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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 253 records · Page 14

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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 early 2019, 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 20K flight-like environment, as well as predicted the payload performance at cryo-stable conditions. The current work is a preliminary assessment of thermal model performance against actual payload response during the OTIS CV test. It 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. It is hoped that the insight gained from the OTIS CV test thermal modeling will benefit planning and execution for upcoming cryogenic missions.

JWST↗

NASA NTRS1973

Thruster array thermal control

This paper presents the results of a preliminary investigation of the thermal interactions between elements in the thruster array for a proposed Encke flyby mission. A clustered eight-thruster array was considered as the trial configuration in the current study. Electrically heated dummy thrusters were calibrated to represent the thruster thermal performance. The thermal behavior of the thruster array thermal mockup and the effects of thermal coating applications were investigated. Temperature measurements of the thruster array mockup were performed under various operational modes to substantiate the analytical results. A resultant analytical thermal network model was established to provide pertinent information for thruster array design tradeoff studies.

Wen, L.↗

NASA NTRS1992

Performance of thermal control tape in the protection of composite materials

The selection of materials for construction of long duration mission spacecraft has presented many challenges to the aerospace design community. After nearly six years in low earth orbit, NASA's Long duration Exposure Facility (LDEF), retrieved in January of 1990, has provided valuable information on both the nature of the space environment as well as the effects of the space environment on potential spacecraft materials. Composites, long a favorite of the design community because of a high strength-to-weight ratio, were flown in various configurations on LDEF in order to evaluate the effects of radiation, atomic oxygen, vacuum, micrometeoroid debris, and thermal variation on their performance. Fiberglass composite samples covered with an aluminum thermal control tape were flown as part of the flight experiment A0171, the Solar Array Materials Passive LDEF Experiment (SAMPLE). Visual observations and test results indicate that the thermal control tape suffered little degradation from the space exposure and proved to be a reliable source of protection from atomic oxygen erosion and UV radiation for the underlying composite material.

Kamenetzky, Rachel R.↗

NASA NTRS2014

Structural-Thermal-Optical-Performance (STOP) Model Development and Analysis of a Field-widened Michelson Interferometer

An integrated Structural-Thermal-Optical-Performance (STOP) model was developed for a field-widened Michelson interferometer which is being built and tested for the High Spectral Resolution Lidar (HSRL) project at NASA Langley Research Center (LaRC). The performance of the interferometer is highly sensitive to thermal expansion, changes in refractive index with temperature, temperature gradients, and deformation due to mounting stresses. Hand calculations can only predict system performance for uniform temperature changes, under the assumption that coefficient of thermal expansion (CTE) mismatch effects are negligible. An integrated STOP model was developed to investigate the effects of design modifications on the performance of the interferometer in detail, including CTE mismatch, and other three- dimensional effects. The model will be used to improve the design for a future spaceflight version of the interferometer. The STOP model was developed using the Comet SimApp'TM' Authoring Workspace which performs automated integration between Pro-Engineer®, Thermal Desktop®, MSC Nastran'TM', SigFit'TM', Code V'TM', and MATLAB®. This is the first flight project for which LaRC has utilized Comet, and it allows a larger trade space to be studied in a shorter time than would be possible in a traditional STOP analysis. This paper describes the development of the STOP model, presents a comparison of STOP results for simple cases with hand calculations, and presents results of the correlation effort to bench-top testing of the interferometer. A trade study conducted with the STOP model which demonstrates a few simple design changes that can improve the performance seen in the lab is also presented.

Scola, Salvatore J.↗

DOE OSTI2026

Minimized aging of isocyanurate-based rigid cellular foams for buildings through tailored barrier facers and optimized formulation

The thermal resistivity (h·ft 2 ·°F/Btu/in.) of closed-cell rigid foam insulation materials significantly decreases over time. Diffusion-tight facers are designed to significantly enhance initial thermal resistivity and long-term thermal performance by preventing gas diffusion into the foam cells and inhibiting the escape of low thermal conductivity blowing agents. In addition to the gas diffusion property of the facer film, adhesion between the foam and the facer is crucial for achieving diffusion-tight bonding. Here, this study addresses the challenge of thermal aging by investigating how facer film properties and foam formulation influence the durability of thermal performance. A systematic evaluation was conducted to understand the effects of polymeric barrier films, surface treatments, facer coverage, and foam matrix rigidity on thermal resistivity over time. Key findings reveal that diffusion-tight facers, particularly those with metallized layers and compatible heat seal layers, significantly reduce gas exchange and improve foam-facer adhesion. The optimized system, incorporating barrier facers and a tailored polyisocyanurate foam formulation, achieved initial and aged thermal resistivity values after 200 days of approximately 8.3 and 7.4 h ft 2 ·°F/Btu/in., respectively representing only a 10 % reduction compared to a 17 % reduction observed in control samples without facers. Notably, polyurethane spray foams with facers exhibited only a 4 % reduction in thermal resistivity, compared to a 23 % decrease in control samples, demonstrating nearly six times better retention of thermal performance. This innovative facer technology presents a promising solution for reducing energy costs and represents a significant advancement in optimizing energy management for building envelopes in future technologies. This technology can also be adapted for other applications that necessitate the preservation of long-term thermal performance.

Wanasinghe, Shiwanka Vidarshi [Oak Ridge National ↗

DOE OSTI2025

Hydronic Shell: An Affordable Solution for Multifamily Deep Energy Retrofit

Approximately 42% of multi-family buildings in the United States have do not have insulation as required by the building codes. Envelope retrofits of these buildings are needed to improve their thermal performance, provide thermal resilience, and enable a pathway to electrification of space heating systems. Hydronic shell (HS) is a retrofit technique where a stud wall layer is added to a masonry wall along with a convective coil and a fan coil unit fitted in the façade cavity which can provide both heating and cooling to the space. The HS system serves a dual purpose of 1) retrofitting the building envelope and 2) retrofitting the HVAC system and enabling electrification of space heating. The electrification of space heating is possible from the installation of a combination of hydronic system/fan coil unit system which uses a central heat pump as a source of heating water in the cavity between the existing wall and retrofit insulation layer. This study evaluates the performance of the HS system at varying outdoor conditions mimicked by a climate chamber and hot water supply temperature from a water bath. During the ramp-up period, the indoor chamber temperature could be increased from 66 ºF to 69.5 ºF within an hour using heating water at 120 ºF when the outdoor chamber temperature was at 0 ºF. When the indoor chamber temperature was maintained within a deadband, variation in cavity air temperature was mostly influenced by the duration when water was flowing through the cavity convector. It was seen from the testing that the hydronic system alone without use of fan in the system is able to maintain the space temperature at coldest outdoor condition used in the experiment (0 ºF) even at lowest hot water supply temperature chosen (90 ºF). During the ramp-down period, the fastest decline in temperature took 6.4 hours from temperature to drop from 69.6 ºF to 66 ºF which shows tremendous potential of thermal resilience and peak load shifting.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1976

Nozzle designs with pitch precursor ablatives

Recent developments in carbon phenolic ablatives for solid rocket motor nozzles have yielded a pitch precursor carbon fiber offering significant raw material availability and cost saving advantages as compared to conventional rayon precursor material. This paper discusses the results of an experimental program conducted to assess the thermal performance and characterize the thermal properties of pitch precursor carbon phenolic ablatives. The end result of this program is the complete thermal characterization of pitch fabric, pitch mat, hybrid pitch/rayon fabric and pitch mat molding compound. With these properties determined an analytic capability now exists for predicting the thermal performance of these materials in rocket nozzle liner applications. Further planned efforts to verify material performance and analytical prediction procedures through actual rocket motor firings are also discussed.

Blevins, H. R.↗

NASA NTRS1985

Thermal design of AOTV heatshields for a conical drag brake

Results are presented from an on-going study of the thermal performance of thermal protection systems for a conical drag brake type AOTV. Three types of heatshield are considered: rigid ceramic insulation, flexible ceramic blankets, and ceramic cloths. The results for the rigid insulation apply to other types of AOTV as well. Charts are presented in parametric form so that they may be applied to a variety of missions and vehicle configurations. The parameters considered include: braking maneuver heat flux and total heat load, heatshield material and thickness, heatshield thermal mass and conductivity, absorptivity and emissivity of surfaces, thermal mass of support structure, and radiation transmission through thin heatshields. Results of temperature calculations presented show trends with and sensitivities to these parameters. The emphasis is on providing information that will be useful in estimating the minimum required mass of these heatshield materials.

Pitts, W. C.↗

NASA NTRS1991

Thermal design and test results for SUNLITE ultra-stable reference cavity

SUNLITE (Stanford University-NASA Laser In-Space Technology Experiment) is a space-based experiment which uses a reference cavity to provide a stable frequency reference for a terahertz laser oscillator. Thermal stability of the cavity is a key factor in attaining a stable narrow-linewidth laser beam. The mount which is used to support and align the cavity will provide thermal isolation from the environment. The baseline requirement for thermal stability of the cavity is 0.025 C/min, but the design is directed toward achieving stability well beyond this requirement to improve the science data gained. A prototype of the cavity mount was fabricated and tested to characterize the thermal performance. The thermal vacuum test involved stable high-resolution temperature measurements and stable baseplate temperature control over long durations. Based on test data, the cavity mount design satisfies the severe requirement for the cavity thermal stability.

Amundsen, Ruth M.↗

NASA NTRS2003

Pulsed Plasma Thruster (PPT) Technology: Earth Observing-1 PPT Operational and Advanced Components Being Developed

In 2002 the pulsed plasma thruster (PPT) mounted on the Earth Observing-1 spacecraft was operated successfully in orbit. The two-axis thruster system is fully incorporated in the attitude determination and control system and is being used to automatically counteract disturbances in the pitch axis of the spacecraft. The first tests conducted in space demonstrated the full range of PPT operation, followed by calibration of control torques from the PPT in the attitude control system. Then the spacecraft was placed in PPT control mode. To date, it has operated for about 30 hr. The PPT successfully controlled pitch momentum during wheel de-spin, solar array acceleration and deceleration during array rewind, and environmental torques in nominal operating conditions. Images collected with the Advanced Landsat Imager during PPT operation have demonstrated that there was no degradation in comparison to full momentum wheel control. In addition, other experiments have been performed to interrogate the effects of PPT operation on communication packages and light reflection from spacecraft surfaces. Future experiments will investigate the possibility of orbit-raising maneuvers, spacecraft roll, and concurrent operation with the Hyperion imager. Future applications envisioned for pulsed plasma thrusters include longer life, higher precision, multiaxis thruster configurations for three-axis attitude control systems or high-precision, formationflying systems. Advanced components, such as a "dry" mica-foil capacitor, a wear-resistant spark plug, and a multichannel power processing unit have been developed under contract with Unison Industries, General Dynamics, and C.U. Aerospace. Over the last year, evaluation tests have been conducted to determine power processing unit efficiency, atmospheric functionality, vacuum functionality, thruster performance evaluation, thermal performance, and component life.

Pencil, Eric J.↗

NASA NTRS2009

HST Replacement Battery Initial Performance

The Hubble Space Telescope (HST) original Nickel-Hydrogen (NiH2) batteries were replaced during the Servicing Mission 4 (SM4) after 19 years and one month on orbit.The purpose of this presentation is to highlight the findings from the assessment of the initial sm4 replacement battery performance. The batteries are described, the 0 C capacity is reviewed, descriptions, charts and tables reviewing the State Of Charge (SOC) Performance, the Battery Voltage Performance, the battery impedance, the minimum voltage performance, the thermal performance, the battery current, and the battery system recharge ratio,

Krol, Stan↗

NASA NTRS2017

Wide-Field Infrared Survey Telescope (WFIRST) Integrated Modeling

Contents: introduction to WFIRST (Wide-Field Infrared Survey Telescope) and integrated modeling; WFIRST stability requirement summary; instability mitigation strategies; dynamic jitter results; STOP (structural-thermal-optical performance) (thermal distortion) results; STOP and jitter capability limitations; model validation philosophy.

Integrated Modelin↗

DOE OSTI2024

Simulating Discharge Curves of an All-Aqueous TRAB to Identify Pathways for Improving System Performance

Thermally regenerative ammonia batteries (TRABs) are an emerging technology that use low temperature heat (T < 150 °C) to recharge a flow battery that produces electrical power on demand. The all-aqueous copper TRAB can provide high power densities and thermal energy efficiencies relative to other devices that harvest energy from waste heat, but its performance is adversely impacted by the crossover of undesired species through the membrane and lower cell voltages compared to conventional batteries. In this work, we developed a numerical model to simulate discharge curves while accounting for crossover inefficiencies without tracking all electrolyte species through the membrane. The model was able to successfully reproduce discharge curves across a diverse range of battery conditions using a single fitting parameter to account for decay of electrode standard potential due to species crossover with minimal error (< 5%). The model was then used to simulate different design scenarios to estimate changes in energy output from alterations to the aspects of the battery electrolyte chemistry. Results from this study are used to identify pathways for improving future TRAB designs with respect to energy capacity and cost-effectiveness of the technology.

25 ENERGY STORAGE↗

DOE OSTI2024

Selecting Appropriate Model Complexity: An Example of Tracer Inversion for Thermal Prediction in Enhanced Geothermal Systems

Abstract A major challenge in the inversion of subsurface parameters is the ill‐posedness issue caused by the inherent subsurface complexities and the generally spatially sparse data. Appropriate simplifications of inversion models are thus necessary to make the inversion process tractable and meanwhile preserve the predictive ability of the inversion results. In this study, we investigate the effect of model complexity on fracture aperture inversion and thermal performance prediction in a field‐scale EGS model. Principal component analysis was used to map the aperture field to a low‐dimensional latent space. The complexity of the inversion model was quantitatively represented by the percentage of total variance in the original aperture fields preserved by the latent space. Tracer, pressure and flow rate data were used to invert for fracture aperture through an ensemble‐based inversion method, and the inferred aperture field was used to predict thermal performance. With an over‐simplified aperture model, ensemble collapse occurred. The inverted aperture models failed to resolve necessary flow and transport features, leading to a biased thermal performance prediction. A complex aperture model involved excessive features and was prone to overinterpreting the inversion data. Both the tracer/pressure/flow rate data reproduction and thermal prediction showed significant uncertainties, making it difficult to properly estimate long‐term thermal performance. Fortunately, our results indicate that there exists an appropriate model complexity which can simultaneously match inversion data and predict thermal performance with an acceptable uncertainty. The quality of the fit of tracer data appears to be a useful indicator of such an appropriate model complexity.

15 GEOTHERMAL ENERGY↗

DOE OSTI2026

Thermal-Hydraulic Performance of a Zeotropic Refrigerant in a Brazed Plate Evaporator

In this work we report the results of a preliminary investigation focused on evaluating the thermal-hydraulic performance of R455A (CO2, R32, R1234yf – 3/21.5/75.5) in a commercial brazed plate heat exchanger. Three key parameters were measured which were refrigerant flow maldistribution, overall refrigerant side heat transfer coefficient, and total refrigerant side pressure drop. These same parameters were also measured for R134a which served as a base-line refrigerant for comparison. The experimental test matrix was set up to investigate the influence of refrigerant mass flux (3 ≤ Gref ≤ 5 kg m-2 s-1), refrigerant inlet vapor quality (0.1 ≤ xin ≤ 0.4), and refrigerant exit superheat (5 ≤ Tsh ≤ 10 K) on the above mentioned thermal-hydraulic parameters. For these experimental conditions, on average, the overall refrigerant side heat transfer coefficients for R455A were 45.2% lower than those of R134a. Refrigerant flow maldistribution for R455A, on average, was observed to be 62.6 % higher than that measured for R134a, and the total pressure drop across the heat exchanger (minor and frictional losses) for R455A was on average 26.5% higher than that measured for R134a. These initial results set the stage for a comprehensive investigation focused on further investigating the thermal-hydraulic performance of zeotropic refrigerants in brazed plate heat exchangers.

Jajja, Saad [ORNL]↗

NASA NTRS2004

Performance of Thermal Mass Flow Meters in a Variable Gravitational Environment

The performance of five thermal mass flow meters, MKS Instruments 179A and 258C, Unit Instruments UFM-8100, Sierra Instruments 830L, and Hastings Instruments HFM-200, were tested on the KC-135 Reduced Gravity Aircraft in orthogonal, coparallel, and counterparallel orientations relative to gravity. Data was taken throughout the parabolic trajectory where the g-level varied from 0.01 to 1.8 times normal gravity. Each meter was calibrated in normal gravity in the orthogonal position prior to flight followed by ground testing at seven different flow conditions to establish a baseline operation. During the tests, the actual flow rate was measured independently using choked-flow orifices. Gravitational acceleration and attitude had a unique effect on the performance of each meter. All meters operated within acceptable limits at all gravity levels in the calibrated orthogonal position. However, when operated in other orientations, the deviations from the reference flow became substantial for several of the flow meters. Data analysis indicated that the greatest source of error was the effect of orientation, followed by the gravity level. This work emphasized that when operating thermal flow meters in a variable gravity environment, it is critical to orient the meter in the same direction relative to gravity in which it was calibrated. Unfortunately, there was no test in normal gravity that could predict the performance of a meter in reduced gravity. When operating in reduced gravity, all meters indicated within 5 percent of the full scale reading at all flow conditions and orientations.

Brooker, John E.↗

NASA NTRS1980

Thermal vacuum performance testing of the Space Shuttle Orbiter radiator system

A space shuttle orbiter system thermal vacuum performance test was conducted at NASA-Johnson Space Center in Chamber A of the space environment simulation laboratory. The test of objective was to verify the radiator system heat rejection performance capability utilizing two development and two flight radiator panels comprising one of the two Orbiter Freon-21 coolant loops. Radiator performance over the range of expected flight conditions was as predicted, and there was no degradation of performance after extended vacuum exposure.

Behrend, A. F., Jr.↗

DOE OSTI2024

Thermal-hydraulic Performance of Emerging Low GWP Refrigerant Mixture under Flow Boiling in Brazed Plate Heat Exchangers

The hydrofluorocarbon (HFC) refrigerants used in the current refrigeration systems are facing a phase-down due to their higher greenhouse effect resulting in global warming, and thus HVAC&R industry has undergone a transition to low Global Warming Potential (GWP) refrigerants. Refrigerant mixtures are attractive alternatives since their composition can be tailored to comply with environmental regulations while preserving favorable thermophysical properties. However, the new low-GWP zeotropic mixture refrigerants have two or more components with different saturation temperatures at the same pressure level, known as temperature glide, which can cause the degradation of the overall heat transfer performance. The brazed plate heat exchangers (BPHX) provide excellent heat transfer performance due to a compact design and are used in several air-conditioning and refrigeration applications. In this study, flow boiling heat transfer and the associated pressure drop of the refrigerant mixture in a vertical BPHX were experimentally investigated. The single-phase water-to-water experiments were conducted in the tested heat exchanger with a counter-flow configuration. The flow boiling experiments charged with R-134a and R-454C were then performed in a pumped refrigerant loop to evaluate its thermal-hydraulic performance. Furthermore, parametric studies of various heat fluxes, mass fluxes, vapor qualities, and saturation temperatures were also conducted.

Yang, Cheng-Min↗