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At least 235 records · Page 13

TechEdSat 7, 10, 13, 15: Exo-brake Experiments on the ISS, First Virgin Orbit, and First Firefly-Alpha Test Flights.

The TechEdSat flight series (TES-n), developed by the Nano Orbital Workshop (NOW) group at NASA Ames, has been studying cube satellite re-entry technologies with a focus on Exo-Brake drag device research. An exo-atmospheric braking device, the Exo-Brake uses the tenuous upper atmosphere acting in a free molecular flow regime to enable controllable adjustment of the drag profile of the host spacecraft, currently enabling rapid disposal of small spacecraft after mission conclusion, and eventual targeted de-orbit to a desired entry point at the Von Karman line, or approximately 100km in altitude. The TES-7 mission, flown on the first successful Virgin Orbit flight January 17, 2021, was injected into a 500km, 61-degree inclination orbit, with an expected orbital lifetime of approximately ten years. After successful deployment of a unique hydrogen gas-cell inflation design ‘disposal’-type Mylar Exo-Brake intended to rapidly de-orbit the spacecraft, the maximum expected orbital lifetime of the TES-7 spacecraft was successfully reduced from ten years to 1.3 years, an 87% reduction in orbit lifetime via a passive, fuel-less system. The subsequent TES-13 mission utilized a new, less complex ‘disposal’-type Exo-Brake design made from collapsible rigid struts rather than inflated struts to reduce the engineering, construction, and safety complexities introduced by the prior hydrogen gas inflation design. The rigid strut Exo-Brake design is stowed via rotational compression and deploys using only stored spring energy once released via electronic actuator. This new rotation compression storage design has become the new Exo-Brake design standard used on TES missions thanks to its simplicity. Following on the success of this new Exo-Brake design demonstrated by TES-13, the design was further refined to enabled active manipulation of the Exo-Brake effective drag area though a winch-like system. Both the TES-10 and TES-15 spacecraft were equipped with geometrically similar Exo-Brake devices capable of such active drag modulation, with the intent of studying the operational impact of having such devices on cube satellite missions. To increase the survival time of the Exo-Brake at low altitudes and thus gain more experiment time and better guidance capability, TES-15 was equipped with a modulated Exo-Brake constructed from 3M™ Nextel™ 440 ceramic oxide fiber, the same fabric material used in the Space Shuttle TPS system, rather than Mylar. After launching on Alpha Flight 2 October 1st, 2022, Firefly’s first successful launch, TES-15 met the same modulation restrictions as TES-10, with modulation prohibited above 200km to avoid possible collision with other spacecraft. In this case, a low deployment orbit caused an extremely short mission life, which, coupled with delayed spacecraft identification, exacerbated collision concerns and caused performance data of the high-temperature Exo-Brake design to be inconclusive. As such, the Nano Orbital Workshop has taken a new approach of only conducting modulated Exo-Brake research on missions deploying below ISS altitude to avoid collision avoidance restrictions, and is working to improve spacecraft identification and location reporting techniques to increase experiment durations. Upcoming TES mission will therefore use one of two classes of Exo-Brake depending on their target altitude, as to be described in the submission.

M Murbach↗

TechEdSat 7, 10, 13, 15: Exo-brake Experiments on the ISS, First Virgin Orbit, and First Firefly-Alpha Test Flights

The TechEdSat flight series (TES-n), developed by the Nano Orbital Workshop (NOW) group at NASA Ames, has been studying cube satellite re-entry technologies with a focus on Exo-Brake drag device research. An exo-atmospheric braking device, the Exo-Brake uses the tenuous upper atmosphere acting in a free molecular flow regime to enable controllable adjustment of the drag profile of the host spacecraft, currently enabling rapid disposal of small spacecraft after mission conclusion, and eventual targeted de-orbit to a desired entry point at the Von Karman line, or approximately 100km in altitude. The TES-7 mission, flown on the first successful Virgin Orbit flight January 17, 2021, was injected into a 500km, 61-degree inclination orbit, with an expected orbital lifetime of approximately ten years. After successful deployment of a unique hydrogen gas-cell inflation design ‘disposal’-type Mylar Exo-Brake intended to rapidly de-orbit the spacecraft, the maximum expected orbital lifetime of the TES-7 spacecraft was successfully reduced from ten years to 1.3 years, an 87% reduction in orbit lifetime via a passive, fuel-less system. The subsequent TES-13 mission utilized a new, less complex ‘disposal’-type Exo-Brake design made from collapsible rigid struts rather than inflated struts to reduce the engineering, construction, and safety complexities introduced by the prior hydrogen gas inflation design. The rigid strut Exo-Brake design is stowed via rotational compression and deploys using only stored spring energy once released via electronic actuator. This new rotation compression storage design has become the new Exo-Brake design standard used on TES missions thanks to its simplicity. Following on the success of this new Exo-Brake design demonstrated by TES-13, the design was further refined to enabled active manipulation of the Exo-Brake effective drag area though a winch-like system. Both the TES-10 and TES-15 spacecraft were equipped with geometrically similar Exo-Brake devices capable of such active drag modulation, with the intent of studying the operational impact of having such devices on cube satellite missions. To increase the survival time of the Exo-Brake at low altitudes and thus gain more experiment time and better guidance capability, TES-15 was equipped with a modulated Exo-Brake constructed from 3M™ Nextel™ 440 ceramic oxide fiber, the same fabric material used in the Space Shuttle TPS system, rather than Mylar. After launching on Alpha Flight 2 October 1st, 2022, Firefly’s first successful launch, TES-15 met the same modulation restrictions as TES-10, with modulation prohibited above 200km to avoid possible collision with other spacecraft. In this case, a low deployment orbit caused an extremely short mission life, which, coupled with delayed spacecraft identification, exacerbated collision concerns and caused performance data of the high-temperature Exo-Brake design to be inconclusive. As such, the Nano Orbital Workshop has taken a new approach of only conducting modulated Exo-Brake research on missions deploying below ISS altitude to avoid collision avoidance restrictions, and is working to improve spacecraft identification and location reporting techniques to increase experiment durations. Upcoming TES mission will therefore use one of two classes of Exo-Brake depending on their target altitude, as to be described in the submission.

Marcus Murbach↗

The Impact of Transition-Edge Sensor Design on Internal Thermal Fluctuation Noise and Thermal Conductance

The measured noise in transition-edge sensor (TES) microcalorimeters with a Mo/Au bilayer has been shown to have a significant contribution from internal thermal fluctuation noise (ITFN) between the absorber and the TES. Previous measurements showed the relevant thermal link leading to the noise was the thermal conductance of the TES bilayer, and ITFN has been shown to correlate with the sheet resistance of the TES. As a result, ITFN is particularly significant in devices with a large bilayer sheet resistance. However, because of more favorable transition shapes, such high resistance devices have recently been shown to be preferable under alternating current bias, which is required for the frequency division multiplexed readout baselined for the X-ray Integral Field Unit (X-IFU) instrument on the ATHENA satellite. Therefore, it is important to investigate how else to minimize the ITFN beyond changes to the sheet resistance. In this presentation, we will discuss our investigation of how changes to the TES design can affect ITFN for a fixed sheet resistance. We will present how ITFN is altered by changes to the aspect ratio of the TES, the addition of normal metal banks parallel to the TES current direction, and the size and position of the connections between the absorber and the TES. We will also discuss how these design changes impact the superconducting transition shape, and the thermal conductance from the TES to the thermal bath. These results may provide routes for further improvements of TES performance, and a deeper understanding of the physics of the thermal network in a TES microcalorimeter.

Nicholas A Wakeham↗

High-Fidelity and High-Performance Computational Simulations for Rapid Design Optimization of Sulfur Thermal Energy Storage

Industrial process heating (IPH) accounts for approximately 70% of US manufacturing energy use and is primarily produced by fossil fuel combustion. Approximately 1500 TWht (approximately 60%) of IPH demand is in the temperature range of 100-300. Industrial applications in this temperature range include drying, hydrothermal processing, thermal enhanced oil recovery, food and beverage, bioethanol production, etc. Cost-effective thermal energy storage (TES) that increases the utilization of waste and renewable heat (solar, geothermal, etc.) could provide significant energy savings and reliable heat sources, decrease emissions, and increase US manufacturing competitiveness through reductions in fuel consumption. TES development has historically been dominated by technologies suitable for deployment with concentrating solar power (CSP). State-of-the-art thermal storage deployed commercially with power tower CSP plants uses a 60%/40% NaNO3/KNO3 molten salt and operates between temperatures of approximately 280 degrees Celsius and 570 degrees Celsius using a two-tank configuration. However, these nitrate salts are unsuitable for operation outside of this temperature range due to a high freezing point of approximately 220 degrees Celsius, and limits on high-temperature salt stability and corrosion resistance of containment alloys. Other materials being investigated for TES include those based on: (1) sensible energy storage (various molten salt compositions, inert solid particles, rocks or pebble beds, sulfur, water, concrete, graphite, etc.), (2) latent energy storage in materials that undergo solid-liquid phase change at relevant temperatures (organic materials for low-temperature applications, inorganic salts and/or metals for high-temperature applications), or (3) thermochemical energy storage (hydrides, hydroxides, carbonates, metal oxides, etc.). The application temperature and challenges pertaining to storage material and/or containment cost, energy density, long-term thermal and cyclic stability, and charge/discharge heat transfer effectiveness drive material selection for a given IPH or electricity generation application. Sulfur is a cheap commodity at $80/ton compared to $1100 - 1300/ton for conventional salts. When using a metric of storage cost per kWh, sulfur costs around 2-3 $/kWh. Previous sulfur TES development focused on high temperature (>600 degrees) concentrated solar power applications with sulfur encapsulated in pipes and flow of gaseous HTF (air) in the shell side. However, for lower-temperature IPH applications in the range of approximately 100-300 degrees Celsius Element 16 adopted a compact and scalable TES design with molten sulfur in the shell and HTF pipes submerged in the molten sulfur bath. The low-cost molten sulfur TES for dispatchable IPH has deployment potential for broad applications. The spatial and temporal evolution of the HTF and sulfur temperature is critical to the TES system performance, and thus detailed modeling can improve understanding of the performance and facilitate design improvements. Using high performance computing and computational fluid dynamics (CFD) a low-cost molten sulfur thermal energy storage (TES) system for industrial process heating (IPH) applications was developed. The unique challenges in CFD modeling of sulfur TES are the sharp property changes of sulfur relevant to the working temperatures. Above 159, liquid sulfur undergoes polymerization, and the viscosity of sulfur rapidly increases by several orders of magnitude between 159 degrees Celsius and 188 degrees Celsius, followed by a decrease in viscosity beyond 188 degrees Celsius due to thermal bound dissociation. In addition, various concentrations of H2S impurities can also modify sulfur viscosity. This numerical challenge is especially relevant to transient simulation of the sulfur TES charging and discharging processes as the extreme property variations limit the applicability of traditional heat transfer correlations. Transient CFD simulations including the temperature-dependent sulfur properties and geometric complexity of the TES design were used to predict the effect of natural convection during charging and discharging on the heat transfer process, sulfur temperature uniformity, charge/discharge rates, and performance of the storage devices. The CFD model was validated with experimental results for a full charge and discharge cycle. The work will show 3D and 2D simulation comparisons aimed to facilitate rapid design iterations and a machine learning based design optimization approach.

CFD↗

Integration of a thermoelectric subcooler with an air‑source heat pump to enhance heating capacity and dehumidification

This study presents an innovative configuration of a thermoelectric subcooler (TES) integrated with an air-source heat pump (ASHP). The TES is installed in the liquid line, where it absorbs heat from the refrigerant. On its hot side, it discharges heat to the return air in heating mode or to the supply air in cooling mode, enabling year-round operation. The ASHP–TES system was evaluated under various conditions to reduce supplemental heating needs and improve dehumidification. Experimental heating tests revealed that activating the TES increased the heating capacity by 12%–20%. However, this occurred with a 7.6%–10% reduction in heating coefficient of performance (COP). In cooling mode, TES operation significantly improved moisture removal. The TES reduced the sensible heat ratio (SHR) and enhanced dehumidification, removing 20%–50% more moisture than a conventional system when meeting the same sensible load. The TES can be turned off to use the refrigerant subcooler for reheat supply air or turned on to substantially boost dehumidification. When meeting the same latent load, the ASHP–TES system achieved up to 33% energy savings compared with a conventional ASHP using resistance heating. Relative to a conventional ASHP paired with a whole-house dehumidifier, the ASHP–TES system provided up to 20% energy savings. These findings underscore the potential of TES integration to improve latent load control and enhance overall energy efficiency in hybrid ASHP systems, especially in cold and humid climates.

Hu, Yifeng [ORNL] (ORCID:0000000242875185)↗

Novel thermal energy storage component: Development, performance, and phase transition diagnosis

Thermal energy storage (TES) using phase change materials (PCMs) is a promising technology for capturing and storing excess thermal energy for later use. However, challenges such as poor heat transfer efficiency and a lack of modular, scalable designs have limited widespread adoption of TES in real-world applications. This study developed and evaluated modular brick-type and blade-type TES prototypes featuring an aluminum housing, an embedded serpentine coil for active or passive thermal exchange, and a cost-effective metal mesh to enhance PCM thermal conductivity. The blade-type TES achieved notable geometric efficiency, with a thickness-to-length ratio of 0.03 and a thickness-to-width ratio of 0.08, enabling highly compact and modular thermal storage suitable for space-constrained applications. The paper presents a detailed evaluation of the TES prototypes’ performance. The comparative analysis indicated that the TES prototypes provide a highly cost-effective, thermally optimized alternative for compact energy storage and load shifting. A novel diagnostic technique was also introduced: using a portable endoscope to capture real-time visualizations of PCM phase transitions inside the TES. This method provides critical insights into internal heat transfer mechanisms, identifies potential issues, and offers valuable support for optimizing the TES design and developing the control algorithm. Overall, the modular brick-type and blade-type TES designs demonstrated in this work provide a scalable, efficient, and economically viable solution for advancing TES across residential, commercial, and industrial sectors. The designs’ compact structure, enhanced thermal performance, and integrated diagnostic capabilities make them strong candidates for future deployment in energy-efficient systems.

Gao, Zhiming [ORNL] (ORCID:0000000271397995)↗

Core Temperature Measurement During Submaximal Exercise: Esophageal, Rectal, and Intestinal Temperatures

The purpose of this study was to determine if intestinal temperature (Tin) might be in acceptable alternative to esophageal (Tes) and rectal temperature (Trec) to assess thermoregulation during supine exercise. We hypothesized that Tin would have values similar to Tes and a response time similar to Trec, but the rate of temperature change across time would not be different between measurement sites. Seven subjects completed a continuous supine protocol of 20 min of rest, 20 min of cycle exercise at 40% peak oxygen consumption (VO2pk), 20 min of cycle exercise at 65% V02pk, and 20 min of recovery. Tes, Trec, and Tin were recorded each min throughout the test. Temperatures were not different after 20 min of rest, but Trec was less than the Tes and Tin at the end of the 40% and 65% VO2pk stages. After 20 min of recovery, Tes was less than either Trec or Tin, which were not different from each other. Time to threshold for increased temperature from rest was greater for Trec than Tes but not different from Tin. Time to reach peak temperature was greater for Tin and Trec than Tes. Similarly, time to a decrease in temperature after exercise was greater for Trec than Tes, but not different from Tin. The rate of temperature change from threshold to the end of the 40% VO2pk stage was not different between measurement sites. However, the rate of change during recovery was more negative for Tes than Tin and Trec, which were different from each other. Measurement of Tin may he an acceptable alternative to Tes and Trec with an understanding of its limitations.

Lee, Stuart M. C.↗