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.     

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.     

An improved shape for zero-pressure balloons

Since the 1950s, efforts have been made to optimise the design of zero-pressure balloons. A possible method for improving on the classical natural-shape is discussed in this paper.It is shown by surface element analysis, that the meridional stress in the balloon film can be adjusted by changing the circumferential stress. It is probable that the stress concentration at the top of a natural-shape balloon can be reduced. A mixed-shape balloon, which has positive circumferential stress above the maximum diameter, has been derived and the results are presented in a form similar to Smalley's ‘sigma’ table.The stress distribution for balloons having different shapes, with or without load tapes, are also described.     

Feasibility study of a sea-anchored stratospheric balloon for long-duration flights

Sea-anchored balloons are stratospheric super-pressure balloons that are anchored to the sea. The sea-anchored balloon is a simple system that has the capability for long-duration flights, fixed-point observations, flexible launch windows, easy telemetry links to ground stations, and quick recoveries. Such balloons are not required to fly through the jet stream while tethered to the ground or sea, because the tether is deployed from a reel on the balloon after reaching a floating altitude. In this study, the feasibility of the sea-anchored balloon is investigated, with particular emphasis on the tether strength, balloon altitude, and system mass, based on the present technological level of the tether’s specific strength. Although the wind distribution with altitude is a dominant factor for feasibility, a sea-anchored balloon with an altitude of about 25 km would be feasible if the velocity of the jet stream is sufficiently low. The sea-anchored balloon can be simply flight-tested, since additional ground facilities and special flight operations are not necessary.     

Status of the NASA continuing investigation of catastrophic balloon failures

Since the beginning of the 1980's, the USA National Aeronautics and Space Administration (NASA) Balloon Program has been besieged with a continuing problem of catastrophic balloon failures. In 1983 NASA conducted an investigation to identify possible causes for the failures and to determine the necessary corrective action(s) to prevent further occurrence of the problem. The investigation indicated the most probable cause of the failures was the balloon material. Subsequent corrective action(s) were taken to eliminate the problem by establishing a material acceptance criteria for balloon film. Although improvements have been noted in certain classes of balloons, the problem of catastrophic balloon failures continues. Efforts continue, to determine the cause(s) of the diminished performance of current balloons, including investigation of the microstructure of present and past balloon film, stress effects and simplified stress modeling including shape studies, and the equipment and procedures used in the manufacture of balloons. Most recently, a special team of experts has been assembled to aid in the investigation of the failure problems and the methods needed for a solution. The findings and status of the continuing investigation along with the future plans for the NASA program are presented.     

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.     

A stress index model for balloon design

The modern day scientific research balloon has historically maintained an approximate 85% success rate as launched by the USA National Scientific Balloon Facility (NSBF). Failures were across all operational phases and modes. Balloons fabricated after 1980 have met with less favorable results with catastrophic failures on ascent becoming the principle failure mode. In 1983, the USA National Aeronautics and Space Administration (NASA) conducted an intensive investigation to identify the possible causes for these failures. Although the most probable cause was identified as the balloon material, additional contributing factors were identified. One of these factors, balloon stress, was calculated using a stress equation defining only the total required thickness for launch. No model existed to predict the stress distribution in an ascending balloon. Early in 1984, NASA began the development of a stress index model to establish the relative stress magnitudes at any altitude. Studies were conducted applying this model to several hundred balloon flights. The study indicated a strong correlation between stress levels, failure rates, and the point of maximum stress coinciding with observed failure locations. In January 1985, NASA instituted a stress index design and flight specification that all NASA balloons must meet. The details and results of this work are presented.     

Ballooning activities in Japan

The Scientific Balloon Center of ISAS/JAXA has carried out two balloon campaigns at Sanriku, Iwate, Japan every year. Ten to twelve balloon vehicles are launched annually for scientific and engineering experiments. Since 2005, a Brazilian balloon campaign has also been conducted in cooperation with INPE. In the 2006 Brazilian campaign, large and heavy payloads up to 1500 kg for astronomy will be launched. New generation balloons, such as super-pressure balloons and high-altitude balloons with ultra-thin films, are being developed. The current status and prospect of the Japanese scientific ballooning are discussed.     

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.     

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 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.     

A comprehensive numerical model investigating the thermal-dynamic performance of scientific balloon

The increase of balloon applications makes it necessary for a comprehensive understanding of the thermal and dynamic performance of scientific balloons. This paper proposed a novel numerical model to investigate the thermal and dynamic characteristics of scientific balloon in both ascending and floating conditions. The novel model consists of a dynamic model and thermal model, the dynamic model was solved numerically by a computer program developed with Matlab/Simulink to calculate the velocity and trajectory, the thermal model was solved by the Fluent program to find out the balloon film temperature distribution and inner Helium gas velocity and temperature field. These models were verified by comparing the numerical results with experimental data. Then the thermal and dynamic behavior of a scientific balloon in a real environment were simulated and discussed in details.     

The development of plastic,zero pressure balloon design since 1945

There have been four major thrusts in plastic, zero pressure balloon design in the U.S. since the late 1940's. First, the pioneer balloonists made designs according to geometric shapes. When these balloons began to fail, a study at the University of Minnesota produced the first mathematical model for determining the proper design for “natural shaped” balloons. With the advent of high speed digital computing came the “Sigma” tables of the 1960's. When computers became more widespread and inexpensive, direct or “full-sized” designs began to be used. Now, with the problems involved in flying heavy payloads (greater than 400 lbs) and super pressure balloons, a new tool has become available to the balloon designer. An inexpensive stress analysis code is available but is as yet unproven.     

Properties of tandem balloons connected by extendable suspension wires

The tandem balloon system has been known as a candidate system for long duration flight balloons. In this paper, the properties of the system are analytically studied in a new way by introducing an extendable suspension wire in the Sky Anchor configuration, which consists of a zero-pressure main balloon suspending a payload and a super-pressure balloon suspended below the payload. It was found that extension of the suspension wire between the payload and the super-pressure balloon can extend the capability of the tandem system; the altitude of the zero-pressure balloon can be changed without any consumables except some energy, and the day–night oscillation of the balloon altitude can be suppressed. This property is useful as the vehicle for long duration flights. It is also pointed out that the method to control the altitude of a balloon using an additional suspended super-pressure balloon can also be applied for super-pressure balloons.     

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.     

Performance simulation of high altitude scientific balloons

The design and operation of a high altitude scientific balloon requires adequate knowledge of the thermal characteristics of the balloon to make it safe and reliable. The thermal models and dynamic models of altitude scientific balloons are established in this paper. Based on the models, a simulation program is developed. The thermal performances of a super pressure balloon are simulated. The influence of film radiation property and clouds on balloon thermal behaviors is discussed in detail. The results are helpful for the design and operate of safe and reliable high altitude scientific balloons.     

Systems for long duration flights

This paper describes the systems for long duration flights developed in Japan for scientific observations. Much efforts have been expended to evolve systems for long duration flights in Japan, by controlling the balloon trajectories with a knowledge of wind pattern at high altitudes over Japan. These systems called “Cycling Balloon”, “Boomerang Balloon” and “New Boomerang Balloon” have been successfully used for the observations by keeping the balloons close to the balloon station.“Relay Balloon” is another system to extend the telemetry range by using an additional balloon as a relay station to link the telemetry from the main balloon.Some detailes of the exhaust valve, ascent meter and automatic level control devices used for the balloon control are also described in the paper.     

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.