Improved high-temperature heater with stabilized-zirconia elements
Improved conducting-ceramic heating elements extend performance and life expectancy of 2,100 C furnace.
Engineering topics
Publications and source records attributed to Halbach, C. R..
Improved conducting-ceramic heating elements extend performance and life expectancy of 2,100 C furnace.
Improvements were made in both electrode technology and ceramic conductor quality to increase significantly the lifetime and thermal cycling capability of electrically conducting ceramic heater elements. These elements were operated in vacuum, inert and reducing environments as well as oxidizing atmospheres adding to the versatility of the conducting ceramic as an ohmic heater. Using stabilized zirconia conducting ceramic heater elements, a furnace was fabricated and demonstrated to have excellent thermal response and cycling capability. The furnace was used to melt platinum-20% rhodium alloy (melting point 1904 C) with an isothermal ceramic heating element having a nominal working cavity size of 2.5 cm diameter by 10.0 cm long. The furnace was operated to 1940 C with the isothermal ceramic heating element. The same furnace structure was fitted with a pair of main heater elements to provide axial gradient temperature control over a working cavity length of 17.8 cm.
The design of a high temperature furnace is presented which uses electrically conducting ceramic oxide heating elements. The heating elements are made of either thoria or stabilized zirconia which become conductive when preheated to 700 to 1000 C. These heater elements can be operated to 2200 C in oxidizing or inert atmospheres. The furnace is being designed to have a temperature which can be controlled to within 11 C. By a replacement of the heater element, the working cavity can be changed from isothermal to a cavity with a selected specific axial temperature gradient of up to 200 C per centimeter. This furnace concept is appropriate for the growth of crystals which might be grown best in an oxidizing atmosphere such as sapphire (melting point 2040 C), yttrium aluminum garnet (1970 C) or yttrium orthoaluminate (1875 C).
The feasibility of using electrically conducting ceramics to heat biowaste propellants to 2000 K in resistojet thrustors was demonstrated. These thrustors are being developed for use on the space station. Among the candidate ceramic heater materials, zirconia and thoria are chemically resistant to the biopropellants, and they are also sufficiently conductive at high temperatures to make them suitable for the heater elements in these thrustors. A proof of concept thrustor design is presented, incorporating a multiple passage cylindrical heater made of zirconia ceramic which is capable of operating at 2000 K wall temperature with CO2 and H2O biopropellants. For the 25 mlb size thrustor, specific impulses of 200 seconds for CO2 and 275 seconds for H2O biopropellants are predicted.
Flow restricting devices were studied for their suitability as liquid water propellant flow limiters for the biowaste resistojet. Flow limiting during the start-up transient is required to prevent thrustor instabilities and icing which could result in heater failure in the electrical resistance heated thrustor (resistojet). The study was directed toward simple devices which would function passively (i.e., without power except from the propellant flow itself), and would offer high reliability and simplicity. In addition to the flow limiting devices, a thermal pumping system was studied to determine whether CO2, desorbed from molecular sieves could be pumped thermally in a space station application. The thermal pump is considered a possible replacement for mechanical pumps. It involves a cyclic, constant volume cryopumping system which employs space radiators to achieve the cryotemperatures. The frozen CO2 would be vaporized periodically, using a waste heat loop, to attain sufficient pressure to transfer a large portion of the trapped CO2 to storage tanks.
A literature survey was conducted to collect material properties data on all advanced high temperature materials. Three of these, Y2O3-stabilized ZrO2, ThO2, and ZrB2 with additives of C and SiC were selected for further study. Stabilized ZrO2 and ThO2 were found to have higher temperature oxidation resistance than any metal and great potential for use in advanced biowaste resistojets. ZrO2 has a lower electrical resistivity and sublimation and a higher creep endurance strength. ZrO2 and ThO2 tubular heat exchangers, electrically heated indirectly, were evaluated in short tests to about 1900 K in flowing CO2. ZrO2 was subjected to N2, H2, H2O and vacuum as well. X-ray diffraction and fluorescence analyses were made. The metal-to-ceramic seal technology for ZrO2 and ThO2 was developed using chemical vapor deposition of tantalum for metallizing and 82 Au - 18 Ni filler braze.
Description of the experimental characteristics of a heater for advanced biowaste resistojets, potentially operable to material temperatures of 2400 K in the presence of all of the biowaste gases, with or without oxygen, or in a vacuum. A conservative operating chamber temperature of 2000 K is being considered to ensure a lifetime of thousands of hours. In the small biowaste resistojet sized for 25-mlb (.11 N) of thrust, specific impulses of 200 sec on CO2 and 275 sec on H2O are possible. Typical characteristics for 150 watts of electrical power are 120 V AC at 1.25 A, providing direct adaptability to the space station power systems.
Biowaste resistojet engine design and performance for various propellants and propellant mixtures
Long term life test and vacuum tests of high temperature resistojets, using ammonia and hydrogen propellants
Concentric tube resistojet tested on hydrogen and ammonia propellants for use with biowaste propellants
Long term life test and vacuum tests of high temperature resistojets using ammonia and hydrogen propellants
Concentric tube resistojet life tested on hydrogen and ammonia propellants for use with biowaste propellants
Life test of high temperature /2400 K/ 10 millipound resistojet thrustors, comparing results to theoretical predictions
Resistojet design and fabrication, using hydrogen propellant and having 3-kw power input
Resistojet design and fabrication, using hydrogen propellant and having 3-kw power input