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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 NTRS2004

NASA Tech Briefs, March 2004

Topics covered include: 1) Advanced Signal Conditioners for Data-Acquisition Systems; 2) Downlink Data Multiplexer; 3) Viewing ISS Data in Real Time via the Internet; 4) Autonomous Environment-Monitoring Networks; 5) Readout of DSN Monitor Data; 6) Parallel-Processing Equalizers for Multi-Gbps Communications; 7) AIN-Based Packaging for SiC High-Temperature Electronics; 8) Software for Optimizing Quality Assurance of Other Software; 9) The TechSat 21 Autonomous Sciencecraft Experiment; 10) Software for Analyzing Laminar-to-Turbulent Flow Transitions; 11) Elastomer Filled With Single-Wall Carbon Nanotubes; 12) Modifying Ship Air-Wake Vortices for Aircraft Operations; 13) Strain-Gauge Measurement of Weight of Fluid in a Tank; 14) Advanced Docking System With Magnetic Initial Capture; 15) Blade-Pitch Control for Quieting Tilt-Rotor Aircraft; 16) Solar Array Panels With Dust-Removal Capability; 17) Aligning Arrays of Lenses and Single-Mode Optical Fibers; 18) Automatic Control of Arc Process for Making Carbon Nanotubes; 19) Curved-Focal-Plane Arrays Using Deformed-Membrane Photodetectors; 20) Role of Meteorology in Flights of a Solar-Powered Airplane; 21) Model of Mixing Layer With Multicomponent Evaporating Drops; 22) Solution-Assisted Optical Contacting; 23) Improved Discrete Approximation of Laplacian of Gaussian; 24) Utilizing Expert Knowledge in Estimating Future STS Costs; 25) Study of Rapid-Regression Liquefying Hybrid Rocket Fuels; and 26) More About the Phase-Synchronized Enhancement Method.

Source record↗

NASA NTRS2012

Progress in the Fabrication and Testing of Telescope Mirrors for the James Webb Space Telescope

The telescope of the James Webb Space Telescope (JWST) is an f/20, three mirror anastigmat design, passively cooled (40K) in an L2 orbit. The design provides diffraction limited performance (Strehl > or = 0.8) at .=2 m. To fit within the launch vehicle envelope (Arianne V), the 6.6 meter primary mirror and the secondary mirror support structure are folded for launch, then deployed and aligned in space. The primary mirror is composed of 18 individual, 1.3 meter (flat flat) hexagonal segments, each adjustable in seven degrees of freedom (six rigid body + radius of curvature) provided by a set of high precision actuators. The actuated secondary mirror (approx.0.74m) is similarly positioned in six degrees of rigid body motion. The approx..70x.51m, fixed tertiary and approx. 0.17m, flat fine steering mirror complete the telescope mirror complement. The telescope is supported by a composite structure optimized for performance at cryogenic temperatures. All telescope mirrors are made of Be with substantial light-weighting (21 kg for each 1.3M primary segment). Additional Be mounting and supporting structure for the high precision (approx.10nm steps) actuators are attached to the primary segments and secondary mirror. All mirrors undergo a process of thermal stabilization to reduce stress. An extensive series of interferometric measurements guide each step of the polishing process. Final polishing must account for any deformation between the ambient temperature of polishing and the cryogenic, operational temperature. This is accomplished by producing highly precise, cryo deformation target maps of each surface which are incorporated into the final polishing cycle. All flight mirrors have now completed polishing, coating with protected Au and final cryo testing, and the telescope is on track to meet all system requirements. We here review the measured performance of the component mirrors and the predicted performance of the flight telescope.

Bowers, Charles↗

NASA NTRS2017

Thermal Considerations for Reducing the Cooldown and Warmup Duration of the James Webb Space Telescope OTIS Cryo-Vacuum Test

The James Webb Space Telescope (JWST), set to launch in 2018, is NASAs next-generation flagship telescope. The Optical Telescope Element (OTE) and Integrated Science Instrument Module (ISIM) contain all of the optical surfaces and instruments to capture and analyze the telescopes infrared targets. The integrated OTE and ISIM are denoted as OTIS, and will be tested as a single unit in a critical thermal-vacuum test in mid-2017 at NASA Johnson Space Centers Chamber A facility. The payload will be evaluated for workmanship and functionality in a 20K simulated flight environment during this thermal-vacuum test. However, the sheer thermal mass of the OTIS payload as well as the restrictive gradient, rate, and contamination-related constraints placed on test components precludes rapid cooldown or warmup to its steady-state cryo-balance condition. Hardware safety considerations precludes injection of helium gas for free molecular heat transfer. Initial thermal analysis predicted that transient radiative cooldown from ambient temperatures, while meeting all limits and constraints, would take 33.3 days; warmup similarly would take 28.4 days. This paper discusses methods used to reduce transition times from the original predictions through modulation of boundary temperatures and environmental conditions. By optimizing helium shroud transition rates and heater usage, as well as rigorously re-examining previously imposed constraints, savings of up to three days on cooldown and up to a week on warmup can be achieved. The efficiencies gained through these methods allow the JWST thermal test team to create faster cooldown and warmup profiles, thus reducing the overall test duration and cost, while keeping all of the required test operations.

Thermal↗

NASA NTRS2017

Thermal Considerations for Reducing the Cooldown and Warmup Duration of the James Webb Space Telescope OTIS Cryo-Vacuum Test

JWST↗

NASA NTRS2016

Erasing the Milky Way: New Cleaning Technique Applied to GBT Intensity Mapping Data

We present the first application of a new foreground removal pipeline to the current leading HI intensity mapping dataset, obtained by the Green Bank Telescope (GBT). We study the 15- and 1-h field data of the GBT observations previously presented in Masui et al. (2013) and Switzer et al. (2013), covering about 41 square degrees at 0.6 less than z is less than 1.0, for which cross-correlations may be measured with the galaxy distribution of the WiggleZ Dark Energy Survey. In the presented pipeline, we subtract the Galactic foreground continuum and the point source contamination using an independent component analysis technique (fastica), and develop a Fourier-based optimal estimator to compute the temperature power spectrum of the intensity maps and cross-correlation with the galaxy survey data. We show that fastica is a reliable tool to subtract diffuse and point-source emission through the non-Gaussian nature of their probability distributions. The temperature power spectra of the intensity maps is dominated by instrumental noise on small scales which fastica, as a conservative sub-traction technique of non-Gaussian signals, can not mitigate. However, we determine similar GBT-WiggleZ cross-correlation measurements to those obtained by the Singular Value Decomposition (SVD) method, and confirm that foreground subtraction with fastica is robust against 21cm signal loss, as seen by the converged amplitude of these cross-correlation measurements. We conclude that SVD and fastica are complementary methods to investigate the foregrounds and noise systematics present in intensity mapping datasets.

Wolz, L.↗

NASA NTRS2019

Solar power for deep-space applications: state of art and development

Solar arrays have been used successfully as the power source for multiple NASA spacecraft, including in deep space as far as the Jupiter orbit at 5.5AU. In this paper, we outline the challenges to solar array performance in deep space environments, and overview the current state of practice. We also highlight recent results from our work on developing solar cells optimized for low irradiance, low temperature (LILT) operating conditions, and the implications on extending the range of solar power out to the Saturn orbit at 9.5AU.

Kowalczyk, Robert S.↗

NASA NTRS2003

Neural Network and Regression Methods Demonstrated in the Design Optimization of a Subsonic Aircraft

The neural network and regression methods of NASA Glenn Research Center s COMETBOARDS design optimization testbed were used to generate approximate analysis and design models for a subsonic aircraft operating at Mach 0.85 cruise speed. The analytical model is defined by nine design variables: wing aspect ratio, engine thrust, wing area, sweep angle, chord-thickness ratio, turbine temperature, pressure ratio, bypass ratio, fan pressure; and eight response parameters: weight, landing velocity, takeoff and landing field lengths, approach thrust, overall efficiency, and compressor pressure and temperature. The variables were adjusted to optimally balance the engines to the airframe. The solution strategy included a sensitivity model and the soft analysis model. Researchers generated the sensitivity model by training the approximators to predict an optimum design. The trained neural network predicted all response variables, within 5-percent error. This was reduced to 1 percent by the regression method. The soft analysis model was developed to replace aircraft analysis as the reanalyzer in design optimization. Soft models have been generated for a neural network method, a regression method, and a hybrid method obtained by combining the approximators. The performance of the models is graphed for aircraft weight versus thrust as well as for wing area and turbine temperature. The regression method followed the analytical solution with little error. The neural network exhibited 5-percent maximum error over all parameters. Performance of the hybrid method was intermediate in comparison to the individual approximators. Error in the response variable is smaller than that shown in the figure because of a distortion scale factor. The overall performance of the approximators was considered to be satisfactory because aircraft analysis with NASA Langley Research Center s FLOPS (Flight Optimization System) code is a synthesis of diverse disciplines: weight estimation, aerodynamic analysis, engine cycle analysis, propulsion data interpolation, mission performance, airfield length for landing and takeoff, noise footprint, and others.

Hopkins, Dale A.↗

NASA NTRS1993

Moderate temperature control technology for a lunar base

A parametric analysis is performed to compare different heat pump based thermal control systems for a Lunar Base. Rankine cycle and absorption cycle heat pumps are compared and optimized for a 100 kW cooling load. Variables include the use or lack of an interface heat exchanger, and different operating fluids. Optimization of system mass to radiator rejection temperature is performed. The results indicate a relatively small sensitivity of Rankine cycle system mass to these variables, with optimized system masses of about 6000 kg for the 100 kW thermal load. It is quantitaively demonstrated that absorption based systems are not mass competitive with Rankine systems.

Swanson, Theodore D.↗

NASA NTRS1994

Optimal experimental designs for the estimation of thermal properties of composite materials

Reliable estimation of thermal properties is extremely important in the utilization of new advanced materials, such as composite materials. The accuracy of these estimates can be increased if the experiments are designed carefully. The objectives of this study are to design optimal experiments to be used in the prediction of these thermal properties and to then utilize these designs in the development of an estimation procedure to determine the effective thermal properties (thermal conductivity and volumetric heat capacity). The experiments were optimized by choosing experimental parameters that maximize the temperature derivatives with respect to all of the unknown thermal properties. This procedure has the effect of minimizing the confidence intervals of the resulting thermal property estimates. Both one-dimensional and two-dimensional experimental designs were optimized. A heat flux boundary condition is required in both analyses for the simultaneous estimation of the thermal properties. For the one-dimensional experiment, the parameters optimized were the heating time of the applied heat flux, the temperature sensor location, and the experimental time. In addition to these parameters, the optimal location of the heat flux was also determined for the two-dimensional experiments. Utilizing the optimal one-dimensional experiment, the effective thermal conductivity perpendicular to the fibers and the effective volumetric heat capacity were then estimated for an IM7-Bismaleimide composite material. The estimation procedure used is based on the minimization of a least squares function which incorporates both calculated and measured temperatures and allows for the parameters to be estimated simultaneously.

Scott, Elaine P.↗

NASA NTRS1987

Study of solid state photomultiplier

Available solid state photomultiplier (SSPM) detectors were tested under low-background, low temperature conditions to determine the conditions producing optimal sensitivity in a space-based astronomy system such as a liquid cooled helium telescope in orbit. Detector temperatures varied between 6 and 9 K, with background flux ranging from 10 to the 13th power to less than 10 to the 6th power photons/square cm-s. Measured parameters included quantum efficiency, noise, dark current, and spectral response. Experimental data were reduced, analyzed, and combined with existing data to build the SSPM data base included herein. The results were compared to analytical models of SSPM performance where appropriate models existed. Analytical models presented here were developed to be as consistent with the data base as practicable. Significant differences between the theory and data are described. Some models were developed or updated as a result of this study.

Hays, K. M.↗

NASA NTRS2009

Characterization of 6H-SiC JFET Integrated Circuits Over A Broad Temperature Range from -150 C to +500 C

The NASA Glenn Research Center has previously reported prolonged stable operation of simple prototype 6H-SiC JFET integrated circuits (logic gates and amplifier stages) for thousands of hours at +500 C. This paper experimentally investigates the ability of these 6H-SiC JFET devices and integrated circuits to also function at cold temperatures expected to arise in some envisioned applications. Prototype logic gate ICs experimentally demonstrated good functionality down to -125 C without changing circuit input voltages. Cascaded operation of gates at cold temperatures was verified by externally wiring gates together to form a 3-stage ring oscillator. While logic gate output voltages exhibited little change across the broad temperature range from -125 C to +500 C, the change in operating frequency and power consumption of these non-optimized logic gates as a function of temperature was much larger and tracked JFET channel conduction properties.

Neudeck, Philip G.↗

NASA NTRS1987

Composition optimization of chromium carbide based solid lubricant coatings for foil gas bearings at temperatures to 650 C

A test program to determine the optimum composition of chromium carbide based solid lubricant coatings for compliant gas bearings is described. The friction and wear properties of the coatings are evaluated using a foil gas bearing test apparatus. The various coatings were prepared by powder blending, then plasma sprayed onto Inconel 718 test journals and diamond ground to the desired coating thickness and surface finish. The journals were operated against preoxidized nickel-chromium alloy foils. The test bearings were subjected to repeated start/stop cycles under a 14 kPa (2 psi) bearing unit load. The bearings were tested for 9000 start/stop cycles or until the specimen wear reached a predetermined failure level. In general, the addition of silver and eutectic to the chromium carbide base stock significantly reduced foil wear and increased journal coating wear. The optimum coating composition, PS212 (70 wt% metal bonded Cr3C2, 15 wt% Ag, 15% BaF2/CaF2 eutectic), reduced foil wear by a factor of two and displayed coating wear well within acceptable limits. The load capacity of the bearing using the plasma-sprayed coating prior to and after a run-in period was ascertained and compared to polished Inconel 718 specimens.

Dellacorte, Christopher↗

NASA NTRS1986

Low-background InSb array development

Photovoltaic indium antimonide (PV InSb) detector technology has matured over the past several years to enable a wide variety of applications to use this high-performance detector material to advantage. The operating conditions for most of the applications to date for back-side illuminated PV InSb arrays have encompassed focal plane temperatures ranging from 40 to approximately 95 K, with the majority in the narrower range between 60 and 80 K. Background flux conditions have ranged from 10 to the 10th power ph/sq cm/sec to 10 to the 16th power ph/sq cm/sec, most typically between 10 to the 12th power and 10 to the 14th power ph/sq cm/sec. Appropriately, the array parameters were optimized for maximum performance over these temperature and background ranges. The key parameters which were peaked in this process were the resistance-area product of the detectors and their quantum efficiency. The Space Infrared Telescope Facility (SIRTF) Infrared Array Camera requirements, however, present very low temperature and background operating conditions, plus the need for very high signal to noise ratios. Preliminary analysis indicates that back-side illuminated PV InSb arrays can be optimized for operation under these conditions, and some performance projections will be presented.

Thom, R. D.↗

NASA NTRS2002

A Multilayered Thin Film Insulator for Harsh Environments

The status of work to develop a reliable high temperature dielectric thin film for use with thin film sensors is presented. The use of thin films to electrically insulate thin film sensors on engine components minimizes the intrusiveness of the sensor and allows a more accurate measurement of the environment. A variety of insulating films were investigated for preventing electrical shorting caused by insulator failure between the sensor and the component. By alternating layers of sputtered high temperature ceramics, a sequence of insulating layers was devised that prevents pinholes from forming completely through the insulator and maintains high electrical resistivity at high temperatures. The major technical challenge remaining is to optimize the fabrication of the insulator with respect to composition to achieve a reliable high temperature insulating film. Data from the testing of various potentially insulating thin film systems is presented and their application to thin film sensors is also discussed.

Wrbanek, John D.↗

NASA NTRS2004

On-Orbit Repair of RCC Structures

On-orbit repair technologies for reinforced carbon-carbon composite (RCC) structures are critically needed for space shuttle return to flight (RTF) efforts. These technologies are also critically needed for the repair and refurbishment of thermal protection system of future Crew Entry Vehicles (CEV) of space exploration programs. GRABER (Glenn Adhesive Refractory for Bonding and Exterior Repair) has shown multiuse capability for in-space repair of both large repairs and small cracks in space shuttle Reinforced Carbon Carbon (RCC) leading edge material. The concept consists of preparing an adhesive paste and then applying the paste tot he damaged/cracked area of the RCC composites with caulking gun. The adhesive paste cures at 100-120 C and transforms into a high temperature ceramic during vehicle re-entry conditions. Further development and testing are underway to optimize the materials properties and extend the application temperature.

Singh, M.↗

NASA NTRS2026

A Modular Conjugate Heat Transfer Optimization Framework for Thermal Management of Electric Aircraft

Conjugate heat transfer (CHT) analysis and optimization is a powerful method for improving thermal management, as it simultaneously resolves the temperature distribution in both fluid and solid domains. This paper presents a modular, discrete adjoint-based CHT optimization capability integrated within the OpenMDAO/MPhys framework. A unique feature of the proposed framework is its flexibility to extend to multidisciplinary optimization, including aero-structural-thermal applications. The fluid domain is modeled using a finite-volume Computational Fluid Dynamics (CFD) solver, and the solid domain with a conduction heat transfer solver. A mixed Neumann-Dirichlet boundary condition is developed to enable full submersion of the solid geometry within the fluid domain, while ensuring consistent temperature and heat flux coupling at the CHT interface. Gradient-based optimization is performed; the gradients are efficiently computed using the discrete adjoint solvers implemented in DAFoam. To demonstrate the method, this paper considers two cases related to electric aircraft thermal management: a U-bend heat exchanger and an actively cooled battery pack. The U-bend case aims to minimize pressure loss while maximizing heat flux by changing the pipe geometry. The optimized design reduces pressure loss by 52.7% and increases total heat flux by 2.3%. In the battery pack case, a 3-by-3 cell configuration is cooled by ambient airflow, with constant heat generation prescribed in the cells. The battery casing shape serves as the design variable, and the objective function is a weighted sum of pressure loss and pack weight, subject to a maximum temperature constraint. The optimized design achieves a 44.6% reduction in pressure loss and a 1.5% reduction in weight, while satisfying the thermal constraint. To ensure the reliability of the optimized designs, this study validates coarse-mesh, steady-state predictions against fine-mesh unsteady simulations, demonstrating consistency within acceptable errors. This work demonstrates the potential of the developed framework to enable rapid, high-fidelity design of thermal management systems for electric aircraft.

heat transfer↗

NASA NTRS1992

Thermal control design of the Lightning Mapper Sensor narrow-band spectral filter

The performance of the Lightning Mapper Sensor is dependent on the temperature shifts of its narrowband spectral filter. To perform over a 10 degree FOV with an 0.8 nm bandwidth, the filter must be 15 cm in diameter and mounted externally to the telescope optics. The filter thermal control required a filter design optimized for minimum bandpass shift with temperature, a thermal analysis of substrate materials for maximum temperature uniformity, and a thermal radiation analysis to determine the parameter sensitivity of the radiation shield for the filter, the filter thermal recovery time after occultation, and heater power to maintain filter performance in the earth-staring geosynchronous environment.

Flannery, Martin R.↗

NASA NTRS1985

Suppression of Marangoni Convection in Float Zones

The basic purpose of this program is to demonstrate by means of an Earth-based 1-g experiment that the undesirable Marangoni (surface tension) convection can be suppressed or significantly reduced by means of gas jets directed tangentially to the free surface of the liquid in a float zone. These jets will establish the tangential shear stress field over the surface which must be adjusted to equal the counter-stress resultant of the Marangoni shear stress which causes the convection. For proposed materials processing in space (o-g), particularly of important, highly reactive semiconductor materials, e.g., silicon, microgravity will virtually eliminate the unwanted thermal-buoyancy convection in the liquid silicon, but will have no effect in reducing the Marangoni convection. Unless this can be sufficiently suppressed by other means, there may be no significant advantages to the proposed space processing of reactive semiconductors. Although some inert gas such as argon must be used for the corrosive liquid silicon, the Earth-based experiment uses air jets and various transparent oils, since the basic principle involved is the same. The first float zone is enclosed in a very small rectangular box with a quasi-planar free surface. Stable Marangoni convection has been achieved and velocities measured photographically. The air jet system with variable velocity and temperature is under construction. Three independent parameters must be optimized to attain maximum suppression: the gas velocity, angle of attack, and gas temperature.

Dressler, R. F.↗