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Thermal systems

Find NASA NTRS and DOE OSTI research on heat transfer and thermal systems. Search heat pipes, cooling and thermal management in report titles and abstracts.

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All sources NASA NTRS DOE OSTI

NASA NTRSDate not supplied

Thermal Control System Architecture and Technology Challenges for a Lunar Surface Habitat

NASA’s current plans for exploration of the Lunar South Pole region include a Surface Habitat (SH) to provide up to 60-day habitability for a crew of four. The SH concept is comprised of several elements including an inflatable volume for the habitable space and a metallic airlock for access to a pressurized rover and other surface assets. A conceptual architecture for the SH Thermal Control System (TCS) is presented. A TCS dual loop design is utilized with a water/propylene glycol mix for the internal crew spaces and an external loop with low temperature coolant. The internal loop is partitioned into low and moderate temperature service with a sublimator available for operational scenarios prior to thermal radiator deployment (or redeployment). Waste heat is rejected through thermal radiators contained in the external loop. Optimization of the thermal radiator geometry/orientation as well as the TCS internal/external loop architecture is accomplished via analytical models of the system. Low mass, dust tolerant, deployable/retractable thermal radiators (in partial gravity) and thermal control surfaces, along with accommodating infrequent eclipse periods lasting up to 100 hours, present the major technology challenges. Mitigation strategies to reduce the energy needed to maintain the SH and associated systems above survival temperature limits during the eclipse period are considered in the paper. Options include retractable radiators, re-generable heat exchangers, temperature excursions, thermal energy storage and optimized inflatable optical properties. TCS sensitivity to potential SH Electrical Power System (EPS) growth is also a consideration for both operational and dormant mission phases.

Thermal Control System↗

NASA NTRSDate not supplied

Thermal Control System Architecture and Technology Challenges for a Lunar Surface Habitat

Thermal Control System↗

NASA NTRSDate not supplied

Electrospun Silica Nanofibers as Passive Thermal Control Materials for the Extreme Environment of Low Earth Orbit

Effective thermal management is crucial for maintaining spacecraft and onboard systems at optimal temperatures, ensuring their longevity in space missions. Passive thermal management is particularly promising due to its lower power consumption compared to active systems. This study focuses on developing materials with low solar absorptance and large thermal emittance to facilitate self-cooling under the harsh thermal conditions of space. We employ electrospinning, a nano/micro-manufacturing technique, to create a lightweight, fibrous thermal control material from silica (SiO 2 ). Using scanning electron microscopy (SEM), we examine the nanoporous structure of the electrospun material. Its optical properties, including reflectance, transmittance, and absorptance across ultraviolet, visible, and infrared wavelengths, are assessed using spectrometers interfaced with integrating spheres. To test durability in space, we conduct high temperature endurance and ultraviolet resistance tests to observe changes in optical properties of the materials and evaluate their performance in low Earth orbit (LEO). We also compare the material's solar reflectance and thermal emittance to existing spacecraft materials. The findings suggest that electrospun silica nanofibers presents a new paradigm for passive thermal control in space applications.

thermal emittance↗

DOE OSTI2016

Battery Thermal Characterization

This poster shows the progress in battery thermal characterization over the previous year. NREL collaborated with U.S. DRIVE and USABC battery developers to obtain thermal properties of their batteries, obtained heat capacity and heat generation of cells under various power profiles, obtained thermal images of the cells under various drive cycles, and used the measured results to validate thermal models. Thermal properties are used for the thermal analysis and design of improved battery thermal management systems to support achieve life and performance targets.

25 ENERGY STORAGE↗

DOE OSTI2017

Metallic Nanocomposites as Next-Generation Thermal Interface Materials: Preprint

Thermal interface materials (TIMs) are an integral and important part of thermal management in electronic devices. The electronic devices are becoming more compact and powerful. This increase in power processed or passing through the devices leads to higher heat fluxes and makes it a challenge to maintain temperatures at the optimal level during operation. Herein, we report a free standing nanocomposite TIM in which boron nitride nanosheets (BNNS) are uniformly dispersed in copper matrices via an organic linker, thiosemicarbazide. Integration of these metal-organic-inorganic nanocomposites was made possible by a novel electrodeposition technique where the functionalized BNNS (f-BNNS) experience the Brownian motion and reach the cathode through diffusion, while the nucleation and growth of the copper on the cathode occurs via the electrochemical reduction. Once the f-BNNS bearing carbonothioyl/thiol groups on the terminal edges come into the contact with copper crystals, the chemisorption reaction takes place. We performed thermal, mechanical, and structural characterization of these nanocomposites using scanning electron microcopy (SEM), diffusive laser flash (DLF) analysis, phase-sensitive transient thermoreflectence (PSTTR), and nanoindentation. The nanocomposites exhibited a thermal conductivity ranging from 211 W/mK to 277 W/mK at a filler mass loading of 0-12 wt.percent. The nanocomposites also have about 4 times lower hardness as compared to copper, with values ranging from 0.27 GPa to 0.41 GPa. The structural characterization studies showed that most of the BNNS are localized at grain boundaries - which enable efficient thermal transport while making the material soft. PSTTR measurements revealed that the synergistic combinations of these properties yielded contact resistances on the order of 0.10 to 0.13 mm2K/W, and the total thermal resistance of 0.38 to 0.56 mm2K/W at bondline thicknesses of 30-50 um. The coefficient of thermal expansion (CTE) of the nanocomposite is 11 ppm/K, which lies between the CTEs of aluminum (22 ppm/K) and silicon (3 ppm/K), which are common heat sink and heat source materials, respectively. The nanocomposite can also be deposited directly on to heat sink which will simplify the packaging processes by removing one possible element to assemble. These unique properties and ease of assembly makes the nanocomposite a promising next-generation TIM.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Tutorial - Electric Motor and Integrated Traction Drive Thermal Management

The share of vehicles with fully electric propulsion systems is constantly increasing, and so is their traction drive power. The continuous push to increase power of electric vehicle (EV) traction drives necessitates their efficient cooling to prevent damage to temperature sensitive components of the drive system and achieving higher power outputs in a smaller footprint. With increasing power and power density of electric traction drives, their thermal management is becoming increasingly challenging. This tutorial will provide an overview of thermal management approaches for electric motors and power electronics in EV applications. It will review examples of current industry solutions for power-dense electric motor cooling, power electronics (inverter) cooling, their integration concepts and thermal management system solutions. We'll look at the advantages and challenges of power electronics integration into a single traction drive unit and respective thermal management system concepts. We'll talk about barriers to implementation of a unified thermal management system. The tutorial will also review key aspects of thermal management system design: modeling and simulation using FEA and CFD tools, experimental characterization, and general workflow for thermal management system evaluation.

ADVANCED PROPULSION SYSTEMS,DIRECT ENERGY CONVERSI↗

DOE OSTI2021

Evaluation of Formate Salt PCM’s for Latent Heat Thermal Energy Storage

This work examines formate salts as potential phase change materials (PCMs) for middle-high temperature (≤250 °C) latent heat thermal energy storage applications. The thermophysical properties of three formate salts were characterized: pure sodium formate and binary blends of sodium/potassium formate and sodium/calcium formate. The stability of formate PCM’s was evaluated by thermal cycling using differential scanning calorimetry where sodium formate and sodium/potassium formate appeared stable over 600 cycles, while sodium/calcium formate exhibited a monotonic decrease in heat of fusion over the test period. A longer test with sodium formate led to gas release and decomposition of the salt. FTIR analysis of the PCM showed degradation of formate to oxalate. T-history experiments with 50-g PCM quantities demonstrated a bulk supercooling of only 2–3 °C for these salts. Thermal conductivity enhancement of over 700% was achieved by embedding aluminum in the solid PCM. Finally, mild carbon steel was immersed in molten sodium formate for up to 2000 h. Sodium formate was found to be non-corrosive, as calculated by mass loss and confirmed by cross-sectional high-resolution microscopy. FTIR analysis of the PCM after 2000 h shows oxidation at the free surface, while the bulk PCM remained unchanged, further indicating a need to protect the formate from atmospheric exposure when used as a PCM.phase change materials; formate salts; latent heat thermal energy storage; thermal cycling; supercooling; thermal conductivity enhancement; corrosion

25 ENERGY STORAGE↗

DOE OSTI2017

Enabling fast charging – Battery thermal considerations

Battery thermal barriers are reviewed with regards to extreme fast charging. Present-day thermal management systems for battery electric vehicles are inadequate in limiting the maximum temperature rise of the battery during extreme fast charging. If the battery thermal management system is not designed correctly, the temperature of the cells could reach abuse temperatures and potentially send the cells into thermal runaway. Furthermore, the cell and battery interconnect design needs to be improved to meet the lifetime expectations of the consumer. Each of these aspects is explored and addressed as well as outlining where the heat is generated in a cell, the efficiencies of power and energy cells, and what type of battery thermal management solutions are available in today’s market. Here, thermal management is not a limiting condition with regard to extreme fast charging, but many factors need to be addressed especially for future high specific energy density cells to meet U.S. Department of Energy cost and volume goals.

25 ENERGY STORAGE↗

DOE OSTI2021

A perspective on the electro-thermal co-design of ultra-wide bandgap lateral devices

Fundamental research and development of ultra-wide bandgap (UWBG) semiconductor devices are under way to realize next-generation power conversion and wireless communication systems. Devices based on aluminum gallium nitride (AlxGa1-xN, x is the Al composition), ..beta..-phase gallium oxide (..beta..-Ga2O3), and diamond give promise to the development of power switching devices and radio frequency power amplifiers with higher performance and efficiency than commercial wide bandgap semiconductor devices based on gallium nitride (GaN) and silicon carbide (SiC). However, one of the most critical challenges for the successful deployment of UWBG device technologies is to overcome adverse thermal effects that impact the device performance and reliability. Overheating of UWBG devices originates from the projected high power density operation and poor intrinsic thermal properties of AlxGa1-xN and ..beta..-Ga2O3. This Perspective delineates the need and process for the "electro-thermal co-design" of laterally configured UWBG electronic devices and provides a comprehensive review of current state-of-the-art thermal characterization methods, device thermal modeling practices, and both device- and package-level thermal management solutions.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2022

High temperature ceramic thermal insulation material

Flexible and lightweight thermal insulation materials with hierarchical microstructures are ubiquitous in thermal management and protection systems. Ceramic aerogels promise high-temperature thermal insulation but lack mechanical robustness, while the fibrous materials with excellent mechanical elasticity display modest thermal insulation. Here we describe flexible hierarchical superhydrophobic ceramic insulation nanocomposites through the densified architectured hierarchical nanostructures, radiative insulation coating, and interfacial cross-linking among composites. The lightweight flexible ceramic nanocomposites exhibit a density of 0.13 g/cm 3 , high-temperature fire resistance with thermal conductivity of 0.024 W/(m·K), and super-hydrophobicity with the water contact angle of 152°. The mechanical robustness and high-temperature thermal insulation of ceramic nanocomposites, together with its soundproof performance, shed light on the low-cost flexible insulation materials manufacturing with scalability for high-temperature thermal insulation applications under high mechanical loading conditions.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Signatures of Coherent Phonon Transport in Ultralow Thermal Conductivity Two-Dimensional Ruddlesden–Popper Phase Perovskites

An emerging class of methylammonium lead iodide (MAPbI 3 )-based Ruddlesden-Popper (RP) phase perovskites, BA 2 MA n-1 Pb n I 3n+1 (n = 1-7), exhibit enhanced stability to environmental conditions relative to MAPbI 3 , yet still degrade at elevated temperatures. Here, we experimentally determine the thermal conductivities of these layered RP phases for n = 1-6, where n defines the number of repeated perovskite octahedra per layer. We measure thermal conductivities of 0.37 ± 0.13/0.12, 0.17 ± 0.08/0.07, 0.21 ± 0.05/0.04, and 0.19 ± 0.04/0.03 W/m∙K in thin films of n = 1-4 and 0.08 ± 0.06/0.04, 0.06 ± 0.04/0.03, 0.06 ± 0.03/0.03, and 0.08 ± 0.07/0.04 W/m∙K in single crystals of n = 3-6. With the exception of n = 1, these thermal conductivities are lower than the range of 0.34-0.50 W/m∙K reported for single-crystal MAPbI 3 . Reduced-order lattice dynamics modeling suggests that the initially decreasing trend of thermal conductivity in similarly oriented perovskites with increasing n may result from the transport properties of coherent phonons, emergent from the superstructure, that do not scatter at the interfaces of organic butylammonium chains and perovskite octahedra. Reduced group velocity of coherent phonons in n = 3-6, a consequence of band flattening in the phonon dispersion, is primarily responsible for their ultralow thermal conductivities. Similar effects on thermal conductivity have been experimentally demonstrated in deposited superlattices, but never in naturally defined materials such as RP phases. GIWAXS measurements reveal that higher n RP phase thin films are less orientationally controlled and therefore possess apparently elevated thermal conductivities relative to single crystals of the same n.

2D perovskites↗

DOE OSTI2024

Node Distortions in UiO-66 Inform Negative Thermal Expansion Mechanisms: Kinetic Effects, Frustration, and Lattice Hysteresis

In metal–organic frameworks (MOFs) the interplay between the dynamics of individual components and how these are constrained by the extended lattice can yield unusual emergent phenomena. For the archetypal Zr-MOF, UiO-66, we explore the cooperative dynamics of a Zr-node transformation that gives rise to negative thermal expansion (NTE). Here, using in situ synchrotron X-ray scattering, with powder diffraction and pair distribution function (PDF) analyses, we identify lattice hysteresis and a thermal ramp-rate-dependence of the thermal expansion. Specifically, kinetic trapping of distorted node states formed at high temperature, leads to broad variability in the apparent thermal expansion which ranges from large positive to large negative thermal expansion with coefficients of thermal expansion (CTE) from +45 to –80 × 10 –6 K –1 . Time-resolved relaxation studies at selected temperatures suggest that when equilibrated UiO-66 is intrinsically NTE, with a CTE of –35 × 10 –6 K –1 . Kinetic trapping of the node-distorted state following high temperature activation has broad implications for characterization and applications of these Zr-MOFs; the nonequilibrium node state depends on the thermal history of the sample with quench vs slow cooling likely to impact gas binding, pore volume, and accessible catalytic sites.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Thermal conductivity of α -U with point defects

Here, we develop a theoretical model for thermal conductivity of α-U that combines density functional theory calculations and the coupled electron–phonon Boltzmann transport equation. The model incorporates both electron and phonon contributions to thermal conductivity and achieves good agreement with experimental data over a wide temperature range. The dominant scattering mechanism governing thermal transport in α-U at different temperatures is examined. By including phonon–defect and electron–defect scatterings in the model, we study the effect of point defects including U-vacancy, U-interstitial, and Zr-substitution on the thermal conductivity of α-U. The degradation of anisotropic thermal conductivity due to point defects as a function of defect concentration, defect type, and temperature is reported. This model provides insights into the impact of defects on both phonon and electron thermal transport. It will promote the fundamental understanding of thermal transport in α-U and provide a ground for investigation of coupled electron–phonon transport in metallic materials.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2022

Uncertainty Quantification of a Light Water Pulsed-Neutron Die-Away Experiment to Thermal Neutron Scattering Laws

Thermal neutron scattering laws are important nuclear data for many nuclear science and engineering applications. Validation helps to ensure that a thermal neutron scattering law has a high quality and often employs critical benchmarks as integral experiments. Recently, pulsed-neutron die-away benchmarks have been used as an experiment to validate thermal neutron scattering laws. Herein, we evidence how this alternative integral experiment has a high sensitivity to these nuclear data by performing an uncertainty quantification analysis. The analysis randomly sampled the nuclear model parameters associated with hydrogen bound in light water thermal neutron scattering law and sampled other nuclear data that influenced the experiment’s integral parameter (e.g., elastic scattering, absorption in hydrogen and oxygen) from their respective covariance matrices. The thermal neutron scattering law caused an uncertainty in the integral parameter that reached 2.67%, which exceeds by an order of magnitude the uncertainties induced in commonly used thermal solution critical benchmarks. The validation performed here, although limited due to a poor description of the historical experiment, indicated that the ENDF/B-VIII.0 thermal neutron scattering law well predicted the integral parameter. These results motivate further benchmark and validation efforts using pulsed-neutron die-away experiments.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2023

Implications of phonon anisotropy on thermal conductivity of fluorite oxides

Abstract Fluorite oxides are attractive ionic compounds for a range of applications with critical thermal management requirements. In view of recent reports alluding to anisotropic thermal conductivity in this face-centered cubic crystalline systems, we perform a detailed analysis of the impact of direction-dependent phonon group velocities and lifetimes on the thermal transport of fluorite oxides. We demonstrate that the bulk thermal conductivity of this class of materials remains isotropic despite notable anisotropy in phonon lifetime and group velocity. However, breaking the symmetry of the phonon lifetime under external stimuli including boundary scattering present in nonequilibrium molecular dynamics simulations of finite size simulation cell gives rise to apparent thermal conductivity anisotropy. We observe that for accurate determination of thermal conductivity, it is important to consider phonon properties not only along high symmetry directions commonly measured in inelastic neutron or x-ray scattering experiments but also of those along lower symmetry. Our results suggests that certain low symmetry directions have a larger contribution to thermal conductivity compared to high symmetry ones.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2023

Interface-independent sound speed and thermal conductivity of atomic-layer-deposition-grown amorphous AlN / Al 2 O 3 multilayers with varying oxygen composition

Dielectric amorphous multilayers (AMLs) play a critical role in a wide array of technologies such as optical coatings, nanoelectronics, energy harvesting, and recovery devices. However, despite their wide applications, a robust understanding of the effect of the interplay between chemical and structural disorder on the thermal properties of AMLs is still lacking. Therefore, in this paper, we experimentally and numerically investigate the effects of composition and interface density on the sound speed and thermal conductivity of a series of amorphous aluminum nitride and aluminum oxide multilayers grown via plasma-enhanced atomic layer deposition. To systematically change the composition, the oxygen content of the AMLs is proportionally varied with interface density during growth. We find that the longitudinal sound speed of these AMLs is dictated by the oxygen content instead of the number of interfaces. The thermal conductivity, in contrast, is dictated by both interface density and oxygen content. The interfaces act to decrease the thermal conductivity, whereas the oxygen content increases the thermal conductivity. Due to the competing influence of the interfaces and oxygen content, the thermal conductivity of the AMLs remains nearly constant as a function of interface density. Furthermore, our study provides crucial insights into the effect of the interplay of composition and interfaces on the sound speed and thermal conductivity of AMLs.

36 MATERIALS SCIENCE↗

NASA NTRS2018

Thermal Model Performance for the James Webb Space Telescope OTIS Cryo-Vacuum Test

The James Webb Space Telescope (JWST), set to launch in mid-2020, is currently undergoing a series of system-level environmental tests to verify its workmanship and end-to-end functionality. As part of this series, the Optical Telescope Element and Integrated Science Instrument Module (OTIS) Cryo-Vacuum (CV) test, the most complex cryogenic test executed to date by NASA, has recently been completed at the Johnson Space Center's Chamber A facility. The OTIS CV test was intended as a comprehensive test of the integrated instrument and telescope systems to fully understand its optical, structural, and thermal performance within its intended flight environment. Due to its complexity, extensive pre-test planning was required to ensure payload safety and compliance with all limits and constraints. A system-level pre-test thermal model was constructed which fully captured the behavior of the payload, ground support equipment, and surrounding test chamber. This thermal model simulated both the transient cooldown to and warmup from a 20 K flight-like environment, as well as predicted the payload performance at cryo-stable conditions. The current work is an assessment of thermal model pre-test prediction performance against actual payload response during the OTIS CV test. Overall, the thermal model performed exceedingly well at predicting schedule and payload response. Looking in depth, this work examines both the benefits and shortcomings of assumptions made pre-test to simplify model execution when compared against test data. It explores in detail the role of temperature-dependent emissivities during transition to cryogenic temperatures, as well as the impact that model geometry simplifications have on tracking of critical hardware limits and constraints. This work concludes with a list of recommendations to improve the accuracy of thermal modeling for future large cryogenic tests. The insight gained from the OTIS CV test thermal modeling will benefit planning and execution for upcoming cryogenic missions.

Testing↗

NASA NTRS2024

Exploration Extravehicular Mobility Unit (xEMU) Hard Upper Torso (HUT) Chamber B Thermal Vacuum Testing Results

NASA’s Exploration Extravehicular Mobility Unit (xEMU) is the government reference next-generation spacesuit design and is engineered to protect astronauts from extreme lunar environmental temperatures. To evaluate the xEMU hardware thermal requirements, the xEMU Testing Team invented, designed, and executed a dual-suit, uncrewed thermal vacuum (TVAC) test at Johnson Space Center’s (JSC) Chamber B. This paper details the test methodology, hardware setup, and results from the xEMU hard upper torso (HUT). Two HUTs, one composite HUT and one aluminum HUT, were tested simultaneously in Chamber B, with different thermal environments. For the aluminum HUT on the Short xEMU (SxEMU) test article, five thermal profiles were tested during five simulated EVAs. For the composite HUT on the second xEMU, eleven unique thermal profiles were tested including both cold and hot environmental cases over the course of five continuous days of testing. The radiative thermal environment was controlled through exposure to liquid-nitrogen shrouds on the chamber walls and through two separate heater cages surrounding each respective test article. Seventy-two temperature sensors were used to collect data in critical locations in the xEMU HUT assembly. This paper will document the testing results and compare the test data against the xEMU HUT and system-level thermal models for model validation.

xEMU↗