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.     

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.     

External caps: An approach to stress reduction in balloons

Recent findings of the catastrophic balloon failures investigation in the U.S.A. indicate that very large gross inflations, in balloons using present design philosophy, over-stress currently available materials. External caps are proposed as an economic approach to reducting those stresses to an acceptable level.     

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.     

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.     

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.     

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.     

Viscoelastic behaviour of pumpkin balloons

The lobes of the NASA ULDB pumpkin-shaped super-pressure balloons are made of a thin polymeric film that shows considerable time-dependent behaviour. A nonlinear viscoelastic model based on experimental measurements has been recently established for this film. This paper presents a simulation of the viscoelastic behaviour of ULDB balloons with the finite element software ABAQUS. First, the standard viscoelastic modelling capabilities available in ABAQUS are examined, but are found of limited accuracy even for the case of simple uniaxial creep tests on ULDB films. Then, a nonlinear viscoelastic constitutive model is implemented by means of a user-defined subroutine. This approach is verified by means of biaxial creep experiments on pressurized cylinders and is found to be accurate provided that the film anisotropy is also included in the model. A preliminary set of predictions for a single lobe of a ULDB is presented at the end of the paper. It indicates that time-dependent effects in a balloon structure can lead to significant stress redistribution and large increases in the transverse strains in the lobes.     

The limits of stratofilm®

An abnormally large number of catastrophic failures have occurred in recent years which have prompted a number of investigations. This paper documents the efforts by Winzen engineers to determine the cause of these dangerous failures. It is concluded that catastrophic failure will occur if internal caps separate from the wall of the balloon at too low an altitude. Cap separation may be prevented by the use of external caps.     

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.     

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.     

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.     

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.     

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.     

Development of the High Altitude Student Platform

The High Altitude Student Platform (HASP) was originally conceived to provide student groups with access to the near-space environment for flight durations and experiment capabilities intermediate between what is possible with small sounding balloons and low Earth orbit rocket launches. HASP is designed to carry up to twelve student payloads to an altitude of about 36 km with flight durations of 15–20 h using a small zero-pressure polyethylene film balloon. This provides a flight capability that can be used to flight-test compact satellites, prototypes and other small payloads designed and built by students. HASP includes a standard mechanical, power and communication interface for the student payload to simplify integration and allows the payloads to be fully exercised. Over the last two years a partnership between the NASA Balloon Program Office (BPO), Columbia Scientific Balloon Facility (CSBF), Louisiana State University (LSU), the Louisiana Board of Regents (BoR), and the Louisiana Space Consortium (LaSPACE) has led to the development, construction and, finally, the first flight of HASP with a complement of eight student payloads on September 4, 2006. Here we discuss the primary as-built HASP systems and features, the student payload interface, HASP performance during the first flight and plans for continuing HASP flights. The HASP project maintains a website at http://laspace.lsu.edu/hasp/ where flight application, interface documentation and status information can be obtained.     

Scientific ballooning in Japan

Activities in scientific ballooning in Japan during 1998–1999 are reported. The total number of scientific balloons flown in Japan in 1998 and 1999 was sixteen, eight flights in each year. The scientific objectives were observations of high energy cosmic electrons, air samplings at various altitudes, monitoring of atmospheric ozone density, Galactic infrared observations, and test flights of new type balloons. Balloon expeditions were conducted in Antarctica by the National Institute of Polar Research, in Russia, in Canada and in India in collaboration with foreign countries' institutes to investigate cosmic rays, Galactic infrared radiation, and Earth's atmosphere. There were three flights in Antarctica, four flights in Russia, three flights in Canada and two flights in India. Four test balloons were flown for balloon technology, which included pumpkin-type super-pressure balloon and a balloon made with ultra-thin polyethylene film of 3.4 μm thickness.     

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.     

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.     

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.