such as aluminum to increase demisability during re-entry. The fuel tanks for the NASA Global Precipitation Measurement satellite (GPM) have been designed with aluminum fuel tanks and PMDs for this purpose. A special surface treatment to increase the chemical compatibility and wettability of aluminum alloys used for the GPM components has been expensive, labor intensive, and difficult to verify in completed tank structures.

SUMMARY

In one embodiment, a demisable fuel supply system has a liquid storage tank and propellant management devices. The liquid storage tank and propellant management devices are fabricated from aluminum alloys. Selected areas of the inside surface of the liquid storage tank and surfaces of the propellant management devices are coated with a titanium based coating to guarantee high wettability of and corrosion protection against the propellant.

In another embodiment, a method of manufacturing a demisable fuel supply system comprises first fabricating aluminum based components of the fuel supply system. The components are then partially assembled and joined, such as by welding or mechanical fastening. Selected areas of the tank and component inside surfaces are then coated with a titanium based coating before final assembly of the tank by welding.

DETAILED DESCRIPTION

National and international agreements have emphasized end of mission re-entry from near earth orbit (NEO) to minimize hazardous orbital debris. Controlled re-entry, whereby the space craft is put into a trajectory with a predetermined landing site, such as an ocean, has been the accepted practice in order to minimize personal or property damage. Uncontrolled re-entry requires that the space craft completely burn up (demise) before impact. A demisable satellite mission can be extended for up to a number of years because of the fuel saved by not having to position the spacecraft in an orientation for a proper trajectory during controlled re-entry.

The recent NASA Global Precipitation Measurement (GPM) satellite has been the first to design according to a “design for demise” (DfD) specification for exactly the above reasons. In DfD designs, low melting metals and other materials comprise most or all of the structures. Aluminum is favored because of its relatively low melting point. Steel and titanium satellite components do not demise during re-entry. A fuel supply system for the GPM satellite comprises a pressurized composite over-wrapped pressure vessel (COPV), an aluminum tank liner and aluminum propellant management devices (PMD). In a zero gravity environment, fuel transport in PMD systems is by capillary action and wettability of the tank and PMD components by the propellant is an absolute necessity for the fuel systems to operate. Unfortunately, the wettability of hydrazine and other fuels and oxidizers on normal clean aluminum surfaces is insufficient to allow aluminum PMD systems to work. A solution was found, however, that creates a hydrated oxide surface layer on certain aluminum alloys that achieved sufficient wettability and allowed the aluminum PMD systems to function. The surface treatment is expensive, labor intensive, and fragile. Exposure to normal “shop air” for example, can render the surface non-wettable and would disable the GPM PMD before launch. Additionally, exposure to common chemicals normally used in processing and testing satellite fuel tanks are destructive to the hydrated oxide coated aluminum surfaces. Finally, the wettability of the treated aluminum surfaces cannot be directly tested after the tank has been constructed and use of similarly treated test coupons is an inferior and marginally acceptable qualification and certification procedure.

An embodiment of this invention is to coat the tank interior and all internal PMD structures with a thin layer of a titanium based coating before final assembly, thereby guaranteeing acceptable wettability and corrosion resistance of the propellant delivery system. Another embodiment is to coat only the PMD and all its fluid communication components and not the entire tank liner.

An example of a propellant delivery system will now be discussed. The system is only an example and is not to be taken as limiting in any respect to propellant delivery systems now known or to be developed. A schematic sketch of propellant delivery system10is shown inFIG. 1. Propellant delivery system10is a monopropellant delivery system where a single fuel such as hydrazine is used. Bipropellant propulsion systems using a fuel and an oxidizer are also in common use. Delivery system10includes tank12, inlet gas flow line14, outlet liquid flow line16, propellant18, vanes20, and sponge22. Vanes20deliver propellant18to sponge22where collected and stored propellant18in sponge22is drawn from liquid flow line16when required by the propulsion system.

Demisable propellant delivery system10is preferably fabricated from an aluminum alloy. Aluminum alloys suitable for this purpose include, but are not limited to, 6061, 2219, and 2014 alloys.

In zero gravity environments, surface tension forces and capillary action are necessary driving forces to deliver propellant in spacecraft such as satellites. A primary function of propellant management devices is to deliver fuel without gas bubbles to a propulsion system. Gas entrained in a fuel line may result in engine malfunction. Normal filters for this purpose are titanium alloy screens where liquid passes through the screens by capillary action and gas bubbles are left behind.

Vanes20may be simple thin metallic ribs aligned perpendicular to tank shell12as shown inFIG. 1. The propellant collects at the intersection of vane20and tank shell12and is held in place by surface tension and meniscus forces. Collecting sponge22may be a radial assembly of vertical panels.FIGS. 1A and 1Bare top and side view, respectively, of sponge22. In a similar fashion, propellant is held in place by surface tension and meniscus forces and fills area inside dotted circle24along the entire length of sponge22. Other collection reservoirs (not shown) are traps and troughs. Vanes, sponges, traps and troughs are described by D. E. Jaekle, Jr. in American Institute of Aeronautics and Astronautics Papers AIAA-91-2172, AIAA-93-1970, and AIAA-95-2531, respectively, for instance.

As noted above, an embodiment of the present invention is to coat all surfaces of the fuel supply system that are in contact with propellant with a titanium based coating in order to guarantee wettability and corrosion resistance throughout the life of a mission. Preferable titanium based coatings are, but are not limited to, pure titanium and titanium-based alloys, such as Ti-6Al-4V and Ti-15V-3Cr-3Sn-3Al alloys. During re-entry, the thin titanium based coating becomes an inconsequential component of the structure as the aluminum components burn up. As mentioned above, another embodiment is to coat only PMD components and fluid communication surfaces with the titanium based coating to ensure acceptable fuel supply during the mission.

Two tank configurations are preferred for satellite fuel systems. One embodiment is a simple aluminum pressurized tank containing propellant management devices (PMD). The other embodiment is an aluminum pressurized tank surrounded by an overwrap of a composite containment shell called a composite overwrap pressure vessel or COPV. In a COPV, the aluminum tank is called a liner in the art.

A method of fabricating demisable fuel systems with pressurized aluminum propellant tanks and with COPV tanks is shown inFIG. 2. The process starts with the procurement of aluminum alloy material, preferably sheet stock. (Step30). Liquid propellant tank shell sections are then fabricated from the sheet stock, preferably by spinning and other methods known in the art (Step32). A preferred thickness of the tank sections is between about 0.9 millimeters and 7 millimeters. Aluminum alloys suitable for the tank include, but are not limited to, 6061, 2219, and 2014 alloys.

Optionally, the interior surface or portions of the interior surface of the tank shell sections are then coated with a titanium based coating. (Step34). Preferably, titanium based coatings for the tank shell interior sections include, but are not limited to, pure titanium and titanium-based alloys, such as Ti-6Al-4V and Ti-15V-3Cr-3Sn-3Al alloys. The thickness of the titanium based coating is between about 1 micron and about 10 microns.

Aluminum PMD components such as vanes, sponges, traps, troughs, and others are then fabricated or acquired from qualified vendors. (Step36). Aluminum alloys suitable for the PMD components include, but are not limited to, 6061, 2219, and 2014 alloys.

A titanium based coating is then applied to the PMD components (Step38). Suitable coatings include, but are not limited to, pure titanium and titanium-based alloys, such as Ti-6Al-4V and Ti-15V-3Cr-3Sn-3Al alloys (Step38). The PMD components are then assembled into PMD fixtures by processes known in the art (Step40) and then installed into the tank shell components (Step42). The PMD components are installed into the tank shell components by attaching the components to the tank shell by welding, brazing, mechanical fasteners, or other methods known in the art (Step42).

The tank shell components containing installed PMD devices are then assembled and joined into finished tanks and liners (Step44). Assembling and joining comprise gas tungsten arc welding, electron beam welding, laser beam welding and other methods known in the art. If the finished product is a tank, the tank is then qualified for service (Step46). If the finished product is a COPV, the assembled liner containing installed PMD devices is then overwrapped with composite fibers to form a COPV (Step48). The COPV is then qualified for service (Step50).

As noted earlier, compatibility, in particular chemical stability and wettability between hydrazine fuel, fuel tank interior surfaces, and PMD components is critical for mission success. Thin film coatings of titanium and titanium alloys on aluminum alloy fuel tank systems have achieved successful mission requirements and eliminated the need for bulk titanium or titanium alloy tank structures. The titanium and titanium alloy coatings disclosed in commonly owned Ser. No. 13/052,862 and incorporated herein in its entirety are deposited by physical vapor deposition, chemical vapor deposition, sputtering, and electroplating. As shown below, hydrazine wettability of the coated surfaces was less than complete and additional surface treatment is required to satisfy mission requirement of complete wettability.

Wettability of hydrazine on a titanium or titanium alloy coated aluminum alloy surface can be conveniently measured by the wetting or contact angle between a fuel droplet and the substrate surface as shown schematically inFIGS. 3A and 3B. InFIG. 3A, the wettability of hydrazine droplet52on aluminum alloy substrate54is indicated by contact angle56. InFIG. 3A, aluminum alloy substrate54is partially wet by hydrazine droplet52as indicated by wetting or contact angle56being positive. Wettability increases as the contact angle decreases. Complete wettability, as shown inFIG. 3B, occurs when the contact angle is zero.

Evaluations were made of the compatibility of hydrazine on CP Titanium coatings produced by physical vapor deposition on 6061-T6 aluminum alloy substrates. The coatings were deposited in an argon purged chamber at 200° C. after a maximum bake out temperature of 400° C. The compatibility was measured by examining the profile of a hydrazine droplet on a clean titanium coated aluminum alloy substrate in an argon purged chamber at room temperature. The results are shown inFIG. 4.FIG. 4is a photograph showing the profile of hydrazine droplet52on aluminum alloy substrate54wherein contact angle56is indicated by a line tangent to the droplet at the point of intersection of the droplet with the substrate surface. In this case, contact angle56is about 20 degrees, indicating acceptable contact but incomplete wetting. This feature was a general result of titanium or titanium alloy films deposited on aluminum alloys by vapor phase processes such as physical vapor deposition. Complete wetting (i.e. zero contact angle) was achieved in all cases by treating the surface with an aqueous solution of 30 wt. % nitric acid and 3 wt. % hydrofluoric acid. A vacuum solution heat treat at 529° C. followed by an argon quench and a 177° C. aging treatment restored the T6 properties and subsequent usefulness of the 6061 aluminum alloy PMD component substrate.

In an embodiment of the present invention, intermediate surface treatments to enhance wettability and heat treatments to restore mechanical properties are unnecessary. The titanium and titanium alloy coating deposition process of the present invention produces coatings that exhibit complete wetting against hydrazine fuel with no additional treatment or chemical processing. The titanium and titanium alloy coatings of the present invention are produced on aluminum alloy components for PMD application by plasma powder spray.

A schematic of plasma powder spray process60is shown inFIG. 5. Plasma spray process60comprises plasma torch62, powder source70, and target80. Plasma torch62comprises cathode64, anode66, and a plasma gas source, not shown, but indicated by arrows68. A DC or AC, typically RF, potential between cathode64and anode66ignites plasma plume78directed at target80. Powder source70provides feedstock for plasma coating82on substrate84. Powder source70comprises tube72carrying a powder feedstock in a gas stream indicated schematically by arrow74. Powders injected in plasma plume78are accelerated towards target70in arrays of partially and/or completely molten particles76where they impact target80to form coating82.

In the present invention, particle feedstock74may be pure titanium or titanium alloy powder. Plasma powder spraying may be carried out in vacuum or inert atmospheres. Plasma powder sprayed titanium or titanium alloy thicknesses may range from about 30 microns (1.2 mil) to about 200 microns (7.8 mil). Alternatively, from about 50 microns (2 mil) to about 130 microns (5.1 mil).

In contrast to PVD titanium and titanium alloy thin film coatings on aluminum alloy substrates, plasma spray titanium and titanium alloy coatings exhibited complete wetting when contacted with hydrazine fuel. Furthermore, the coatings may be deposited at room temperature. Post coating acid etching and solution quench and age heat treatments are not necessary. Since plasma spray is a line of sight coating process, the process is suitable for larger robust and structural PMD components. Vapor phase coating is still recommended for smaller, delicate aluminum PMD components.