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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

Validation of RU-WRF, the Custom Atmospheric Mesoscale Model of the Rutgers Center for Ocean Observing Leadership

The Rutgers University Center for Ocean Observing Leadership (RU-COOL) contracted the National Renewable Energy Laboratory (NREL) to evaluate RU-COOL's atmospheric observation and modeling capabilities for characterizing the New Jersey offshore wind resource. The observational network used by RU-COOL consists of mostly public but some private coastal and offshore buoy-based stations. The core wind resource modeling capability of RU-COOL is a custom setup of the Weather Research and Forecasting (WRF) mesoscale model, referred to in this report as RU-WRF. The most unique feature of RU-WRF and not found in other WRF model setups is the use of custom sea surface temperature (SST) product generated by RU-COOL. This custom product was designed to better capture the unique coastal upwelling and strong storm mixing in the Mid-Atlantic Bight, which other typical SST products are not designed to capture. Funding for the development, maintenance, and use of RU-WRF by RU-COOL is provided by the New Jersey Board of Public Utilities, who also funded the validation work presented in this report. In this validation study, NREL was specifically tasked to: 1) Assess the observational network used by RU-COOL to validate RU-WRF and make recommendations for improvement, 2) Assess methods used by RU-COOL to validate RU-WRF and make recommendations for improvement, 3) Examine the inputs to and setup within RU-WRF, compare against available NREL data sets, and make recommendations for improvement.

17 WIND ENERGY↗

Space station freedom resource nodes internal thermal control system

This paper presents an overview of the design and operation of the internal thermal control system (ITCS) developed for Space Station Freedom by the NASA-Johnson Space Center and McDonnell Douglas Aerospace to provide cooling for the resource nodes, airlock, and pressurized logistics modules. The ITCS collects, transports and rejects waste heat from these modules by a dual-loop, single-phase water cooling system. ITCS performance, cooling, and flow rate requirements are presented. An ITCS fluid schematic is shown and an overview of the current baseline system design and its operation is presented. Assembly sequence of the ITCS is explained as its configuration develops from Man Tended Capability (MTC), for which node 2 alone is cooled, to Permanently Manned Capability (PMC) where the airlock, a pressurized logistics module, and node 1 are cooled, in addition to node 2. A SINDA/FLUINT math model of the ITCS is described, and results of analyses for an MTC and a PMC case are shown and discussed.

Merhoff, Paul↗

Aerospace Structural Materials Handbook Supplement GRCop-84

GRCop-84 is a high strength-high conductivity copper-based alloy developed at NASA Glenn Research Center for combustion chamber liners of regeneratively cooled rocket engines. It also has promise for other high heat flux applications operating at temperatures up to 700 C (1292 F) and potentially higher. The alloy must be made by powder metallurgy techniques such as gas atomization. Slower cooling rates such as those experienced during casting do not develop a proper microstructure. Once made into powder, the alloy exhibits excellent processability using conventional consolidation and forming techniques, e.g., extrusion and rolling. GRCop-84 is strengthened by a combination of dispersion and precipitation strengthening by fine (50-500 nanometer (2-20 microinch)) Cr2Nb particles and Hall-Petch strengthening from a fine copper grain size. The presence of a high volume fraction of particles prevents grain boundary sliding at high temperatures and contributes to the alloy's overall good high temperature mechanical properties. Maximum thermal conductivity is obtained by using two alloying elements (Cr, Nb) with limited solubility in solid Cu that form a high temperature intermetallic compound with an even lower solid solubility. The resulting matrix of the alloy is nearly pure copper. The limited solubility also minimizes Cr2Nb particle coarsening at elevated temperatures and enhances microstructural and mechanical property stability. Further enhancement of the microstructural stability is obtained by using a high volume fraction (approx. 14 vol.%) of Cr2Nb particles that effectively pin grain growth.

Ellis, David L.↗

Solar Collectors

Solar Energy's solar panels are collectors for a solar energy system which provides heating for a drive-in bank in Akron, OH. Collectors were designed and manufactured by Solar Energy Products, a firm established by three former NASA employees. Company President, Frank Rom, an example of a personnel-type technology transfer, was a Research Director at Lewis Research Center, which conducts extensive solar heating and cooling research, including development and testing of high-efficiency flat-plate collectors. Rom acquired solar energy expertise which helped the company develop two types of collectors, one for use in domestic/commercial heating systems and the other for drying grain.

Source record↗

Structures Self-Assembled Through Directional Solidification

Nanotechnology has created a demand for new fabrication methods with an emphasis on simple, low-cost techniques. Directional solidification of eutectics (DSE) is an unconventional approach in comparison to low-temperature biomimetic approaches. A technical challenge for DSE is producing microstructural architectures on the nanometer scale. In both processes, the driving force is the minimization of Gibb's free energy. Selfassembly by biomimetic approaches depends on weak interaction forces between organic molecules to define the architectural structure. The architectural structure for solidification depends on strong chemical bonding between atoms. Constituents partition into atomic-level arrangements at the liquid-solid interface to form polyphase structures, and this atomic-level arrangement at the liquid-solid interface is controlled by atomic diffusion and total undercooling due to composition (diffusion), kinetics, and curvature of the boundary phases. Judicious selection of the materials system and control of the total undercooling are the keys to producing structures on the nanometer scale. The silicon-titanium silicide (Si-TiSi2) eutectic forms a rod structure under isothermal cooling conditions. At the NASA Glenn Research Center, directional solidification was employed along with a thermal gradient to promote uniform rods oriented with the thermal gradient. The preceding photomicrograph shows the typical transverse microstructure of a solidified Si-TiSi2 eutectic composition. The dark and light gray regions are Si and TiSi2, respectively. Preferred rod orientation along the thermal gradient was poor. The ordered TiSi2 rods have a narrow distribution in diameter of 2 to 3 m, as shown. The rod diameter showed a weak dependence on process conditions. Anisotropic etch behavior between different phases provides the opportunity to fabricate structures with high aspect ratios. The photomicrographs show the resulting microstructure after a wet chemical etch and a dry plasma etch. The wet chemical etches the silicon away, exposing the TiSi2 rods, whereas plasma etching preferentially etches the Si-TiSi2 interface to form a crater. The porous architectures are applicable to fabricating microdevices or creating templates for part fabrication. The porous rod structure can serve as a platform for fabricating microplasma devices for propulsion or microheat exchangers and for fabricating microfilters for miniatured chemical reactors. Although more work is required, self-assembly from DSE can have a role in microdevice fabrication.

Dynys, Frederick W.↗

Turbulent Simulations of Cooling Jets in Crossflow

Turbulent flow simulations were completed of the THX-III single hole film cooling experiment performed at NASA Glenn Research Center (GRC). Two different Large-Eddy Simulation (LES) approaches were completed along with a RANS based study. The first LES approach utilizes the Flux Reconstruction (FR) based finite element code GFR, while the second approach makes use of the compact difference solver FDL3DI. Both LES codes were run on grids larger than 1.5 Billion degrees of freedom (DoF). The RANS simulations used FUN3D and included a grid convergence as a turbulence closure study. A summary of the computational approaches and key findings are presented along with the experimental measurements. Significant progress has been made towards the completion of this work, as all but one simulation have been completed. The preliminary findings have shown the LES approaches have excellent agreement with each other, and closely follow the trends of the experiment. The Reynolds stress RANS closure, while the best of the RANS results, had difficulty matching the results of the LES and experimental measurements.

High-Order Methods↗

Qualification of System-Level Advanced Reactor Safety Analysis Software for Lead Systems: Final CRADA Report

SAS4A/SASSYS-1 is a simulation tool used to perform deterministic analysis of anticipated events as well as design basis and beyond design basis accidents for advanced liquid-metal-cooled nuclear reactors. With its origin as SAS1A in the late 1960s, the SAS series of codes has been under continuous use and development for over forty-five years and represents a critical investment in safety analysis capabilities for the U.S. Department of Energy. Although SAS4A/SASSYS-1 was developed to support the analysis of any liquid-metal-cooled nuclear reactor, it has primarily been utilized to design and analyze Sodium Fast Reactors (SFRs). As a result, most of the qualification basis for SAS4A/SASSYS-1 has utilized sodium as a coolant and geometry descriptions that are prototypic of SFR configurations. In this project, which partnered with Westinghouse Electric Company, LLC, the initial foundation for a qualification basis centered on prototypic pool-type lead-cooled systems has been established, where the end goal is to extend support for utilization of SAS4A/SASSYS-1 in Lead Fast Reactor (LFR) licensing or authorization. This project included three fundamental technical tasks: LFR V&V test suite development (Task 1); qualification support for LFRs (Task 2); and LFR modeling capabilities evaluation and improvement (Task 3)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

ISM stripping from cluster galaxies and inhomogeneities in cooling flows

Analyses of the x ray surface brightness profiles of cluster cooling flows suggest that the mass flow rate decreases towards the center of the cluster. It is often suggested that this decrease results from thermal instabilities, in which denser blobs of gas cool rapidly and drop below x ray emitting temperatures. If the seeds for the thermal instabilities are entropy perturbations, these perturbations must enter the flow already in the nonlinear regime. Otherwise, the blobs would take too long to cool. Here, researchers suggest that such nonlinear perturbations might start as blobs of interstellar gas which are stripped out of cluster galaxies. Assuming that most of the gas produced by stellar mass loss in cluster galaxies is stripped from the galaxies, the total rate of such stripping is roughly M sub Interstellar Matter (ISM) approx. 100 solar mass yr(-1). It is interesting that the typical rates of cooling in cluster cooling flows are M sub cool approx. 100 solar mass yr(-1). Thus, it is possible that a substantial portion of the cooling gas originates as blobs of interstellar gas stripped from galaxies. The magnetic fields within and outside of the low entropy perturbations can help to maintain their identities, both by suppressing thermal conduction and through the dynamical effects of magnetic tension. One significant question concerning this scenario is: Why are cooling flows seen only in a fraction of clusters, although one would expect gas stripping to be very common. It may be that the density perturbations only survive and cool efficiently in clusters with a very high intracluster gas density and with the focusing effect of a central dominant galaxy. Inhomogeneities in the intracluster medium caused by the stripping of interstellar gas from galaxies can have a number of other effects on clusters. For example, these density fluctuations may disrupt the propagation of radio jets through the intracluster gas, and this may be one mechanism for producing Wide-Angle-Tail radio galaxies.

Soker, Noam↗

High-Thermal-Conductivity Fabrics

Heat management with common textiles such as nylon and spandex is hindered by the poor thermal conductivity from the skin surface to cooling surfaces. This innovation showed marked improvement in thermal conductivity of the individual fibers and tubing, as well as components assembled from them. The problem is centered on improving the heat removal of the liquid-cooled ventilation garments (LCVGs) used by astronauts. The current design uses an extensive network of water-cooling tubes that introduces bulkiness and discomfort, and increases fatigue. Range of motion and ease of movement are affected as well. The current technology is the same as developed during the Apollo program of the 1960s. Tubing material is hand-threaded through a spandex/nylon mesh layer, in a series of loops throughout the torso and limbs such that there is close, form-fitting contact with the user. Usually, there is a nylon liner layer to improve comfort. Circulating water is chilled by an external heat exchanger (sublimator). The purpose of this innovation is to produce new LCVG components with improved thermal conductivity. This was addressed using nanocomposite engineering incorporating high-thermalconductivity nanoscale fillers in the fabric and tubing components. Specifically, carbon nanotubes were added using normal processing methods such as thermoplastic melt mixing (compounding twin screw extruder) and downstream processing (fiber spinning, tubing extrusion). Fibers were produced as yarns and woven into fabric cloths. The application of isotropic nanofillers can be modeled using a modified Nielsen Model for conductive fillers in a matrix based on Einstein s viscosity model. This is a drop-in technology with no additional equipment needed. The loading is limited by the ability to maintain adequate dispersion. Undispersed materials will plug filtering screens in processing equipment. Generally, the viscosity increases were acceptable, and allowed the filled polymers to still be processed.The novel feature is that fabrics do not inherently possess good thermal conductivity. In fact, fabrics are used for thermal insulation, not heat removal. The technology represents the first material that is a wearable fabric, based on company textiles and materials that will significantly conduct heat.

Chibante, L. P. Felipe↗

A Three-Dimensional Coupled Internal/External Simulation of a Film-Cooled Turbine Vane

A three-dimensional Navier-Stokes simulation has been performed for a realistic film-cooled turbine vane using the LeRC-HT code. The simulation includes the flow regions inside the coolant plena and film cooling holes in addition to the external flow. The vane is the subject of an upcoming NASA Glenn Research Center experiment and has both circular cross-section and shaped film cooling holes. This complex geometry is modeled using a multi-block grid which accurately discretizes the actual vane geometry including shaped holes. The simulation matches operating conditions for the planned experiment and assumes periodicity in the spanwise direction on the scale of one pitch of the film cooling hole pattern. Two computations were performed for different isothermal wall temperatures, allowing independent determination of heat transfer coefficients and film effectiveness values. The results indicate separate localized regions of high heat transfer coefficient values, while the shaped holes provide a reduction in heat flux through both parameters. Hole exit data indicate rather simple skewed profiles for the round holes, but complex profiles for the shaped holes with mass fluxes skewed strongly toward their leading edges.

Heidmann, James D.↗

Microelectromechanical System (MEMS) Device Being Developed for Active Cooling and Temperature Control

High-capacity cooling options remain limited for many small-scale applications such as microelectronic components, miniature sensors, and microsystems. A microelectromechanical system (MEMS) using a Stirling thermodynamic cycle to provide cooling or heating directly to a thermally loaded surface is being developed at the NASA Glenn Research Center to meet this need. The device can be used strictly in the cooling mode or can be switched between cooling and heating modes in milliseconds for precise temperature control. Fabrication and assembly employ techniques routinely used in the semiconductor processing industry. Benefits of the MEMS cooler include scalability to fractions of a millimeter, modularity for increased capacity and staging to low temperatures, simple interfaces, limited failure modes, and minimal induced vibration. The MEMS cooler has potential applications across a broad range of industries such as the biomedical, computer, automotive, and aerospace industries. The basic capabilities it provides can be categorized into four key areas: 1) Extended environmental temperature range in harsh environments; 2) Lower operating temperatures for electronics and other components; 3) Precision spatial and temporal thermal control for temperature-sensitive devices; and 4) The enabling of microsystem devices that require active cooling and/or temperature control. The rapidly expanding capabilities of semiconductor processing in general, and microsystems packaging in particular, present a new opportunity to extend Stirling-cycle cooling to the MEMS domain. The comparatively high capacity and efficiency possible with a MEMS Stirling cooler provides a level of active cooling that is impossible at the microscale with current state-of-the-art techniques. The MEMS cooler technology builds on decades of research at Glenn on Stirling-cycle machines, and capitalizes on Glenn s emerging microsystems capabilities.

Beach, Duane E.↗

High-Accuracy Surface Figure Measurement of Silicon Mirrors at 80 K

This report describes the equipment, experimental methods, and first results at a new facility for interferometric measurement of cryogenically-cooled spherical mirrors at the Goddard Space Flight Center Optics Branch. The procedure, using standard phase-shifting interferometry, has an standard combined uncertainty of 3.6 nm rms in its representation of the two-dimensional surface figure error at 80, and an uncertainty of plus or minus 1 nm in the rms statistic itself. The first mirror tested was a concave spherical silicon foam-core mirror, with a clear aperture of 120 mm. The optic surface was measured at room temperature using standard absolute techniques; and then the change in surface figure error from room temperature to 80 K was measured. The mirror was cooled within a cryostat. and its surface figure error measured through a fused-silica window. The facility and techniques will be used to measure the surface figure error at 20K of prototype lightweight silicon carbide and Cesic mirrors developed by Galileo Avionica (Italy) for the European Space Agency (ESA).

Blake, Peter↗

Corrosion Prevention in Copper Combustion Chamber Liners of Liquid Oxygen/Methane Booster Engines

Prior research conducted by United Technologies Research Center and Rockwell International Rocketdyne Division encountered severe copper corrosion while flowing hydrocarbon fuels through copper cooling tubes. These experimental results have very important implications for the development of low-cost, regeneratively cooled, oxygen/hydrocarbon bipropellant booster engines. Aerojet TechSystems undertook a program sponsored by NASA/Lewis Research Center in 1986 with two objectives: (1) to define the corrosive interaction process that occurs between hydrocarbon fuels and copper combustion chamber liner materials, using both static and dynamic test methods, and (2) to identify and demonstrate protective measures against this corrosive process. The results of the first program task demonstrated that the most damaging corrosive process was caused by trace amounts of sulfur-containing impurities in the hydrocarbon fuel which react with the copper chamber liner material to form cuprous sulfide (Cu2S), as reported in Paper No. AlAA 88-3215. Experiments were conducted which demonstrated this corrosive process with Mil-Spec RP-1, propane, and methane fuels in contact with OFHC, NASA-Z, and ZrCu coppers. The preliminary results of the second program task demonstrated that electrodeposited gold and platinum coatings held promise of preventing corrosion of copper chamber liners by methane contaminated with sulfur-containing impurities, as reported in Paper No. AIAA 89-2738. Experiments were conducted which demonstrated greatly reduced corrosion of copper by hydrogen sulfide (H2S) and methyl mercaptan (CH3SH) as measured impurities in methane. This paper presents the concluding, confirmatory results from the second program task. The efficacy of a protective gold coating on NASA-Z copper cooling channel walls was conclusively demonstrated. Tests were conducted in the Aerojet Carbothermal Test Facility which provide realistic simulations of booster engine cooling channel conditions such as temperature, pressure, flow velocity, and heat flux. Dynamic test series were performed with methane containing 5 and 10 ppm (by volume) hydrogen sulfide. Gold-plated and unplated copper alloy specimens were evaluated. The tests demonstrated that gold coatings were effective in preventing corrosion of the copper. Posttest metallographic examinations of the unplated specimens showed severe corrosion as a result of reaction with the sulfur containing contaminant in the fuel. In contrast, posttest metallographic examination of the gold-coated specimens showed no corrosion under similar operating conditions. The findings from metallurgical and chemical analyses of the copper specimens, chemical analysis of the methane, and description of all test conditions are provided. Conclusions are reached as to the efficacy of the plating methods and the effectiveness of the metal coatings in the prevention of corrosion in hydrocarbon-fueled booster engine combustion chamber liners.

S D Rosenberg↗

Design of a Mechanical NaK Pump for Fission Space Power

Alkali liquid metal cooled fission reactor concepts are under development for spaceflight power requirements. One such concept utilizes a sodium-potassium eutectic (NaK) as the primary loop working fluid, which has specific pumping requirements. Traditionally, electromagnetic linear induction pumps have been used to provide the required flow and pressure head conditions for NaK systems but they can be limited in performance, efficiency, and number of available vendors. The objective of the project was to develop a mechanical NaK centrifugal pump that takes advantages of technology advances not available in previous liquid metal mechanical pump designs. This paper details the design, build, and performance test of a mechanical NaK pump developed at NASA Marshall Space Flight Center. The pump was designed to meet reactor cooling requirements using commercially available components modified for high temperature NaK service.

Mireles, Omar R.↗

Design principles for nickel-hydrogen cells and batteries

Nickel-hydrogen cells and, more recently, bipolar batteries have been built by a variety of organizations. The design principles that have been used by the technology group at the NASA Lewis Research Center draw upon their extensive background in separator technology, alkaline fuel cell technology, and several alkaline cell technology areas. These design principles have been incorporated into both the more contemporary individual pressure vessel (IPV) designs that were pioneered by other groups, as well as the more recent bipolar battery designs using active cooling that are being developed at NASA Lewis Research Center and under contract. These principles are rather straightforward applications of capillary force formalisms, coupled with the slowly developing data base resulting from careful post test analyses. The objective of this overall effort is directed towards the low-Earth-orbit (LEO) application where the cycle life requirements are much more severe than the geosynchronous-orbit (GEO) application. A summary of the design principles employed is presented along with a discussion of the recommendations for component pore sizes and pore size distributions, as well as suggested materials of construction. These will be made based on our experience in these areas to show how these design principles have been translated into operating hardware.

Thaller, L. H.↗

Design principles for nickel-hydrogen cells and batteries

Nickel-hydrogen cells and, more recently, bipolar batteries have been built by a variety of organizations. The design principles that have been used by the technology group at the NASA Lewis Research Center draw upon their extensive background in separator technology, alkaline fuel cell technology, and several alkaline cell technology areas. These design principles have been incorporated into both the more contemporary individual pressure vessel (IPV) designs that were pioneered by other groups, as well as the more recent bipolar battery designs using active cooling that are being developed at NASA Lewis Research Center and under contract. These principles are rather straightforward applications of capillary force formalisms, coupled with the slowly developing data base resulting from careful post test analyses. The objective of this overall effort is directed towards the low-earth-orbit (LEO) application where the cycle life requirements are much more severe than the geosynchronous-orbit (GEO) application. A summary of the design principles employed is presented along with a discussion of the recommendations for component pore sizes and pore size distributions, as well as suggested materials of construction. These will be made based on our experience in these areas to show how these design principles have been translated into operating hardware.

Thaller, L. H.↗

Infrared astronomy takes center stage

Characteristics of infrared astronomy, including the ability to detect cool matter, explore the hidden universe, reveal a wealth of spectral lines, and reach back to the beginning of time are outlined. Ground-based infrared observations such as observations in the thermal infrared region are discussed as well as observations utilizing infrared telescopes aboard NASA aircraft and orbiting telescopes. The Space Infrared Telescope Facility and the Stratospheric Observatory for Infrared Astronomy are described, and it is pointed out that infrared astronomers can penetrate obscuring dust to study stars and interstellar matter throughout the Milky Way galaxy. Application of various infrared instruments to the investigation of stars and planets is emphasized, and focus is placed on the discovery of clouds or disks of particles around mature stars and acquisition of high-resolution spectra of the gaseous and solid materials orbiting on the fringes of the solar system.

Gillett, Frederick C.↗

Optimized Heat Pipe Backup Cooling System Tested with a Stirling Convertor

In a Stirling Radioisotope Power System (RPS), heat must be continuously removed from the General Purpose Heat Source (GPHS) modules to maintain the modules and surrounding insulation at acceptable temperatures. The Stirling convertor normally provides this cooling. If the Stirling convertor stops in the current system, the insulation is designed to spoil, preventing damage to the GPHS at the cost of an early termination of the mission. An alkali-metal variable conductance heat pipe (VCHP) can be used to passively allow multiple stops and restarts of the Stirling convertor by bypassing the heat during stops. In a previous NASA Small Business Innovation Research (SBIR) Program, Advanced Cooling Technologies, Inc. (ACT) developed a series of sodium VCHPs as backup cooling systems for the Stirling RPS. In 2012, one of these VCHPs was successfully tested at NASA Glenn Research Center with a Stirling convertor as an Advanced Stirling Radioisotope Generator (ASRG) backup cooling system. The prototype; however, was not optimized and did not reflect the final heat rejection path. ACT through further funding has developed a semioptimized prototype with the finalized heat path for testing at Glenn with a Stirling convertor. The semioptimized system features a two-phase radiator and is significantly smaller and lighter than the prior prototype to reflect a higher level of flight readiness. The VCHP is designed to activate and remove heat from the GPHS during stoppage with a small temperature increase from the nominal vapor temperature. This small temperature increase from nominal is low enough to avoid risking standard ASRG operation and spoiling of the multilayer insulation (MLI). The VCHP passively allows the Stirling convertor to be turned off multiple times during a mission with potentially unlimited off durations. Having the ability to turn the Stirling off allows for the Stirling to be reset and reduces vibrations on the platform during sensitive measurements or procedures. This paper presents the design of the VCHP and its test results with a Stirling convertor at Glenn. Tests were carried for multiple on and off cycles to demonstrate repeatability. The impacts associated with the addition of the VCHP to the system are also addressed in terms of mass and additional heat losses due to the presence of the VCHP.

Heat Pipe↗