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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS2011

International Space Station Active Thermal Control Sub-System On-Orbit Pump Performance and Reliability Using Liquid Ammonia as a Coolant

The International Space Station (ISS) contains two Active Thermal Control Sub-systems (ATCS) that function by using a liquid ammonia cooling system collecting waste heat and rejecting it using radiators. These subsystems consist of a number of heat exchangers, cold plates, radiators, the Pump and Flow Control Subassembly (PFCS), and the Pump Module (PM), all of which are Orbital Replaceable Units (ORU's). The PFCS provides the motive force to circulate the ammonia coolant in the Photovoltaic Thermal Control Subsystem (PVTCS) and has been in operation since December, 2000. The Pump Module (PM) circulates liquid ammonia coolant within the External Active Thermal Control Subsystem (EATCS) cooling the ISS internal coolant (water) loops collecting waste heat and rejecting it through the ISS radiators. These PM loops have been in operation since December, 2006. This paper will discuss the original reliability analysis approach of the PFCS and Pump Module, comparing them against the current operational performance data for the ISS External Thermal Control Loops.

Morton, Richard D.↗

NASA NTRS1977

Technology advancement of the electrochemical CO2 concentrating process

A five-cell, liquid-cooled advanced electrochemical depolarized carbon dioxide concentrator module was fabricated. The cells utilized the advanced, lightweight, plated anode current collector concept and internal liquid-cooling. The five cell module was designed to meet the carbon dioxide removal requirements of one man and was assembled using plexiglass endplates. This one-man module was tested as part of an integrated oxygen generation and recovery subsystem.

Schubert, F. H.↗

NASA NTRS2012

Use of Aquaporins to Achieve Needed Water Purity on the International Space Station for the Extravehicular Mobility Unit Space Suit System

With the retirement of the U.S. Space Shuttle fleet, the supply of extremely high quality water required for the Extravehicular Mobility Unit (EMU) space suit cooling on the International Space Station (ISS) will become a significant operational hardware challenge in the very near future. One proposed solution is the use of a filtration system consisting of a semipermeable membrane embedded with aquaporin proteins, a special class of transmembrane proteins that facilitate passive, selective transport of water in vivo. The specificity of aquaporins is such that only water is allowed through the protein structure, and it is this novel property that invites their adaptation for use in water filtration systems, specifically those onboard the ISS for the EMU space suit system. These proteins are also currently being developed for use in terrestrial filtration systems.

Hill, Terry R.↗

NASA NTRS2004

Debonding Stress Concentrations in a Pressurized Lobed Sandwich-Walled Generic Cryogenic Tank

A finite-element stress analysis has been conducted on a lobed composite sandwich tank subjected to internal pressure and cryogenic cooling. The lobed geometry consists of two obtuse circular walls joined together with a common flat wall. Under internal pressure and cryogenic cooling, this type of lobed tank wall will experience open-mode (a process in which the honeycomb is stretched in the depth direction) and shear stress concentrations at the junctures where curved wall changes into flat wall (known as a curve-flat juncture). Open-mode and shear stress concentrations occur in the honeycomb core at the curve-flat junctures and could cause debonding failure. The levels of contributions from internal pressure and temperature loading to the open-mode and shear debonding failure are compared. The lobed fuel tank with honeycomb sandwich walls has been found to be a structurally unsound geometry because of very low debonding failure strengths. The debonding failure problem could be eliminated if the honeycomb core at the curve-flat juncture is replaced with a solid core.

Ko, William L.↗

NASA NTRS1976

The pressure and energy balance of the cool corona over sunspots

The 22 largest sunspots observed with the Skylab SO55 spectrometer are studied for a relation between their EUV radiation and their umbral size or magnetic classification. The ultimate goal is to determine why the coronal plasma is so cool over a sunspot and how this cool plasma manages to support itself against gravity. Based on the time behavior of the EUV emission, a steady-state model is developed for the pressure and energy balance of the cool coronal-plasma loops over the spots. Analysis of the temperature structure in a typical loop indicates that the loop is exceedingly well insulated from the outside corona, that its energy balance is determined purely by internal heating and cooling processes, and that a heat input of about 0.0001 erg/cu cm per sec is required along the full length of the loop. It is proposed that: (1) coronal material flows steadily across the field lines at the tops of the loops and falls downward along both sides under gravity; (2) the corona is heated by mechanical-energy transport across the very thin transition region immediately over network-cell interiors; and (3) strong magnetic fields tend to inhibit mechanical-energy dissipation in the corona.

Foukal, P. V.↗

NASA NTRS1983

A model to determine open or closed cellular convection

The horizontal asymmetry of cellular convection is demonstrated to be detectable by consideration of the vertical asymmetry of the driving force. A two-dimensional numerical model for convection in an internally heated and cooled fluid is presented, based on equations for the conservation of temperature and vorticity. Attention is focused on the steady-state finite-amplitude solutions for fixed Rayleigh number, Prandtl number, and aspect ratio. Temperature in the model corresponds to potential temperature under dry conditions and the equivalent potential temperature under saturated conditions. Slowly varying convection driven by asymmetric boundary fluxes is expressed in terms of steady-state convection driven by an asymmetric internal heat source. It is shown that heating near the ground produces open convection patterns where most of the fluid is descending, while cooling near the top of the flow leads to closed cellular patterns with a preponderance of ascending fluid. Extension of the model to three dimensions is indicated.

Helfand, H. M.↗

NASA NTRSDate not supplied

Al6061-RAM2 Development and Hot-Fire Testing using Additive Manufacturing Laser Powder Directed Energy Deposition for Liquid Rocket Engine Channel-Cooled Nozzles

Aluminum 6061-RAM2 is a high-strength aluminum feedstock developed for additive manufacturing (AM)processes. This alloy leverages Reactive Additive Manufacturing (RAM) technology. The RAM aluminum alloys were developed to be weldable—therefore printable—while equaling or exceeding strength properties of high strength wrought aluminum alloys. NASA and industry partners developed Laser Powder Directed Energy Deposition (LP-DED)additive manufacturing of Al6061-RAM2 for use in aerospace applications. Efforts included establishing build parameters, characterizing the alloy, fabricating components, and completing hot-fire testing of complex internal channel-cooled nozzles. These efforts are to address the growing need for large-scale parts using high-performance light-weight materials. Two rocket engine nozzles were fabricated using LP-DED Al6061-RAM2 that included integral cooling channels. The Al6061-RAM2 has completed process development and initial properties were established. This paper provides an overview of the LP-DED process development, material characterization and properties, component manufacturing, supplemental development, and hot-fire testing. Results from hot-fire testing are provided for a lander-class 31kN (7,000lbf)thrust engine using Liquid Oxygen (LOX)/Liquid Hydrogen(LH2) and LOX/Methane(LCH4).

Al6061-RAM2↗

NASA NTRSDate not supplied

Al6061-RAM2 Development and Hot-Fire Testing using Additive Manufacturing Laser Powder Directed Energy Deposition for Liquid Rocket Engine Channel-Cooled Nozzles

Al6061-RAM2↗

NASA NTRSDate not supplied

Al6061-RAM2 Development and Hot-Fire Testing using Additive Manufacturing Laser Powder Directed Energy Deposition for Liquid Rocket Engine Channel-Cooled Nozzles

Aluminum 6061-RAM2 is a high-strength aluminum feedstock developed for additive manufacturing (AM)processes. This alloy leverages Reactive Additive Manufacturing (RAM) technology. The RAM aluminum alloys were developed to be weldable—therefore printable—while equaling or exceeding strength properties of high strength wrought aluminum alloys. NASA and industry partners developed Laser Powder Directed Energy Deposition (LP-DED)additive manufacturing of Al6061-RAM2 for use in aerospace applications. Efforts included establishing build parameters, characterizing the alloy, fabricating components, and completing hot-fire testing of complex internal channel-cooled nozzles. These efforts are to address the growing need for large-scale parts using high-performance light-weight materials. Two rocket engine nozzles were fabricated using LP-DED Al6061-RAM2 that included integral cooling channels. The Al6061-RAM2 has completed process development and initial properties were established. This paper provides an overview of the LP-DED process development, material characterization and properties, component manufacturing, supplemental development, and hot-fire testing. Results from hot-fire testing are provided for a lander-class 31kN (7,000lbf) thrust engine using Liquid Oxygen (LOX)/Liquid Hydrogen (LH2) and LOX/Methane (LCH4).

Al6061-RAM2↗

NASA NTRS1979

Heat pipe cooling of power processing magnetics

The constant demand for increased power and reduced mass has raised the internal temperature of conventionally cooled power magnetics toward the upper limit of acceptability. The conflicting demands of electrical isolation, mechanical integrity, and thermal conductivity preclude significant further advancements using conventional approaches. However, the size and mass of multikilowatt power processing systems may be further reduced by the incorporation of heat pipe cooling directly into the power magnetics. Additionally, by maintaining lower more constant temperatures, the life and reliability of the magnetic devices will be improved. A heat pipe cooled transformer and input filter have been developed for the 2.4 kW beam supply of a 30-cm ion thruster system. This development yielded a mass reduction of 40% (1.76 kg) and lower mean winding temperature (20 C lower). While these improvements are significant, preliminary designs predict even greater benefits to be realized at higher power. This paper presents the design details along with the results of thermal vacuum operation and the component performance in a 3 kW breadboard power processor.

Hansen, I. G.↗

NASA NTRS1972

Evaluation of a self-aspirating local total enthalpy probe in a low-density arc-heated hypersonic wind tunnel

A shock-swallowing, self-aspirating, local total enthalpy probe has been evaluated in a low density nonequilibrium, hypervelocity airstream. The probe, which incorporated an air gap to separate the internal and external cooling passages, was tested in an electric archeated wind tunnel at an average Mach number of 11.7 and an average Reynolds number per meter of 57,000. The free stream enthalpy probe data are compared with bulk calorimeter measurements of total enthalpy at the beginning of the gas expansion and with local total enthalpy inferred from a theoretical nonequilibrium gas expansion model by using free stream velocity measurements obtained from a mass flow probe. The three techniques are in relative agreement at the lower enthalpies. However, at the higher enthalpies, the enthalpy probe data lie considerably below the other data. This low data may be caused by the chemical and vibrational energy frozen in the flow not being sensed by the probe. Other problems associated with the shock-swallowing total enthalpy probe are discussed, and recommendations for improving the probe performance are presented.

Guy, R. W.↗

NASA NTRS1972

The Viking Orbiter 1975 beryllium INTEREGEN rocket engine assembly.

Description of the conversion of the Mariner 9 rocket engine for Viking Orbiter use. Engine conversion consists of replacing the 40:1 expansion area ratio nozzle with a 60:1 nozzle of the internal regeneratively (INTEREGEN) cooled rocket engine. Five converted engines using nitrogen tetroxide and monomethylhydrazine demonstrated thermal stability during the nominal 2730-sec burn, but experienced difficulty at operating extremes. The thermal stability characteristic was treated in two ways. The first treatment consisted of mapping the operating regime of the engine to determine its safest operating boundaries as regards thermal equilibrium. Six engines were used for this purpose. Two of the six engines were then modified to effect the second approach - i.e., extend the operating regime. The engines were modified by permitting fuel injection into the acoustic cavity.

Martinez, R. S.↗

NASA NTRS1976

Refinement of Promising Coating Compositions for Directionally Cast Eutectics

The successful application of high creep strength, directionally solidified gamma/gamma prime-delta (Ni-19.7Cb-6Cr-2.5Al) eutectic superalloy turbine blades requires the development of suitable coatings for airfoil, root and internal blade surfaces. In order to improve coatings for the gamma/gamma prime-delta alloy, the current investigation had the goals of (1) refining promising coating compositions for directionally solidified eutectics, (2) evaluating the effects of coating/ substrate interactions on the mechanical properties of the alloy, and (3) evaluating diffusion aluminide coatings for internal surfaces. Burner rig cyclic oxidation, furnace cyclic hot corrosion, ductility, and thermal fatigue tests indicated that NiCrAlY+Pt(63 to 127 micron Ni-18Cr-12Al-0.3Y + 6 micron Pt) and NiCrAlY(63 to 127 micron Ni-18Cr-12Al-0.3Y) coatings are capable of protecting high temperature gas path surfaces of eutectic alloy airfoils. Burner rig (Mach 0.37) testing indicated that the useful coating life of the 127 micron thick coatings exceeded 1000 hours at 1366 K (2000 deg F). Isothermal fatigue and furnance hot corrosion tests indicated that 63 micron NiCrAlY, NiCrAlY + Pt and platinum modified diffusion aluminide (Pt + Al) coating systems are capable of protecting the relatively cooler surfaces of the blade root. Finally, a gas phase coating process was evaluated for diffusion aluminizing internal surfaces and cooling holes of air-cooled gamma/gamma prime-delta turbine blades.

Strangman, T. E.↗

NASA NTRS1980

Compact, super heat exchanger

Heat exchanger uses porous media to enhance heat transfer through walls of cooling channels, thereby lowering wall temperature. Porous media within cooling channel increases internal surface area from which heat can be transferred to coolant. Comparison data shows wall has lower temperature and coolant has higher temperature when porous medium is used within heat exchanger. Media can be sintered powedered metal, metal fibers, woven wire layers, or any porous metal having desired permeability and porosity.

Fortini, A.↗

NASA NTRS1982

Experimental study of an integral catalytic combustor: Heat exchanger for Stirling engines

The feasibility of using catalytic combustion with heat removal for the Stirling engine to reduce exhaust emissions and also improve heat transfer to the working fluid was studied using spaced parallel plates. An internally air-cooled heat exchanger was placed between two noble metal catalytic plates. A preheated fuel-air mixture passed between the plates and reacted on the surface of the catalyzed plates. Heat was removed from the catalytic surface by radiation and convection to the aircooled heat exchangers to control temperature and minimize thermal nitrogen oxide emissions. Test conditions were inlet combustion air temperatures from 850 to 900 K, inlet velocities of about 10 m/s, equivalence ratios from 0.5 to 0.9, and pressures from 1.3x10 to the 5th power to 2.0x10 to the 5th power Pa. Propane fuel was used for all testing. Combustion efficiencies greater than 99.5 percent were measured. Nitrogen oxide emissions ranged from 1.7 to 3.3 g NO2/kg fuel. The results demonstrate the feasibility of the concept and indicate that further investigation of the concept is warranted.

Bulzan, D. L.↗

NASA NTRS1987

Experimental data correlations for the effects of rotation on impingement cooling of turbine blades

The effects of rotation on impingement cooling have been experimentally studied under simulated gas turbine operating conditions. A large scale model of a blade is spun in vacuum. External heating is simulated by resistve dissipation in the thin wall of the model, which is impingement cooled. The local internal Nu is measured by an IR radiometric technique with high spatial resolution. At low rotational speeds the data agree well with published measurements taken under stationary conditions. At higher speeds, a decrease in the average Nu by up to 20-30 percent is observed. Severe gradients are generated near the hub region. Empirical correlations, which fit the data well and render it more useful for design purposes, are presented. Measurements and correlations suggest that rotational effects are very important and can cause premature blade failure.

Kreatsoulas, J. C.↗

NASA NTRS2000

Satellite and Ground-based Radiometers Reveal Much Lower Dust Absorption of Sunlight than Used in Climate Models

The ability of dust to absorb solar radiation and heat the atmosphere is one of the main uncertainties in climate modeling and the prediction of climate change. Dust absorption is not well known due to limitations of in situ measurements. New techniques to measure dust absorption are needed in order to assess the impact of dust on climate. Here we report two new independent remote sensing techniques that provide sensitive measurements of dust absorption. Both are based on remote sensing. One uses satellite spectral measurements, the second uses ground based sky measurements from the AERONET network. Both techniques demonstrate that Saharan dust absorption of solar radiation is several times smaller than the current international standards. Dust cooling of the earth system in the solar spectrum is therefore significantly stronger than recent calculations indicate. We shall also address the issue of the effects of dust non-sphericity on the aerosol optical properties.

Kaufman, Y. J.↗

NASA NTRS2002

Efficient Design in a DC to DC Converter Unit

Space Flight hardware requires high power conversion efficiencies due to limited power availability and weight penalties of cooling systems. The International Space Station (ISS) Electric Power System (EPS) DC-DC Converter Unit (DDCU) power converter is no exception. This paper explores the design methods and tradeoffs that were utilized to accomplish high efficiency in the DDCU. An isolating DC to DC converter was selected for the ISS power system because of requirements for separate primary and secondary grounds and for a well-regulated secondary output voltage derived from a widely varying input voltage. A flyback-current-fed push-pull topology or improved Weinberg circuit was chosen for this converter because of its potential for high efficiency and reliability. To enhance efficiency, a non-dissipative snubber circuit for the very-low-Rds-on Field Effect Transistors (FETs) was utilized, redistributing the energy that could be wasted during the switching cycle of the power FETs. A unique, low-impedance connection system was utilized to improve contact resistance over a bolted connection. For improved consistency in performance and to lower internal wiring inductance and losses a planar bus system is employed. All of these choices contributed to the design of a 6.25 KW regulated dc to dc converter that is 95 percent efficient. The methodology used in the design of this DC to DC Converter Unit may be directly applicable to other systems that require a conservative approach to efficient power conversion and distribution.

Bruemmer, Joel E.↗