Simulating clefts in pumpkin balloons

The geometry of a large axisymmetric balloon with positive differential pressure, such as a sphere, leads to very high film stresses. These stresses can be significantly reduced by using a tendon re-enforced lobed pumpkin-like shape. A number of schemes have been proposed to achieve a cyclically symmetric pumpkin shape, including the constant bulge angle (CBA) design, the constant bulge radius (CBR) design, CBA/CBR hybrids, and NASA’s recent constant stress (CS) design. Utilizing a hybrid CBA/CBR pumpkin design, Flight 555-NT in June 2006 formed an S-cleft and was unable to fully deploy. In order to better understand the S-cleft phenomenon, a series of inflation tests involving four 27-m diameter 200-gore pumpkin balloons were conducted in 2007. One of the test vehicles was a 1/3-scale mockup of the Flight 555-NT balloon. Using an inflation procedure intended to mimic ascent, the 1/3-scale mockup developed an S-cleft feature strikingly similar to the one observed in Flight 555-NT. Our analysis of the 1/3-scale mockup found it to be unstable. We compute asymmetric equilibrium configurations of this balloon, including shapes with an S-cleft feature.     

Cleft formation in pumpkin balloons

NASA’s development of a large payload, high altitude, long duration balloon, the Ultra Long Duration Balloon, centers on a pumpkin shape super-pressure design. Under certain circumstances, it has been observed that a pumpkin balloon may be unable to pressurize into the desired cyclically symmetric equilibrium configuration, settling into a distorted, undesired state instead. Success of the pumpkin balloon for NASA requires a thorough understanding of the phenomenon of multiple stable equilibria and developing of means for the quantitative assessment of design measures that prevent the occurrence of undesired equilibrium. In this paper, we will use the concept of stability to classify cyclically symmetric equilibrium states at full inflation and pressurization. Our mathematical model for a strained equilibrium balloon, when applied to a shape that mimics the Phase IV-A balloon of Flight 517, predicts instability at float. Launched in Spring 2003, this pumpkin balloon failed to deploy properly. Observations on pumpkin shape type super-pressure balloons that date back to the 1980s suggest that within a narrowly defined design class of pumpkin shape super-pressure balloons where individual designs are fully described by the number of gores n_g and by a single measure of the bulging gore shape, the designs tend to become more vulnerable with the growing number of gores and with the diminishing size of the bulge radius r_B Weight efficiency considerations favor a small bulge radius, while robust deployment into the desired cyclically symmetrical configuration becomes more likely with an increased bulge radius. In an effort to quantify this dependency, we will explore the stability of a family of balloon shapes parametrized by (n_g, r_B) which includes a design that is very similar, but not identical, to the balloon of Flight 517. In addition, we carry out a number of simulations that demonstrate other aspects related to multiple equilibria of pumpkin balloons.     

Mechanical properties of ANTRIX balloon film and fabrication of single cap large volume balloons

The zero pressure plastic balloons used for high altitude studies are generally made from polyethylene material. Tensile properties of the thin film polymer are the key parameters for material selection due to extremely low temperature of −90 °C encountered by the balloons in the tropopause region during the ascent at equatorial latitudes. The physical and structural properties of the material determine the uniformity of the stress distribution over the entire shell. Load stresses from the suspended load propagate via load tapes heat sealed along with the gore seals as per the balloon design. A balance between this heat seal strength and the film strength is a desirable property of the basic resin in terms of the bubble strength, gauge uniformity, and long-term storage properties. In addition, the design of the top shell of the balloon and its stress distribution play an important role since only a fraction of the balloon is deployed during the filling operation and the ascent. In this paper we describe the mechanical properties of the ‘ANTRIX’ film developed by us and the optimized design of single cap balloons, which have been successfully used in our experiments over the past 5 years.     

Balloon film strain measurement

In order to understand the state of stress in scientific balloons, a need exists for the measurement of film deformation in flight. The results of a flight test program are reported where material strain was measured for the first time during the inflation, launch, ascent and float of a typical natural shape, zero pressure scientific balloon.     

A challenge to the highest balloon altitude

Development of a balloon to fly at higher altitudes is one of the most attractive challenges for scientific balloon technologies. After reaching the highest balloon altitude of 53.0 km using the 3.4 μm film in 2002, a thinner balloon film with a thickness of 2.8 μm was developed. A 5000 m³ balloon made with this film was launched successfully in 2004. However, three 60,000 m³ balloons with the same film launched in 2005, 2006, and 2007, failed during ascent. The mechanical properties of the 2.8 μm film were investigated intensively to look for degradation of the ultimate strength and its elongation as compared to the other thicker balloon films. The requirement of the balloon film was also studied using an empirical and a physical model assuming an axis-symmetrical balloon shape and the static pressure. It was found that the film was strong enough. A stress due to the dynamic pressure by the wind shear is considered as the possible reason for the unsuccessful flights. A 80,000 m³ balloon with cap films covering 9 m from the balloon top will be launch in 2011 to test the appropriateness of this reinforcement.     

A constitutive equation for stratospheric balloon materials

The selection of a suitable material for use as a reliable stratospheric balloon gas barrier and structural component is based on a variety of properties. Due to a more desirable combination of properties, the low density polyethylene that has been used for the last half century has been replaced during the last decade by linear low density polyethylene (LLDPE). This paper describes the effort to characterize the time dependent properties of a 38 micron coextrusion of LLDPE. The nonlinear viscoelastic constitutive equation presented may be used to accurately describe the creep and/or relaxation of this film when subjected to a biaxial state of stress, such as might be required for an extended balloon flight. Recent laboratory data have been used to modify an existing model of LLDPE to account for differences caused by the coextrusion process. The new model will facilitate structural design optimization and reliability assessment, and may be further utilized as a predictive tool to benefit in-flight operations. Current structural analysis techniques based on linear elastic properties have predicted stresses in excess of those which would actually exist.     

Development of a super-pressure balloon with a diamond-shaped net

The essential reason of the lobed-pumpkin shaped super-pressure balloon to withstand against the high pressure is that the local curvature of the balloon film is kept small. Recently, it has been found that the small local curvature can also be obtained if the balloon is covered by a diamond-shaped net with a vertically elongated shape. The development of the super-pressure balloon using this method was started from a 3-m balloon with a polyethylene film covered by a net using Kevlar ropes. The ground inflation test showed the expected high burst pressure. Then, a 6-m and a 12-m balloon using a polyethylene film and a net using the Vectran were developed and stable deployment was checked through the ground inflation tests. The flight test of a 3000 m³ balloon was performed in 2013 and shown to resist a pressure of at least 400 Pa. In the future, after testing a new design to relax a possible stress concentration around the polar area, test flights of scaled balloons will be performed gradually enlarging their size. The goal is to launch a 300,000 m³ super-pressure balloon.     

Technology development for a long duration,mid-cloud level Venus balloon

This paper describes the results of ongoing technology development activities for a Venus spherical superpressure balloon capable of flying for long durations (30 days) in the middle cloud layer at an altitude of 55.5 km. Data is presented from a successful aerial deployment and inflation flight experiment on a 5.5 m diameter prototype balloon conducted at a 2.5 km altitude above the Earth. Although the balloon in that test was not released for free flight, all other steps in the deployment and inflation process were successfully executed. Experimental and computational results are also presented from an investigation of the stress concentration phenomenon at the junction of the metal end fitting and fabric end cap of the prototype Venus balloon. Good agreement was found between the simulation and experimental results and a stress concentration factor of 1.55 determined for this end cap design compared to the expectations of thin membrane theory. Finally, results are presented for a new, second-generation Venus balloon material utilizing Aclar™ film instead of Teflon. Optical property and sulfuric acid tolerance data are presented for this material based on laboratory testing of samples.     

Investigation of ultra violet (UV) resistance for high strength fibers

Ultra long duration balloons (ULDB), currently under development by the National Aeronautics and Space Administration (NASA), requires the use of high strength fibers in the selected super-pressure pumpkin design. The pumpkin shape balloon concept allows clear separation of the load transferring functions of the major structural elements of the pneumatic envelope, the tendons and the film. Essentially, the film provides the gas barrier and transfers only local pressure load to the tendons. The tendons, in the mean time, provide the global pressure containing strength. In that manner, the strength requirement for the film only depends on local parameters. The tendon is made of p-phenylene-2,6-benzobisoxazole (PBO) fibers, which is selected due to its high strength to weight ratio when compared to other high performance, commercially available, fibers. High strength fibers, however, are known to degrade upon exposure to light, particularly at short wavelengths. This paper reports the results of an investigation of the resistance of four commercial high strength fibers to ultra violet (UV) exposure. The results indicate that exposing high strength fibers in continuous yarn form to UV led to serious loss in strength of the fibers except for Spectra^® fibers. The adverse changes in mechanical behavior occurred over short duration of exposure compared to the 100 day duration targeted for these missions. UV blocking finishes to improve the UV resistance of these fibers are being investigated. The application of these specially formulated coatings is expected to lead to significant improvement of the UV resistance of these high performance fibers. In this publication, we report on the mechanical behavior of the fibers pre- and post-exposure to UV, but without application of the blocking finishes.     

Development overview of the revised NASA Ultra Long Duration Balloon

The desire for longer duration stratospheric flights at constant float altitudes for heavy payloads has been the focus of the development of the National Aeronautics and Space Administration’s (NASA) Ultra Long Duration Balloon (ULDB) effort. Recent efforts have focused on ground testing and analysis to understand the previously observed issue of balloon deployment. A revised approach to the pumpkin balloon design has been tested through ground testing of model balloons and through two test flights. The design approach does not require foreshortening, and will significantly reduce the balloon handling during manufacture reducing the chances of inducing damage to the envelope. Successful ground testing of model balloons lead to the fabrication and test flight of a ∼176,000 m³ (∼6.2 MCF – Million Cubic Foot) balloon. Pre-flight analytical predictions predicted that the proposed flight balloon design to be stable and should fully deploy. This paper provides an overview of this first test flight of the revised Ultra Long Duration Balloon design which was a short domestic test flight from Ft. Sumner, NM, USA. This balloon fully deployed, but developed a leak under pressurization. After an extensive investigation to the cause of the leak, a second test flight balloon was fabricated. This ∼176,000 m³ (∼6.2 MCF) balloon was flown from Kiruna, Sweden in June of 2006. Flight results for both test flights, including flight performance are presented.     

Prototype design and testing of a Venus long duration,high altitude balloon

This paper describes the design, fabrication and testing of a full scale prototype balloon intended for long duration flight in the upper atmosphere of Venus. The balloon is 5.5 m in diameter and is designed to carry a 45 kg payload at an altitude of 55 km. The balloon material is a 180 g/m² multi-component laminate comprised of the following layers bonded together from outside to inside: aluminized Teflon film, aluminized Mylar film, Vectran fabric and a polyurethane coating. This construction provides the required balloon functional characteristics of low gas permeability, sulfuric acid resistance and high strength for superpressure operation. The design burst superpressure is 39,200 Pa which is predicted to be 3.3 times the worst case value expected during flight at the highest solar irradiance in the mission profile. The prototype is constructed from 16 gores with bi-taped seams employing a sulfuric acid resistant adhesive on the outside. Material coupon tests were performed to evaluate the optical and mechanical characteristics of the laminate. These were followed by full prototype tests for inflation, leakage and sulfuric acid tolerance. The results confirmed the suitability of this balloon design for use at Venus in a long duration mission. The various data are presented and the implications for mission design and operation are discussed.     

Experimental and numerical simulation of super-pressure balloon apex section: Mechanical behavior in realistic flight conditions

In order to predict the flight parameters and to improve the life time of long duration super-pressure balloon, a research program on modelization and experimental simulation of the balloon envelope mechanical behavior is carried out.The balloon is a 10 m diameter type made with multilayer polymeric films and tapes. A facility was developed to measure, via a stereo-correlation system, the 3D displacement and the in plane solicitation strain of a 1.5 m diameter balloon envelope part in realistic flight conditions, i.e. pressure, temperature and loading at the sample boundaries. A time dependant non-linear Maxwell model of the polymeric material behavior was identified from uniaxial creep and relaxation tests and implemented in a Finite Elements code, simulating the sample tested in the facility. The Poisson ratio of the transparent and supple balloon film has been measured with an image correlation system.Experimental results are obtained both at room and in cold conditions (−60 °C) for various values of differential pressure.Vertical displacement and in plane 2D strain of apex part deduced from the numerical modeling are compared to experimental results.     

基于褶皱的平流层浮空器升空结构形变模拟

平流层浮空器囊体材料具有非线性、黏弹性、各向异性和不能抗压等特点,起皱现象是在升空膨胀过程中必然会出现的形变状态,褶皱的扩展会影响整个囊体结构的受力状态,改变囊体变形和应力分布.同时,褶皱的存在还会影响囊体结构的动力学行为和空间环境下的热力学分布.通过主应力-主应变相结合准则对褶皱区域进行判别,采用修正褶皱单元的本构矩阵方程的方法对褶皱区域进行处理,地面充氦气试验证明了新方法的模拟结果更加接近测试值.从而为平流层浮空器设计提供了一种有效的分析方法.     

Recent materials problems relating to catastrophic balloon failures

Balloons fabricated of thin polyethylene materials have provided relatively inexpensive and reliable scientific research platforms for approximately three decades. Reliability of the modern day balloon, as launched by the U.S.A. National Scientific Balloon Facility (NSBF), has been approximately 85%. Recent balloon failures, coupled with an increased occurrence of catastrophic failures, created grave concern over the integrity of the present balloon inventory of the U.S.A National Aeronautics and Space Administration (NASA). An investigative team was established by NASA to review the circumstances surrounding the catastrophic balloon failures, determine the cause and to make recommendations to correct the problem and to prevent its reoccurrence. The most probable cause of failure as determined by the investigation was the polyethylene balloon film, although the film had passed the established standard quality control measures of the film manufacturer. The approach, findings, and conclusions of the investigation are presented along with planned procedures to assure future quality balloon film for NASA balloons.     

Scientific ballooning in India – Recent developments

Established in 1971, the National Balloon Facility operated by TIFR in Hyderabad, India, is a unique facility in the country, which provides a complete solution in scientific ballooning. It is also one of its kind in the world since it combines both, the in-house balloon production and a complete flight support for scientific ballooning. With a large team working through out the year to design, fabricate and launch scientific balloons, the Hyderabad Facility is a unique centre of expertise where the balloon design, research and development, the production and launch facilities are located under one roof. Our balloons are manufactured from 100% indigenous components. The mission specific balloon design, high reliability control and support instrumentation, in-house competence in tracking, telemetry, telecommand, data processing, system design and mechanics is its hallmark. In the past few years, we have executed a major programme of upgradation of different components of balloon production, telemetry and telecommand hardware and various support facilities. This paper focuses on our increased capability of balloon production of large sizes up to 780,000 m³ using Antrix film, development of high strength balloon load tapes with the breaking strength of 182 kg, and the recent introduction of S-band telemetry and a commandable timer cut-off unit in the flight hardware. A summary of the various flights conducted in recent years will be presented along with the plans for new facilities.     

High altitude flights in equatorial regions

A thorough analysis of balloon flights made from Hyderabad, India (Latitude 17°28′N, Longitude 78°35′E), and other equatorial sites has been made. It has been shown that limited success is expected for flights made from equatorial latitudes with balloons made out of natural colour polyethylene film, since the best known balloon film in the world today viz. Winzen Stratofilm is tested for low temperature brittleness only at ?80°C., whereas the tropopause temperatures over equatorial latitudes vary between ?80°C and ?90°C. The success becomes even more critical when flights are made with heavy payloads and larger balloons particularly at night when in the absence of solar radiation the balloon film becomes more susceptible to low temperature brittle failure. It is recommended that in case of capped balloons longer caps should be used to fully cover the inflated protion of the balloon at the higher level equatorial tropopause. It is also advised that the conditions such as wind shears in the tropopause should be critically studied before launching and a day with the tropopause temperature nearer to ?80°C should be chosen. Special care also should be taken while handling the balloon on ground and during launching phase. Properties of Winzen Stratofilm have been critically studied and fresh mandates have been recommended on the basis of limiting values of film stresses which caused balloon failures in the equatorial tropopause. It is also emphasized that the data on such flights is still meagre especially for flights with heavy payloads and larger balloons. It has been also shown that it is safest to use balloons made out of grey coloured film which retains its flexibility with the absorption of solar radiation, the success obtained with such balloons so far being 100%. The drawback, however, is that these balloons cannot be used for night flights. Stratospheric wind regimes over Hyderabad are also discussed with a view to determine the period over which long duration flights can be made. The data available, however, is meagre and it is recommended that more frequent special wind ascents be made to collect adequate statistical data from which reliable conclusions could be drawn through critical analysis.     

Development of a 2.8 μm film for scientific balloons

Development of a balloon to fly at higher altitudes is one of the most attractive challenges in scientific balloon technologies. After reaching the highest record setting balloon altitude of 53.0 km using the 3.4 μm film in 2002, we tried to make a thinner balloon film. In 2003, we developed a forming die and an air-ring and succeeded in forming a film with a thickness of 3.0 μm and a width of 220 cm. Using this film, we manufactured a balloon with a volume of 5000 m³ and succeeded in flying the balloon up to an altitude of 46.0 km. We then searched for a good combination of resins to make a thinner and wider film and obtained films with widths of 280 cm, and a thickness of 3.0 μm at first, and then 2.8 μm. In 2004, we performed balloon experiments making a 30,000 m³ balloon with the 3.0 μm film and a 5000 m³ balloon with the 2.8 μm film. Both balloons were well manufactured and reached the highest altitudes of 50.7 and 42.6 km, respectively.     

Developments in balloon stress analysis

The use of large plastic balloons as a research tool has increased dramatically since the developmental work of the early 1950's. The continuing demand by the scientific community for higher float altitudes, heavier payloads, and longer flight durations has severely challenged current design and analysis procedures. Previous simplifying assumptions concerning the balloon shape and stress must be reassessed in order to develop better analytical design and stress analysis procedures. A brief history of balloon stress analysis procedures and accompanying assumptions are presented. The limitations of old methods and recent improvements by Smalley, Alexander, Rand, and others are examined and compared. Finite difference and finite element techniques offer promise for more accuracy with fewer over-simplifying assumptions. Available methods are examined for potential use in various stress analysis requirements.     

Scientific ballooning in Japan – An over view of recent activities

Current status of scientific ballooning in Japan is reviewed. First, I describe successful application of balloon technologies to construct a vessel of transparent plastic film, to contain about 1000 tons of liquid scintillator in Kamioka Liquid Scintillator Anti-Neutrino Detector (KamLAND). KamLAND is a project to study neutrino oscillation phenomena, by detecting anti-neutrinos produced in distant nuclear reactors. Next, I describe high altitude balloons developed by the ISAS balloon group. They developed balloons made from ultra-thin polyethylene film, producing a balloon of volume 60,000 m³ which successfully reached an altitude of 53 km in 2002. This is a world record, the greatest altitude that a balloon has ever achieved. ISAS is applying further effort to develop balloons with even thinner films, to achieve a higher altitude than 53 km. Other recent activities by the ISAS balloon group are briefly described.I also review scientific ballooning projects now operating in Japan, particularly focusing on the Balloon-Borne Experiment with a Superconducting Spectrometer (BESS) program. This is a US–Japan collaborative program that has carried out very precise measurements of antiprotons, protons and other components in primary cosmic rays, as well as measuring the fluxes of atmospheric muons and other components. The results of these observations give us important information to improve our understanding of the production mechanism of antiprotons observed in the primary cosmic rays. The data are also important for analysis of atmospheric neutrino events observed by Super-Kamiokande and other ground-based neutrino detectors. Future prospects of BESS and other balloon-borne cosmic-ray research programs are also presented.