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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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At least 217 records · Page 12

Modeling and analysis of the Space Station Freedom Active Thermal Control System radiators using SINDA/FLUINT

Detailed SINDA/FLUINT models have been developed to assess the adequacy of the Space Station Freedom External Thermal Control System's radiator design, as well as to simulate the effects of various operational scenarios. Design margins can be deduced by quantifying such real-world effects as flow maldistribution due to line-pressure drop and uneven heat loads. The factor which most reduced the heat-rejection capacity is an uneven heat load split between the two low temperature loops.

Andish, Kambiz K.↗

EXPERIMENTAL AND MODELLING ANALYSIS OF A LARGE-SCALE TWO-PHASE LOOP THERMOSYPHON

Liquid pumping requires large quantities of electrical energy, including about 7% of the energy of building heating, ventilation, and air conditioning (HVAC) systems. To replace pumped condenser-cooling tower water loops with a passive alternative system, we implemented a commercial-scale two-phase loop thermosyphon (TPLT). The unit consists of a 13 m riser integrated with a commercially available cooling tower and circulation water heater that simulates heat loads up to 25 kW. In addition to providing passive cooling capabilities, the cooling tower unit is also maintenance free, reliable, and can operate in both dry and wet modes. This study characterizes the performance (temperature difference between the evaporator and condenser) and the two-phase flow behavior of the loop under various refrigerant charges. Sight glasses installed throughout the loop are used to identify the operating flow regimes in the riser and downcomer. Over the range of operating conditions, we identified that there is an optimal refrigerant charge range for a specific heat load at which near-isothermal operation can be achieved. We further developed a model to predict the operating flow rate and gravitational height in the downcomer and compared it with the experimental data. The results show that the model agrees with the experimental data, in particular the threshold gravitational head height at which there will be subcooled liquid at the condenser exit, indicating that it can be used as a predictive tool for identifying the optimal loop charge for a given heat load.

Loop thermosyphon, passive two phase↗

Design and test of a pumped two-phase mounting plate

The design, fabrication, and testing of the full-scale development unit of a pumped two-phase mounting plate (TPMP) used in advanced two-phase spacecraft thermal control systems are described. The mounting plate is tested with R-11 in the evaporator mode for total heat loads of over 3000 watts and local heat fluxes over 4 W/sq cm, and in the condenser mode with condenser loads from 60 to 400 watts and inlet qualities from 8 to 94 percent. The calculated heat-transfer coefficients are between 0.66 and 1.0 W/sq cm/C and are nearly independent of the flow rate and heat load except at very low heat loads. It is shown that the TPMP can be run with inlet conditions down to 22 C subcooling without any significant gradients in the plate and that it performs well with nonuniform heat fluxes.

Grote, M. G.↗

Testing of a Helium Loop Heat Pipe for Large Area Cryocooling

Future NASA space telescopes and exploration missions require cryocooling of large areas such as optics, detector arrays, and cryogenic propellant tanks. One device that can potentially be used to provide closed-loop cryocooling is the cryogenic loop heat pipe (CLHP). A CLHP has many advantages over other devices in terms of reduced mass, reduced vibration, high reliability, and long life. A helium CLHP has been tested extensively in a thermal vacuum chamber using a cryocooler as the heat sink to characterize its transient and steady performance and verify its ability to cool large areas or components in the 3K temperature range. A copper plate with attached electrical heaters was used to simulate the heat source, and heat was collected by the CLHP evaporator and transferred to the cryocooler for ultimate heat rejection. The helium CLHP thermal performance test included cool-down from the ambient temperature, startup, capillary limit, heat removal capability, rapid power changes, and long duration steady state operation. The helium CLHP demonstrated robust operation under steady state and transient conditions. The loop could be cooled from the ambient temperature to subcritical temperatures very effectively, and could start successfully without pre-conditioning by simply applying power to both the capillary pump and the evaporator plate. It could adapt to rapid changes in the heat load, and reach a new steady state very quickly. Heat removal between 10mW and 140mW was demonstrated, yielding a power turn down ratio of 14. When the CLHP capillary limit was exceeded, the loop could resume its normal function by reducing the power to the capillary pump. Steady state operations up to 17 hours at several heat loads were demonstrated. The ability of the helium CLHP to cool large areas was therefore successfully verified.

cryocooling↗

Testing of a Helium Loop Heat Pipe for Large Area Cryocooling

Future NASA space telescopes and exploration missions require cryocooling of large areas such as optics, detector arrays, and cryogenic propellant tanks. One device that can potentially be used to provide closed-loop cryocooling is the cryogenic loop heat pipe (CLHP). A CLHP has many advantages over other devices in terms of reduced mass, reduced vibration, high reliability, and long life. A helium CLHP has been tested extensively in a thermal vacuum chamber using a cryocooler as the heat sink to characterize its transient and steady performance and verify its ability to cool large areas or components in the 3K temperature range. A copper plate with attached electrical heters was used to simulate the heat source, and heat was collected by the CLHP evaporator and transferred to the cryocooler for ultimate heat rejection. The helium CLHP thermal performance test included cool-down from the ambient temperature, startup, capillary limit, heat removal capability, rapid power changes, and long duration steady state operation. The helium CLHP demonstrated robust operation under steady state and transient conditions. The loop could be cooled from the ambient temperature to subcritical temperatures very effectively, and could start successfully without pre-conditioning by simply applying power to both the capillary pump and the evaporator plate. It could adapt to rapid changes in the heat load, and reach a new steady state very quickly. Heat removal between 10mW and 140mW was demonstrated, yielding a power turn down ratio of 14. When the CLHP capillary limit was exceeded, the loop could resume its normal function by reducing the power to the capillary pump. Steady state operations up to 17 hours at several heat loads were demonstrated. The ability of the helium CLHP to cool large areas was therefore successfully verified.

Crycooling↗

Thermal Vacuum Testing of a Helium Loop Heat Pipe for Large Area Cryocooling

Future NASA space telescopes and exploration missions require cryocooling of large areas such as optics, detector arrays, and cryogenic propellant tanks. One device that can potentially be used to provide closed-loop cryocooling is the cryogenic loop heat pipe (CLHP). A CLHP has many advantages over other devices in terms of reduced mass, reduced vibration, high reliability, and long life. A helium CLHP has been tested extensively in a thermal vacuum chamber using a cryocooler as the heat sink to characterize its transient and steady performance and to verify its ability to cool large areas or components in the 3 degrees Kelvin temperature range. The helium CLHP thermal performance test included cool-down from the ambient temperature, startup, capillary limit, heat removal capability, rapid power changes, and long duration steady state operation. The helium CLHP demonstrated robust operation under steady state and transient conditions. The loop could be cooled from the ambient temperature to subcritical temperatures very effectively, and could start successfully by simply applying power to both the capillary pump and the evaporator plate without pre-conditioning. It could adapt to a rapid heat load change and quickly reach a new steady state. Heat removal between 10 megawatts and 140 megawatts was demonstrated, yielding a power turn down ratio of 14. When the CLHP capillary limit was exceeded, the loop could resume its normal function by reducing the power to the capillary pump. Steady state operations up to 17 hours at several heat loads were demonstrated. The ability of the helium CLHP to cool large areas was therefore successfully verified.

Thermal Control Systems↗

Heuristic predictions of RMP configurations for ELM suppression in ITER burning plasmas and their impact on divertor performance

Abstract A subspace of resonant magnetic perturbation (RMP) configurations for edge localized mode (ELM) suppression is predicted for H-mode burning plasmas at 15 MA current and 5.3 T magnetic field in ITER. Perturbations to the core plasma can be reduced by a factor of 2 for equivalent edge stability proxies, while the perturbed plasma boundary geometry remains mostly resilient. The striated domain of perturbed field lines connecting from the main plasma (normalized poloidal flux < 1 ) to the divertor targets is found to be significantly larger than the expected heat load width in the absence of RMPs. This facilitates heat load spreading with peak values at an acceptable level below 10 MW m − 2 on the outer target already at moderate gas fueling and low Ne seeding for additional radiative dissipation of the 100 MW of power into the scrape-off layer (SOL). On the inner target, however, re-attachment is predicted away from the equilibrium strike point due to increased upstream heat flux, higher downstream temperature and less efficient impurity radiation.

3D plasma boundary modeling↗

Numerical analysis of flow and heat transfer in the VAFB LOX storage Dewar tank

The present report describes numerical simulation of three-dimensional transient distributions of velocity and temperature of liquid oxygen (LOX) in the LOX Dewar tank of Vendenberg Air Force Base (VAFB). The present analyses cover the replenish time period only. Four test cases have been considered. For all four cases, the input boundary conditions are comprised of LOX facility heat loads, drain flow rates, recirculation flow rates and dewar heating. All the quantities are prescribed as functions of time. The first two test cases considered sensitivity of results to the computational grid. In Case 3, system heat load was changed, while in Case 4, a lower LOX level was specified. Cases 1 and 2 showed that the temperatures were not sensitive to the grid refinement. This provided a basic check on the numerical model. Cases 3 and 4 showed that the thermal boundary layer motion near the tank surface becomes more significant at the late time, e.g., 5 1/2 hours from replenish start. Comparison between results of Cases 3 and 4 showed, as expected, that the smaller initial LOX volume given in Case 4, results in higher temperature level. All calculated velocity and temperature distributions were found to be plausible.

Tam, L. T.↗

Design of the PIXIE Adiabatic Demagnetization Refrigerators

The Primordial Inflation Explorer (PIXIE) is a proposed mission to densely map the polarization of the cosmic microwave background. It will operate in a scanning mode from a sun-synchronous orbit, using low temperature detectors (at 0.1 K) and located inside a teslescope that is cooled to approximately 2.73 K - to match the background temperature. A mechanical cryocooler operating at 4.5 K establishes a low base temperature from which two adiabatic demagnetization refrigerator (ADR) assemblies will cool the telescope and detectors. To achieve continuous scanning capability, the ADRs must operate continuously. Complicating the design are two factors: 1) the need to systematically vary the temperature of various telescope components in order to separate the small polarization signal variations from those that may arise from temperature drifts and changing gradients within the telescope, and 2) the orbital and monthly variations in lunar irradiance into the telescope barrels. These factors require the telescope ADR to reject quasi-continuous heat loads of 2-3 millwatts, while maintaining a peak heat reject rate of less than 12 milliwatts. The detector heat load at 0.1 K is comparatively small at 1-2 microwatts. This paper will describe the 3-stage and 2-stage continuous ADRs that will be used to meet the cooling power and temperature stability requirements of the PIXIE detectors and telescope.

adiabatic demagnetization refrigerator↗

Development of heat flux sensors for turbine airfoils and combustor liners

The design of durable turbine airfoils that use a minimum amount of cooling air requires knowledge of the heat loads on the airfoils during engine operation. Measurement of these heat loads will permit the verification or modification of the analytical models used in the design process and will improve the ability to predict and confirm the thermal performance of turbine airfoil designs. Heat flux sensors for turbine blades and vanes must be compatible with the cast nickel-base and cobalt-base materials used in their fabrication and will need to operate in a hostile environment with regard to temperature, pressure and thermal cycling. There is also a need to miniaturize the sensors to obtain measurements without perturbing the heat flows that are to be measured.

Atkinson, W. H.↗

Water Based Phase Change Material Heat Exchanger Development

In a cyclical heat load environment such as low Lunar orbit, a spacecraft’s radiators are not sized to reject the full heat load requirement. Traditionally, a supplemental heat rejection device (SHReD) such as an evaporator or sublimator is used to act as a “topper” to meet the additional heat rejection demands. Utilizing a Phase Change Material (PCM) heat exchanger (HX) as a SHReD provides an attractive alternative to evaporators and sublimators as PCM HXs do not use a consumable, thereby leading to reduced launch mass and volume requirements. Studies conducted in this paper investigate utilizing water’s high latent heat of formation as a PCM, as opposed to traditional waxes, and corresponding complications surrounding freezing water in an enclosed volume. Work highlighted in this study is primarily visual and includes understanding ice formation, freeze front propagation, and the solidification process of water/ice. Various test coupons were constructed of copper to emulate the interstitial pin configuration (to aid in conduction) of the proposed water PCM HX design. Construction of a prototypic HX was also completed in which a flexible bladder material and interstitial pin configurations were tested. Additionally, a microgravity flight was conducted where three copper test articles were frozen continuously during microgravity and 2-g periods and individual water droplets were frozen during microgravity.

Hansen, Scott W.↗

System Level Analysis of a Water PCM HX Integrated Into Orion's Thermal Control System Abstract

In a cyclical heat load environment such as low Lunar orbit, a spacecraft's radiators are not sized to reject the full heat load requirement. Traditionally, a supplemental heat rejection device (SHReD) such as an evaporator or sublimator is used to act as a "topper" to meet the additional heat rejection demands. Utilizing a Phase Change Material (PCM) heat exchanger (HX) as a SHReD provides an attractive alternative to evaporators and sublimators as PCM HXs do not use a consumable, thereby leading to reduced launch mass and volume requirements. In continued pursuit of water PCM HX development an Orion system level analysis was performed using Thermal Desktop for a water PCM HX integrated into Orion's thermal control system and in a 100km Lunar orbit. The study analyzed 1) placing the PCM on the Internal Thermal Control System (ITCS) versus the External Thermal Control System (ETCS) 2) use of 30/70 PGW verses 50/50 PGW and 3) increasing the radiator area in order to reduce PCM freeze times. The analysis showed that for the assumed operating and boundary conditions utilizing a water PCM HX on Orion is not a viable option. Additionally, it was found that the radiator area would have to be increased over 20% in order to have a viable water‐based PCM HX.

Navarro, Moses↗

Continued Water-Based Phase Change Material Heat Exchanger Development

In a cyclical heat load environment such as low Lunar orbit, a spacecraft's radiators are not sized to reject the full heat load requirement. Traditionally, a supplemental heat rejection device (SHReD) such as an evaporator or sublimator is used to act as a "topper" to meet the additional heat rejection demands. Utilizing a Phase Change Material (PCM) heat exchanger (HX) as a SHReD provides an attractive alternative to evaporators and sublimators as PCM HXs do not use a consumable, thereby leading to reduced launch mass and volume requirements. In continued pursuit of water PCM HX development two full‐scale, Orion sized water‐based PCM HX's were constructed by Mezzo Technologies. These HX's were designed by applying prior research and experimentation to the full scale design. Design options considered included bladder restraint and clamping mechanisms, bladder manufacturing, tube patterns, fill/drain methods, manifold dimensions, weight optimization, and midplate designs. Design and construction of these HX's led to successful testing of both PCM HX's.

Hansen, Scott↗

System Level Analysis of a Water PCM HX Integrated into Orion's Thermal Control System

In a cyclical heat load environment such as low Lunar orbit, a spacecraft's radiators are not sized to reject the full heat load requirement. Traditionally, a supplemental heat rejection device (SHReD) such as an evaporator or sublimator is used to act as a "topper" to meet the additional heat rejection demands. Utilizing a Phase Change Material (PCM) heat exchanger (HX) as a SHReD provides an attractive alternative to evaporators and sublimators as PCM HXs do not use a consumable, thereby leading to reduced launch mass and volume requirements. In continued pursuit of water PCM HX development an Orion system level analysis was performed using Thermal Desktop for a water PCM HX integrated into Orion's thermal control system in a 100km Lunar orbit. The study verified of the thermal model by using a wax PCM and analyzed 1) placing the PCM on the Internal Thermal Control System (ITCS) versus the External Thermal Control System (ETCS) 2) use of 30/70 PGW verses 50/50 PGW and 3) increasing the radiator area in order to reduce PCM freeze times. The analysis showed that for the assumed operating and boundary conditions utilizing a water PCM HX on Orion is not a viable option for any case. Additionally, it was found that the radiator area would have to be increased by at least 40% in order to support a viable water-based PCM HX.

Navarro, Moses↗

Synergistic effects of W–Ta alloys exposed to various ELM-like fusion events

Abstract Recently tungsten alloys have shown capabilities in suppressing morphological changes when exposed to harsh fusion conditions. Morphological changes due to He + and D + ions at high temperatures (1000–2000 K) can lead to easier erosion and sputtering of tungten (W) particles towards quenching the fusion plasma. This study investigated W–3Ta alloy as potential plasma facing materials (PFMs) exposed to different edge-localized mode (ELM)-like energies and ion loadings. Performance of W–3Ta has been tested as a function of ELM-like energies (0.6–1.5 GW m −2 ) and varying He + and D + ion concentrations (100% He + , 50% He + :50% D + ,10% He + :90% D + (similar ELM-like reactor condition), and 100% D + ions). Early-stage fuzz formation and surface pores were observed during 100% He + ion irradiation and mixed ion loadings but not observed during 100% D + ion loadings. Pores decreased in quantity and increased in size with increasing transient heat loading. Grain boundaries acted as trapping sites of helium and deuterium atoms during dual beam ion irradiations, as observed through increased pore size along the grain boundary. Qualitative erosion estimates were measured using witness plates. Increased erosion was observed with increasing D + ion concentration, which is attributed to D supersaturation in the near surface region affecting thermal and mechanical properties. More erosion was observed for W–3Ta samples compared to pure W, evident through large (>10 µ m) cracks on the surface, and an increase in W metal x-ray photoelectron spectroscopy peaks under similar loading conditions. The slight enhancement in erosion is attributed to the slightly decreased thermal properties, ∼10% thermal diffusivity drop, of W–3Ta at high temperatures. The damage threshold was impacted by ion loading, where distinct cracking was observed for 100% He + at a lower heat loading. This matrix study using reactor-like loading supports the need for extensive studies on future W alloy PFMs before selecting one as an alternative.

Physics↗

Optical Design of $\mathrm{DEI/ABI}$ System at the $\mathrm{HEX}$ Beamline at the $\mathrm{NSLS-II}$

Diffraction Enhanced Imaging (DEI) or Analyzer Based Imaging (ABI) uses a perfect crystal monochromator and matching analyzer to achieve sensitivity to x-ray refraction and ultra small-angle scattering on the order of 0.01 micro-radians. As such, a thermal bump caused by heat-load in the order of 1 W is detrimental. The heat load at the HEX (High Energy Engineering X-ray) super-conducting wiggler (SCW) beamline, under construction at the NSLS-II, is on the order of 1 kW. How to reconcile the three orders of magnitude difference between the HEX source power and the DEI/ABI requirements? The solution involves using a double-crystal bent-Laue monochromator as pre-monochromator to prepare a beam with a large divergence and bandwidth that is matched to a flat crystal post-monochromator. We show through phase-space (x-ray energy vs. angle as viewed by a flat crystal) analysis and Dumond diagrams that there is indeed a unique bending radius that matches the double-crystal bent-Laue monochromator in phase space to the flat Bragg crystal. The matched system has a desirable feature that the phase space of the bent crystal’s output beam is much larger than that of the flat crystal, making the combined system stable. Based on these considerations, here we present our optical design for performing DEI/ABI at the HEX beamline

36 MATERIALS SCIENCE↗

User's guide for the thermal analyst's help desk expert system

A guide for users of the Thermal Analyst's Help Desk is provided. Help Desk is an expert system that runs on a DOS based personal computer and operates within the EXSYS expert system shell. Help Desk is an analysis tool designed to provide users having various degrees of experience with the capability to determine first approximations of thermal capacity for spacecraft and instruments. The five analyses supported in Help Desk are: surface area required for a radiating surface, equilibrium temperature of a surface, enclosure temperature and heat loads for a defined position in orbit, enclosure temperature and heat loads over a complete orbit, and selection of appropriate surface properties. The two geometries supported by Help Desk are a single flat plate and a rectangular box enclosure.

Ormsby, Rachel A.↗

Thermal and Fluid Modeling of the CRYogenic Orbital TEstbed (CRYOTE) Ground Test Article (GTA)

The purpose of this study was to anchor thermal and fluid system models to data acquired from a ground test article (GTA) for the CRYogenic Orbital TEstbed - CRYOTE. To accomplish this analysis, it was broken into four primary tasks. These included model development, pre-test predictions, testing support at Marshall Space Flight Center (MSFC} and post-test correlations. Information from MSFC facilitated the task of refining and correlating the initial models. The primary goal of the modeling/testing/correlating efforts was to characterize heat loads throughout the ground test article. Significant factors impacting the heat loads included radiative environments, multi-layer insulation (MLI) performance, tank fill levels, tank pressures, and even contact conductance coefficients. This paper demonstrates how analytical thermal/fluid networks were established, and it includes supporting rationale for specific thermal responses seen during testing.

Piryk, David↗