Thermal systems — Page 18

NASA NTRS1997

Thermal Fatigue Testing of ZrO2-Y2O3 Thermal Barrier Coating Systems using a High Power CO2 Laser

In the present study, the mechanisms of fatigue crack initiation and propagation, and of coating failure, under thermal loads that simulate diesel engine conditions, are investigated. The surface cracks initiate early and grow continuously under thermal Low Cycle Fatigue (LCF) and High Cycle Fatigue (HCF) stresses. It is found that, in the absence of interfacial oxidation, the failure associated with LCF is closely related to coating sintering and creep at high temperatures. Significant LCF and HCF interactions have been observed in the thermal fatigue tests. The fatigue crack growth rate in the ceramic coating strongly depends on the characteristic HCF cycle number, N*(sub NCF), which is defined as the number of HCF cycles per LCF cycle. The crack growth rate is increased from 0.36 microns/LCF cycle for a pure LCF test to 2.8 microns/LCF cycle for a combined LCF and HCF test at N*(sub NCF) about 20,000. A surface wedging model has been proposed to account for the HCF crack growth in the coating systems. This mechanism predicts that HCF damage effect increases with increasing surface temperature swing, the thermal expansion coefficient and the elastic modulus of the ceramic coating, as well as with the HCF interacting depth. A good agreement has been found between the analysis and experimental evidence.

Zhu, Dongming↗

NASA NTRS1999

Thermal-Mechanical Stability of Single Crystal Oxide Refractive Concentrators for High-Temperature Solar Thermal Propulsion

Single crystal oxides such as yttria-stabilized zirconia (Y2O3-ZrO2), yttrium aluminum garnet (Y3Al5O12, or YAG), magnesium oxide (MgO) and sapphire (Al2O3) are candidate refractive secondary concentrator materials for high temperature solar propulsion applications. However, thermo-mechanical reliability of these components in severe thermal environments during the space mission sun/shade transition is of great concern. Simulated mission tests are important for evaluating these candidate oxide materials under a variety of transient and steady-state heat flux conditions, and thus provide vital information for the component design. In this paper, a controlled heat flux thermal shock test approach is established for the single crystal oxide materials using a 3.0 kW continuous wave CO2 laser, with a wavelength 10.6 micron. Thermal fracture behavior and failure mechanisms of these oxide materials are investigated and critical temperature gradients are determined under various temperature and heating conditions. The test results show that single crystal sapphire is able to sustain the highest temperature gradient and heating-cooling rate, and thus exhibit the best thermal shock resistance, as compared to the yttria-stabilized zirconia, yttrium aluminum garnet, and magnesium oxide.

Zhu, Dongming↗

NASA NTRS1999

Thermal-Mechanical Stability of Single Crystal Oxide Refractive Concentrators for High-Temperature Solar Thermal Propulsion

Single crystal oxides such as yttria-stabilized zirconia (Y2O3-ZrO2), yttrium aluminum garnet (Y3Al5O12, or YAG), magnesium oxide (MgO) and sapphire (Al2O3) are candidate refractive secondary concentrator materials for high temperature solar propulsion applications. However, thermo-mechanical reliability of these components in severe thermal environments during the space mission sun/shade transition is of great concern. Simulated mission tests are important for evaluating these candidate oxide materials under a variety of transient and steady-state heat flux conditions, and thus provide vital information for the component design. In this paper, a controlled heat flux thermal shock test approach is established for the single crystal oxide materials using a 3.0 kW continuous wave CO2 laser, with a wavelength 10.6 micron. Thermal fracture behavior and failure mechanisms of these oxide materials are investigated and critical temperature gradients are determined under various temperature and heating conditions. The test results show that single crystal sapphire is able to sustain the highest temperature gradient and heating-cooling rate, and thus exhibit the best thermal shock resistance, as compared to the yttria-stabilized zirconia, yttrium aluminum garnet and magnesium oxide.

Zhu, Dongming↗

NASA NTRS1999

Validation of Modified Wine-Rack Thermal Design for Nickel-Hydrogen Batteries in Landsat-7 Spacecraft Thermal Vacuum Test and in Flight

A heritage wine-rack thermal/mechanical design for the nickel-hydrogen batteries was the baseline at the Landsat-7 Preliminary Design Review. An integrated thermal and power analysis of the batteries performed by the author in 1994 revealed that the maximum cell-to-cell gradient was 6.6 C. The author proposed modifying the heritage wine-rack design by enhancing heat conduction from cells to cells, and from cells to battery frame. At the 1995 Intersociety Energy Conversion Engineering Conference (IECEC), the author presented a paper on methods of modifying the wine-rack design. It showed that the modified wine-rack option, which uses a metallic filler, could reduce the maximum cell-to-cell temperature gradient to 1.30 C, and could also reduce the maximum cell temperature by as much as 80 C. That design concept was adopted by the Landsat7 Project Office, and a design change was made at the Critical Design Review. Results of the spacecraft thermal vacuum and thermal balance tests, and temperature data in flight show that the temperatures of the battery cells are very uniform. The maximum cell-to-cell gradient is 1.50 C. They validate the modified wine-rack thermal design.

Choi, Michael K.↗

NASA NTRS2002

Thermal Vacuum Facility for Testing Thermal Protection Systems

A thermal vacuum facility for testing launch vehicle thermal protection systems by subjecting them to transient thermal conditions simulating re-entry aerodynamic heating is described. Re-entry heating is simulated by controlling the test specimen surface temperature and the environmental pressure in the chamber. Design requirements for simulating re-entry conditions are briefly described. A description of the thermal vacuum facility, the quartz lamp array and the control system is provided. The facility was evaluated by subjecting an 18 by 36 in. Inconel honeycomb panel to a typical re-entry pressure and surface temperature profile. For most of the test duration, the average difference between the measured and desired pressures was 1.6% of reading with a standard deviation of +/- 7.4%, while the average difference between measured and desired temperatures was 7.6% of reading with a standard deviation of +/- 6.5%. The temperature non-uniformity across the panel was 12% during the initial heating phase (t less than 500 sec.), and less than 2% during the remainder of the test.

Daryabeigi, Kamran↗

NASA NTRS2003

WMAP Observatory Thermal Design and On-Orbit Thermal Performance

The Wilkinson Microwave Anisotropy Probe (WMAP) observatory, launched June 30, 2001, is designed to measure the cosmic microwave background radiation with unprecedented precision and accuracy while orbiting the second Lagrange point (L2). The instrument cold stage must be cooled passively to <95K, and systematic thermal variations in selected instrument components controlled to less than 0.5 mK (rms) per spin period. This paper describes the thermal design and testing of the WMAP spacecraft and instrument. Flight thermal data for key spacecraft and instrument components are presented from launch through the first year of mission operations. Effects of solar flux variation due to the Earth's elliptical orbit about the sun, surface thermo-optical property degradations, and solar flares on instrument thermal stability are discussed.

Glazer, Stuart D.↗

NASA NTRS2003

Analysis of Plasma-Sprayed Thermal Barrier Coatings With Homogeneous and Heterogeneous Bond Coats Under Spatially Uniform Cyclic Thermal Loading

This report summarizes the results of a numerical investigation into the spallation mechanism in plasma-sprayed thermal barrier coatings observed under spatially-uniform cyclic thermal loading. The analysis focuses on the evolution of local stress and inelastic strain fields in the vicinity of the rough top/bond coat interface during thermal cycling, and how these fields are influenced by the presence of an oxide film and spatially uniform and graded distributions of alumina particles in the metallic bond coat aimed at reducing the top/bond coat thermal expansion mismatch. The impact of these factors on the potential growth of a local horizontal delamination at the rough interface's crest is included. The analysis is conducted using the Higher-Order Theory for Functionally Graded Materials with creep/relaxation constituent modeling capabilities. For two-phase bond coat microstructures, both the actual and homogenized properties are employed in the analysis. The results reveal the important contributions of both the normal and shear stress components to the delamination growth potential in the presence of an oxide film, and suggest mixed-mode crack propagation. The use of bond coats with uniform or graded microstructures is shown to increase the potential for delamination growth by increasing the magnitude of the crack-tip shear stress component.

Arnold, Steven M.↗

NASA NTRS2005

Low-Thermal-Conductivity Pyrochlore Oxide Materials Developed for Advanced Thermal Barrier Coatings

When turbine engines operate at higher temperatures, they consume less fuel, have higher efficiencies, and have lower emissions. The upper-use temperatures of the base materials (superalloys, silicon-based ceramics, etc.) used for the hot-section components of turbine engines are limited by the physical, mechanical, and corrosion characteristics of these materials. Thermal barrier coatings (TBCs) are applied as thin layers on the surfaces of these materials to further increase the operating temperatures. The current state-of-the-art TBC material in commercial use is partially yttria-stabilized zirconia (YSZ), which is applied on engine components by plasma spraying or by electron-beam physical vapor deposition. At temperatures higher than 1000 C, YSZ layers are prone to sintering, which increases thermal conductivity and makes them less effective. The sintered and densified coatings can also reduce thermal stress and strain tolerance, which can reduce the coating s durability significantly. Alternate TBC materials with lower thermal conductivity and better sintering resistance are needed to further increase the operating temperature of turbine engines.

Bansal, Narottam P.↗

NASA NTRS2007

Ablation Modeling of Ares-I Upper State Thermal Protection System Using Thermal Desktop

The thermal protection system (TPS) for the Ares-I Upper Stage will be based on Space Transportation System External Tank (ET) and Solid Rocket Booster (SRB) heritage materials. These TPS materials were qualified via hot gas testing that simulated ascent and re-entry aerothermodynamic convective heating environments. From this data, the recession rates due to ablation were characterized and used in thermal modeling for sizing the thickness required to maintain structural substrate temperatures. At Marshall Space Flight Center (MSFC), the in-house code ABL is currently used to predict TPS ablation and substrate temperatures as a FORTRAN application integrated within SINDA/G. This paper describes a comparison of the new ablation utility in Thermal Desktop and SINDA/FLUINT with the heritage ABL code and empirical test data which serves as the validation of the Thermal Desktop software for use on the design of the Ares-I Upper Stage project.

Sharp, John R.↗

NASA NTRS2010

Thermal Performance of Orion Active Thermal Control System With Seven-Panel Reduced-Curvature Radiator

The active thermal control system (ATCS) of the crew exploration vehicle (Orion) uses radiator panels with fluid loops as the primary system to reject heat from spacecraft. The Lockheed Martin (LM) baseline Orion ATCS uses eight-panel radiator coated with silver Teflon coating (STC) for International Space Station (ISS) missions, and uses seven-panel radiator coated with AZ 93 white paint for lunar missions. As an option to increase the radiator area with minimal impact on other component locations and interfaces, the reduced-curvature (RC) radiator concept was introduced and investigated here for the thermal perspective. Each RC radiator panel has 15 percent more area than each Lockheed Martin (LM) baseline radiator panel. The objective was to determine if the RC seven-panel radiator concept could be used in the ATCS for both ISS and lunar missions. Three radiator configurations the LM baseline, an RC seven-panel radiator with STC, and an RC seven-panel radiator with AZ 93 coating were considered in the ATCS for ISS missions. Two radiator configurations the LM baseline and an RC seven-panel radiator with AZ 93 coating were considered in the ATCS for lunar missions. A Simulink/MATLAB model of the ATCS was used to compute the ATCS performance. Some major hot phases on the thermal timeline were selected because of concern about the large amount of water sublimated for thermal topping. It was concluded that an ATCS with an RC seven-panel radiator could be used for both ISS and lunar missions, but with two different coatings STC for ISS missions and AZ 93 for lunar missions to provide performance similar to or better than that of the LM baseline ATCS.

Wang, Xiao-Yen J.↗

NASA NTRS2017

Mars Phoenix Scout Thermal Evolved Gas Analyzer (TEGA) Database: Thermal Database Development and Analysis

The Mars Phoenix Scout Lander mission in 2008 examined the history of water, searched for organics, and evaluated the potential for past/present microbial habitability in a martian arctic ice-rich soil [1]. The Thermal Evolved Gas Analyzer (TEGA) instrument measured the isotopic composition of atmospheric CO2 and detected volatile bearing mineralogy (perchlorate, carbonate, hydrated mineral phases) in the martian soil [2-7]. The TEGA data are archived at the Planetary Data System (PDS) Geosciences Node but are reported in forms that require further processing to be of use to the non-TEGA expert. The soil and blank TEGA thermal data are reported as duty cycle and must be converted to differential power (mW) to allow for enthalpy calculations of exothermic/endothermic transitions. The exothermic/endothermic temperatures are also used to determine what phases (inorganic/organic) are present in the sample. The objectives of this work are to: 1) Describe how interpretable thermal data can be created from TEGA data sets on the PDS and 2) Provide additional thermal data interpretation of two Phoenix soils (Baby Bear, Wicked Witch) and include interpretations from three unreported soils (Rosy Red 1, 2, and Burning Coals).

Sutter, B.↗

NASA NTRS2018

Temperature-Staged Thermal Energy Storage Enabling Low Thermal Exergy Loss Reflux Boiling in Full Spectrum Solar Energy Systems

The efficiency of solar power collection is increased by adding a thermal energy storage stage to a sunlight concentrator and thermodynamic power generator system. The thermal energy storage includes tubes or capsules made of a phase change material that stores thermal energy in different temperature stages through a working fluid. The stored thermal energy is directed to the thermodynamic generator during off-sun periods.

Hendricks, Terry↗

NASA NTRS2014

Fundamental Property Requirements for Thermal and Mechanical Response Analysis of Thermal Protection Materials and Systems

Spacecraft that are designed to reenter the Earth's atmosphere, or enter the atmosphere of another planet, require Thermal Protection Systems (TPS) in order to survive the extreme thermal environments during the atmospheric flight. Analytical modeling of thermal and mechanical response is a fundamental aspect of the design of TPS and development of TPS materials. The analyses are used to understand the response of the materials and systems under representative environments. Performing these analyses, and evaluating the results, requires a variety of fundamental inputs, including: thermal and mechanical material properties; predicted or measured ground test and flight environments; and information about adjacent structure or attachments. We explain the nature of the analyses, highlight the essential fundamental data that are required, and describe the impact of the accuracy in the input data on the final results. We also describe the important priorities in material characterization testing in support of analyses.

Squire, Thomas↗

NASA NTRSDate not supplied

Integrated Computational Fluid Dynamics and Thermal Desktop Thermal Modeling for Assessment of the EMU in Support of ISS EVA 80

Following the reports of water accumulation in the Extravehicular Mobility Unit (EMU) helmet during the ISS US EVA-80, various efforts for mitigation and further understanding of this phenomenon have been undertaken with the goal of prevention and to ensure crew safety in future EVAs. In support of this goal, a combination of Thermal Desktop thermal modeling and Computational Fluid Dynamics (CFD) has been performed in order to characterize the performance of the EMU components, specifically those within the ventilation/cooling water loops. This modeling effort evaluates the dry/wet gas pressure drop and flow distribution through gas and liquid flow paths using CFD, as well as a two-phase flow assessment of condensation production and water separation/removal performance using an integrated Thermal Desktop model of important EMU ventilation loop components. The models assess this overall thermal-fluid performance in comparison with previous existing models, design points, and historical EVA data using their inputs.

Blain Ryan Lancaster↗

NASA NTRS2022

Thermal Design of the Thermal Infrared Spectrometer (TIRS) Instrument on PREFIRE

The Polar Radiant Energy in the Far-Infrared Experiment (PREFIRE) consists of two 6U CubeSats that each host a Thermal Infrared Spectrometer (TIRS) instrument. The CubeSats are scheduled for launch in March and October of 2023. The purpose of the TIRS instrument is to make spectrally resolved measurements of the Earth’s thermal radiation from the top of the atmosphere. PREFIRE will document, for the first time, variability in spectral fluxes from 4 to 54 microns on hourly to seasonal timescales. The primary mission is 12 months in a polar orbit with inclination of 82 to 98 at altitudes between 450 km and 650 km. The TIRS instrument is an Offner spectrometer that uses a thermopile detector array and a Schwarzchild telescope. In addition, there is a scan mirror which is periodically actuated for calibration. The instrument concept of operation is to collect radiation emitted towards zenith in a nadir sounding orientation with periodic internal and space calibrations. The TIRS thermal control architecture consists of entirely passive elements. The instrument requires all elements be maintained between 0 C and 50 C during operation for the duration of the mission. An overview of the overall thermal control design approach is presented.

Andrade, Andres↗

NASA NTRSDate not supplied

Integrated Computational Fluid Dynamics and Thermal Desktop Thermal Modeling for Assessment of the EMU in Support of ISS EVA 80

Following the reports of water accumulation in the Extravehicular Mobility Unit (EMU) helmet during the ISS US EVA-80, various efforts for mitigation and further understanding of this phenomenon have been undertaken with the goal of prevention and to ensure crew safety in future EVAs. In support of this goal, a combination of Thermal Desktop thermal modeling and Computational Fluid Dynamics (CFD) has been performed in order to characterize the performance of the EMU components, specifically those within the ventilation/cooling water loops. This modeling effort evaluates the dry/wet gas pressure drop and flow distribution through gas and liquid flow paths using CFD, as well as a two-phase flow assessment of condensation production and water separation/removal performance using an integrated Thermal Desktop model of important EMU ventilation loop components. The models assess this overall thermal-fluid performance in comparison with previous existing models, design points, and historical EVA data using their inputs.

EVA 80↗

DOE OSTI2022

Thermal measurement apparatus and methods for anisotropic thermal materials

A system for characterizing thermal properties of thermally anisotropic heterogeneous samples includes a heating element, a first temperature sensing device, a second temperature sensing device, and a computing system. The heating element is positioned at a first location within a sample and heats the sample. The first temperature sensing device outputs data indicative of temperatures of the first location to the computing device. The second temperature sensing device outputs data indicative of temperatures of the second location to the computing device. The computing device computes a thermal conductivity of the sample based upon the temperatures of the first location. The computing device further outputs an indication of a portion of the sample to which the thermal conductivity pertains based upon the second temperatures.

Reyes, Karla Rosa↗

DOE OSTI2023

Thermal measurement apparatus and methods for anisotropic thermal materials

A system for characterizing thermal properties of thermally anisotropic heterogeneous samples includes a heating element, a first temperature sensing device, a second temperature sensing device, and a computing system. The heating element is positioned at a first location within a sample and heats the sample. The first temperature sensing device outputs data indicative of temperatures of the first location to the computing device. The second temperature sensing device outputs data indicative of temperatures of the second location to the computing device. The computing device computes a thermal conductivity of the sample based upon the temperatures of the first location. The computing device further outputs an indication of a portion of the sample to which the thermal conductivity pertains based upon the second temperatures.

Reyes, Karla Rosa↗