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Space Administration

IS20

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i

NASA/CR—2012–217472

Design and Fabrication of a Tank-Applied 

Broad Area Cooling Shield Coupon

J.J. Wood and M.R. Middlemas

Yetispace, Huntsville, Alabama

November 2012

Prepared for Marshall Space Flight Center

under Contract NAS8-02060

National Aeronautics and

Space Administration

Marshall Space Flight Center • Huntsville, Alabama 35812
ii

Available from:

NASA Center for AeroSpace Information

7115 Standard Drive

Hanover, MD 21076–1320

443–757–5802

This report is also available in electronic form at

<https://www2.sti.nasa.gov/login/wt/>
iii

TABLE OF CONTENTS

1. INTRODUCTION ............................................................................................................ 1

1.1 Background ................................................................................................................. 1

1.2 Objectives .................................................................................................................... 1

1.3 Approach ..................................................................................................................... 2

2. TEST ARTICLE ELEMENTS .......................................................................................... 3

2.1 Tank Surface and Priming ........................................................................................... 3

2.2 Spray-On Foam Insulation .......................................................................................... 3

2.3 Multilayer Insulation ................................................................................................... 4

2.4 Broad Area Cooling Shield .......................................................................................... 6

2.5 Broad Area Cooling Shield Standoffs .......................................................................... 7

3. TEST RESULTS ................................................................................................................ 12

3.1 Test Setup .................................................................................................................... 12

3.2 Post-Test Evaluation .................................................................................................... 12

4. CONCLUSIONS ............................................................................................................... 13

REFERENCES ....................................................................................................................... 15
iv
v

LIST OF FIGURES

1. Primed aluminum panel ........................................................................................... 3

2. Application of Versi-Foam System 10 ...................................................................... 4

3. Insulation system cross-sectional layup .................................................................... 5

4. Inner MLI blanket: a) side view and b) overhead view ............................................. 5

5. Outer MLI blanket with Beta cloth cover ................................................................ 6

6. BAC shield layup ..................................................................................................... 7

7. Test article configuration .......................................................................................... 8

8. BAC shield standoff assembly .................................................................................. 9

9. BAC shield standoff cap assembly ........................................................................... 9

10. BAC shield: a) without MLI blanket, b) with inner MLI blanket, 

 and c) standoff attachment detail ............................................................................. 11

11. Test panel in acoustic chamber ................................................................................ 12
vi
vii

LIST OF ACRONYMS

BAC broad area cooling 

CFM cryogenic fluid management 

CPST cryogenic propellant storage and transfer 

GTA ground test article

MLI multilayer insulation

MSFC Marshall Space Flight Center

SOFI spray-on foam insulation
viii
CONTRACTOR REPORT

DESIGN AND FABRICATION OF A TANK-APPLIED BROAD AREA COOLING 

SHIELD COUPON

1. INTRODUCTION

1.1 Background

The NASA Cryogenic Propellant Storage and Transfer (CPST) project is developing a 

flight test article to assess cryogenic fluid management (CFM) technologies in a low-gravity 

environment. Multilayer insulation (MLI) and broad area cooling (BAC) shield systems are 

among the key technologies planned for evaluation. BAC shield technology has been developed 

to aid in reducing heat leak through the wall of cryogenic tanks in recent years. Several 

studies1,2,3 have demonstrated the potential thermal benefit of BAC shields; however, the BAC 

shield subsystem has had limited thermal testing and no structural analysis or testing prior to this 

effort. A BAC shield is a tube and fin heat exchanger that wraps around a cryogenic tank to 

provide active cooling. In the case of a hydrogen tank and 90 K cryocooler, the BAC shield is 

imbedded in the MLI blanket’s approximate midpoint. The MLI/BAC shield system must be 

designed to withstand launch dynamic loads. Leaks introduce a conductive heat transport 

mechanism inside the MLI blankets. Seals, fittings, welds, or fractures can be leak sources that 

result in loss of mission. Physical damage to the MLI would reduce its effectiveness and shorten 

mission duration by increasing heat load. The threat of a leak in BAC shield tubing or physical 

damage to MLI during launch is a major risk to a successful CPST mission.

Prior to fielding the CPST flight article, a fully integrated ground test article (GTA) based 

on the anticipated flight article design is being developed. The GTA will include a fully 

integrated MLI/BAC shield system designed for flight.

1.2 Objectives

The overall objective of the small-scale BAC shield acoustic test was to evaluate the 

structural performance of the BAC shield coupon in a simulated launch dynamic environment.

Specific design and test goals are as follows:

1. Develop a preliminary design for restraining an integrated MLI/BAC shield system to 

withstand launch loads.

2. Evaluate varied unsupported BAC shield tube lengths in a simulated launch dynamic 

environment.

3. Assess the interface between the BAC shield tube and the BAC shield support standoff in 

a simulated launch dynamic environment.
2

1.3 Approach

Two structural evaluations of the BAC shield were initially considered: an acoustic test in 

an acoustic chamber, and a random vibration test on a shaker table. The BAC shield is 

lightweight and has a large surface area. These two characteristics suggest that the dominant 

dynamic load on the BAC shield will be due to the launch acoustic loads, rather than dynamic 

loads transmitted through structure, as would be the case for smaller, heavier components 

attached to structure. Acoustic testing will likely provide a worst-case environment for 

evaluating the BAC shield design.

The small-scale BAC shield test is a precursor to a fully tank-integrated system on a 

flight-scale tank. The panel was sized for quick, inexpensive build to gain insight and identify 

issues as quickly as possible. It was designed to be similar to a section taken out of the CPST 

GTA, without the complex curve of the end caps. This approach allowed for multiple BAC tubes 

to be represented with manifolds on either end. The presence of three vertical tubes allowed for 

three different spacings between standoffs to be tested. Unsupported tube lengths between 

standoffs ranged from 18 in to 36 in. Fewer standoffs were desirable to minimize heat leak 

between the 90 K shield and 20 K tank in application. This heat leak decreased the benefit of the 

BAC shield.
3

2. TEST ARTICLE ELEMENTS

2.1 Tank Surface and Priming

The CPST GTA tank is a thin-walled, 5-ft-diameter, aluminum pressure vessel. The test 

panel represented the tank shell with a 1/8-in-thick aluminum sheet that was rolled to a 5-ftdiameter curve. The panel, shown in Figure 1, was cut to a 3-ft-wide by 5-ft-long shape. The 

aluminum was cleaned, wash primed, and epoxy primed. This priming process was required for 

the proper adhesion of spray-on foam insulation (SOFI) to the tank surface. Two pieces of angle 

aluminum were bolted to the lateral edges of the panel to maintain the true shape and to add 

stiffness.

Figure 1. Primed aluminum panel.

2.2 Spray-On Foam Insulation

SOFI installed on hydrogen tanks prevents condensation on the surface of the tank in the 

absence of a complex helium purge bag subsystem normally required with MLI on cryogenic 

tanks during ground hold periods. The SOFI thickness was determined analytically based on the 

system configuration, primarily the number of MLI layers. Applying the minimum allowable 

amount of SOFI was desirable because the SOFI has little benefit in a vacuum and is added 

mass.

The primed aluminum panel was covered with a 1/2-in (+1/4-in-tolerance) layer of VersiFoam System 10, an off-the-shelf high-density foam suitable for cryogenic applications. The 

BAC shield standoffs were mounted to the panel and masked during SOFI application to provide 

needed cavities in the SOFI. After the foam cured, the standoffs were removed and the foam was 

trimmed to the proper dimension. The process is shown in Figure 2a and Figure 2b.
4

a) b)

Figure 2. Application of Versi-Foam System 10.

2.3 Multilayer Insulation

MLI provides thermal protection for cryogenic tanks from radiation in vacuum. The

CPST MLI system consisted of two blankets: a 30-layer inner MLI blanket of a 10-layer/cm

density that was situated between the outer surface of the SOFI and the bottom of the BAC 

shield, and a 30-layer outer MLI blanket of a 20-layer/cm density that was configured on top of 

the BAC shield. The cross-sectional layup of the system is illustrated in Figure 3. The blankets 

were constructed out of the following materials based on the recommendations given in the 

MSFC MLI material guidelines4

: 

• Reflector layers: Double-aluminized 0.25-mil polyester (Mylar) film coated with 1000Å 

of aluminum

• Separator layers: B4A (0.2 oz/yd2

) polyester (Dacron) netting

• Bumper strips: B2A (0.4 oz/yd2

) polyester (Dacron) netting

• Inner covers: Nomex-reinforced polyimide (Kapton) film, aluminized on both sides and 

porolated with ~120 needle perforations per square inch

• Outer cover: Beta cloth

• Blanket edges: Aluminized Kapton tape sewn with Kevlar thread
5

Figure 3. Insulation system cross-sectional layup.

Bumper strips made from folded layers of Dacron netting were used to increase the 

spacing between the reflector layers to achieve the desired density for the inner blanket, shown in 

Figure 4a. Inner covers were added to increase handling strength and to protect the MLI blankets 

from the BAC shield. The Nomex-reinforced Kapton cover is shown in Figure 4b. Beta cloth 

was selected as the outermost blanket layer to represent a flight-like configuration, as shown in 

Figure 5.

a) b)

Figure 4. Inner MLI blanket: a) side view, and b) overhead view.
6

Figure 5. Outer MLI blanket with Beta cloth cover.

The blankets’ layers were draped over the test panel to incorporate the curvature of the 

panel prior to sewing. All of the blanket edges were wrapped with Kapton tape. Strips of Velcro 

loop were sewn along the underside of the long edges of the blankets. Corresponding strips of 

Velcro hook were adhesively attached to the aluminum extrusions used to stiffen the test panel.

The top and bottom edges of the blankets were not attached to the panel. This reduced the 

constraint of the blanket and better represented a tank-integrated blanket.

2.4 Broad Area Cooling Shield

The BAC shield is a tube array used to circulate chilled gas around the cryogenic tank.

Aluminum panels were bonded to the tubes (Figure 6) to maintain a constant temperature across 

the entire BAC shield. The test panel was configured with the dimensions shown in Figure 6.

The upper and lower manifolds were formed from 3/8-in 316L stainless steel tubing. The cooling 

lines were formed from 1/4-in tubing. Orbital welding using Swagelok automatic tube weld 

fittings was used to connect the tubing to minimize the risk of leaks. After welding, the assembly 

was helium leak checked and no detectable leaks were found.

To maximize heat transfer from the stainless steel tubing, aluminum foil panels were 

bonded to both sides of the tubing, shown in Figure 6. The edges of the foil were folded over to 

eliminate any sharp edges that could damage the MLI or cause a safety hazard during 

installation. Beads were formed in the foil to increase the bonding area. The beads were sized to 

allow for a 15-mil-thick bond line between the foil and the tubes. The foil panels were bonded to 

the tubes using an epoxy adhesive (Hysol 9430). The adhesive was cured at 180°F for 2 hr per 

the manufacturer’s instructions.
7

Figure 6. BAC shield layup.

2.5 Broad Area Cooling Shield Standoffs

The BAC shield was supported by 11 standoffs designed and analyzed by ER34, 

ER43/Tec-Masters, and ER41/Dynamic Concepts at MSFC, shown in Figure 7. The standoff 

concept was a proposed solution to balance the thermal and structural requirements of the 

system. In implementation on an LH2 tank, the standoffs extended from the surface of the tank at 

a temperature of approximately 20 K to the BAC shield at a temperature of approximately 90 K.

This dramatic temperature difference resulted in a nontrivial heat leak through the standoff, 

which was undesirable. However, structural instability in the system was also highly undesirable 

due to the risk of a shortened mission or loss of mission or resulting from damage to the BAC 

tubes or MLI.
8

1/4” Stando!s

3/8” Stando!s

18”

18”

18”

15”

15”

6”

16”

36”

2.5” 3” 2.5”

2”

24”

9.5” 6.5”

2.5” 9.5” 3” 9”

50” 54” 60”

36”

Figure 7. Test article configuration.
9

The standoffs were 2.5 in tall to properly position the BAC shield in the MLI blanket. 

They were machined from the polyetherimide material Ultem 1000. Ultem 1000 was selected for

its low thermal conductivity, acceptable mechanical properties at cryogenic temperatures, 

availability, and cost. The BAC tubes were supported in a cradle at the head of the standoffs and 

held in place by a cap secured with two opposed retaining rings, shown in Figure 8 and Figure 9.

The standoffs were bolted to the aluminum panel with the locations situated to give different 

unsupported tube lengths in the BAC shield, as seen in Figure 7. 

Figure 8. BAC shield standoff assembly.

Figure 9. BAC shield standoff cap assembly.
10

Assessing the tube condition during and after testing as a function of the unsupported 

tube length was a primary goal of the test. Unsupported 1/4-in tube lengths of 18-, 24-, and 36-in 

were evaluated in this configuration. The 3/8-in tube manifold lines were also supported by 

standoffs, but these lines were less consequential to the GTA application because the manifold 

lengths were relatively short and existed only at the top of the tank. The 1/4-in tubes spanned the 

entire length of the tank and required more supports; thus, the test setup was focused on 

evaluating the 1/4-inch tube lengths.

Integration of the standoffs into the MLI/BAC shield system was approached in such a 

way as to inflict minimal impact on the existing system. The standoffs were mounted directly to 

the primed aluminum panel, with the SOFI conforming to the bottom 1/2 in of each standoff. The 

inner MLI blanket was perforated at each standoff interface location to allow the MLI blanket to 

lie naturally on the SOFI surface. Holes were punched in the BAC shield material at each 

standoff interface point, but the shield material was otherwise left undisturbed. The outer MLI 

blanket remained completely intact with no impact as a result of the standoffs. The standoff 

integration process is illustrated in Figure 10.

a)

b)
11

c)

Figure 10. BAC shield: a) without MLI blanket, b) with inner MLI blanket, 

and c) standoff attachment detail.
12

3. TEST RESULTS

3.1 Test Setup

The test panel was delivered to the MSFC Acoustic Test Facility located in Building 

4619. The outer MLI blanket was briefly removed to install instrumentation. Before testing, the 

tubes were evacuated and then pressurized with 100 psia neon, which is the gas expected to be 

used in the BAC shield for the GTA. The panel was suspended from the ceiling in the acoustic 

chamber for testing, shown in Figure 11.

Figure 11. Test panel in acoustic chamber.

3.2 Post-Test Evaluation

Immediately following the acoustic test, the pressure in the BAC shield was measured to 

verify that no leaks in the tubing or welds formed as a result of the test. No pressure drop was 

observed. The test panel was disassembled and visually inspected for damage. The inner and 

outer MLI blankets were inspected for tears or abrasion. The BAC shield was inspected for 

cracks or bends in the aluminum foil, or bends in the tube array. No damage was evident in the 

MLI blankets or the BAC shield assembly. Further details regarding the acoustic analysis and 

testing may be found in Reference 5. 
13

4. CONCLUSIONS

The small-scale BAC shield acoustic test article was designed and assembled as a coupon 

representation of the CPST GTA tank-integrated BAC shield. The tank material, primer, SOFI, 

inner MLI blanket, BAC shield, and outer MLI blanket made up the test article per the current 

GTA configuration. This test panel was assembled and delivered to the MSFC Acoustic Test 

Facility for testing in a simulated worst-case launch acoustic environment. Prior to testing, the 

BAC shield tubes were pressurized with 100 psia of gaseous neon. After testing, the pressure in 

the tubes was measured to determine whether a pressure drop occurred during testing. No 

pressure drop was noted, and no damage to the BAC shield or MLI was found during detailed 

visual examination.

This test article development effort focused on the structural element of the BAC shield.

A preliminary design for a standoff to support the BAC shield tube and constrain its movement 

was developed and physically implemented. The interface between this standoff and tube was 

carefully examined to detect any evidence of stress or damage to the tube or standoff; none was 

noted. The unsupported tube length between standoffs was also of interest during testing.

Distances of 18, 24, and 36 in were tested, and all three unsupported tube lengths appeared 

acceptable. A longer unsupported line length was desirable because fewer standoffs were 

required, resulting in less total conductive heat transfer through the standoffs to the tank surface.

Future testing should be performed using an MLI/BAC shield system integrated onto a flightscale tank.

15 

References 

1. Feller, J.R., Salerno, L.J., Kashani, A., Maddocks, J.R., Helvensteijn, B.P.M., Nellis, 

G.F., and Gianchardani, Y.B., “Distributed Cooling Techniques for Cryogenic Boil-Off 

Reduction Systems,” Cryocoolers 15, Kluwer Academic, New York, pp. 631–635, 2009. 

2. Feller, J.R., Plachta, D.W., Mills, G., and McLean, C. “Demonstration of a Cryogenic 

Boil-Off Reduction System Employing an Actively Cooled Thermal Radiation Shield,” 

Cryocoolers 16, International Cryocoolers Conference, Inc., Boulder, Colorado, pp. 601–

609, 2011. 

3. Feller, J.R., Kashani, A., Helvensteijn, B.P.M., and Salerno, L.J., “Characterization of an 

Actively Cooled Metal Foil Thermal Radiation Shield,” Advances in Cryogenic 

Engineering, AIP, New York, 2010. 

4. Finckenor, M.M., and Dooling, D.D., “Multilayer Insulation Material Guidelines,” 

NASA/TP-1999-209263, April 1998. 

5. Jones, J., “Cryogenic Propellant Storage and Transfer Small-Scale Broad Area Cooling 

Shield Acoustic Test,” Report ER41-12-005, Jacobs Engineering Group, Inc., Marshall 

Space Flight Center, Huntsville, Alabama, March 2012. 
ix

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Design and Fabrication of a Tank-Applied 

Broad Area Cooling Shield Coupon

J.J. Wood and M.R. Middlemas

George C. Marshall Space Flight Center, Huntsville, AL 35812

Yetispace, Inc., 3701 Lakewood Dr. N.W., Huntsville, AL 35811

National Aeronautics and Space Administration

Washington, DC 20546–0001

Unclassified-Unlimited

Subject Category 39

Availability: NASA CASI (443–757–5802)

Prepared for Propulsion Systems Department, Engineering Directorate

COTR: Mary Traweek

M–1348

NAS8-02060

Contractor Report March 5, 2012

NASA/CR—2012–217472

cryogenic fluid management, cryogenic propellant storage and transfer, broad area cooling shield, 

multilayer insulation, acoustic test

01–11–2012

UU 28

NASA

U U U

The small-scale broad area cooling (BAC) shield test panel represents a section of the cryogenic propellant storage and transfer 

ground test article, a flight-like cryogenic propellant storage tank. The test panel design includes an aluminum tank shell, primer, 

spray-on foam insulation, multilayer insulation (MLI), and BAC shield hardware. This assembly was sized to accurately represent 

the character of the MLI/BAC shield system, be quickly and inexpensively assembled, and be tested in the Marshall Space Flight 

Center Acoustic Test Facility. Investigating the BAC shield response to a worst-case launch dynamic load was the key purpose 

for developing the test article and performing the test. A preliminary method for structurally supporting the BAC shield using 

low-conductivity standoffs was designed, manufactured, and evaluated as part of the test. The BAC tube-standoff interface and 

unsupported BAC tube lengths were key parameters for evaluation. No noticeable damage to any system hardware element was 

observed after acoustic testing. 

STI Help Desk at email: help@sti.nasa.gov

STI Help Desk at: 443–757–5802
The NASA STI Program...in Profile

Since its founding, NASA has been dedicated to the 

advancement of aeronautics and space science. The 

NASA Scientific and Technical Information (STI) 

Program Office plays a key part in helping NASA 

maintain this important role.

The NASA STI Program Office is operated by 

Langley Research Center, the lead center for 

NASA’s scientific and technical information. The 

NASA STI Program Office provides access to 

the NASA STI Database, the largest collection of 

aeronautical and space science STI in the world. 

The Program Office is also NASA’s institutional 

mechanism for disseminating the results of its 

research and development activities. These results 

are published by NASA in the NASA STI Report 

Series, which includes the following report types:

• TECHNICAL PUBLICATION. Reports of 

completed research or a major significant 

phase of research that present the results of 

NASA programs and include extensive data 

or theoretical analysis. Includes compilations 

of significant scientific and technical data 

and information deemed to be of continuing 

reference value. NASA’s counterpart of peerreviewed formal professional papers but has less 

stringent limitations on manuscript length and 

extent of graphic presentations.

• TECHNICAL MEMORANDUM. Scientific 

and technical findings that are preliminary or of 

specialized interest, e.g., quick release reports, 

working papers, and bibliographies that contain 

minimal annotation. Does not contain extensive 

analysis.

• CONTRACTOR REPORT. Scientific and 

technical findings by NASA-sponsored 

contractors and grantees.

• CONFERENCE PUBLICATION. Collected 

papers from scientific and technical conferences, 

symposia, seminars, or other meetings sponsored 

or cosponsored by NASA.

• SPECIAL PUBLICATION. Scientific, technical, 

or historical information from NASA programs, 

projects, and mission, often concerned with 

subjects having substantial public interest.

• TECHNICAL TRANSLATION. 

English-language translations of foreign 

scientific and technical material pertinent to 

NASA’s mission.

Specialized services that complement the STI 

Program Office’s diverse offerings include creating 

custom thesauri, building customized databases, 

organizing and publishing research results...even 

providing videos.

For more information about the NASA STI Program 

Office, see the following:

• Access the NASA STI program home page at 

<http://www.sti.nasa.gov>

• E-mail your question via the Internet to 

<help@sti.nasa.gov>

• Fax your question to the NASA STI Help Desk 

at 443 –757–5803

• Phone the NASA STI Help Desk at 

443 –757–5802

• Write to:

NASA STI Help Desk

NASA Center for AeroSpace Information

7115 Standard Drive

Hanover, MD 21076–1320
National Aeronautics and

Space Administration

IS20

George C. Marshall Space Flight Center

Huntsville, Alabama 35812