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Thermal comfort during space flight is discussed. Heat production of man during space flight and wear loss as a mean of dissipating heat are described. Water cooled garments are also considered, along with tolerance for extreme heat and body heat storage. Models of human temperature regulation are presented in the form of documented FORTRAN programs.
Second generation high temperature superconducting coils provide a very attractive level of performance for use in the field winding of electric machines for aircraft. Aside from maintaining these coils at cryogenic temperatures, much care must be taken to prevent damaging these relatively fragile materials due to excessive stress. Thermal stresses due to temperature cycling and mechanical stresses due to centrifugal forces are the most critical for the High Efficiency Megawatt Motor. This paper summarizes two test campaigns that were undertaken to reduce the risks posed by these loads. In one campaign, several superconducting coils were fabricated, thermally cycled up to 50~times, and electrically tested in liquid nitrogen to assess the change in superconductivity metrics throughout thermal cycling. In the other campaign, a full-scale superconducting coil was fabricated, a test article was designed to produce a representative stress environment in the coil, the test article and coil were rotated at room temperature up to a speed of 11,800~rpm, and the superconductivity metrics were measured in liquid nitrogen before and after each rotation. The experimental results demonstrate that the superconducting coils manufactured in house can survive both thermal cycling and high speed rotation with no appreciable degradation in superconducting performance.
To develop a new braze to replace the current state-of-the-art Ag-CuO reactive air braze (RAB), two approaches were proposed: 1) development of a new, self-passivating, silver-free braze and 2) development of a CuO-free, silver-based braze. For the first approach, an integrated computational-experimental method was used. Thermo-Calc® was utilized to quickly screen through hundreds of alloy systems to identify candidate braze compositions with the appropriate melting ranges. Material compositions, melting ranges, mechanical properties, oxidation resistance, and wetting characteristics of the candidate alloys were then analyzed experimentally. Substrate surface pre-treatments, active element additions, and novel brazing schemes were also investigated. Unfortunately, the current study failed to identify new silver-free braze compositions suitable for SOFC applications. To help measure the passivation characteristics of surface passivating braze oxide coatings, work was conducted to demonstrate, for the first time, that a variety of disparate and technologically-relevant thermal, mechanical, and electrochemical oxygen-exchange thin film material properties could all be obtained from in situ , current-collector-free wafer curvature measurements. Specifically, temperature or oxygen partial pressure induced changes in the curvature of 230 nm thick (100)-oriented Pr 0.1 Ce 0.9 O 1.95_x (10PCO) films atop 200 mm thick single crystal yttria stabilized zirconia or magnesium oxide substrates were used to measure the biaxial modulus, Young’s modulus, thermal expansion coefficient, thermochemical expansion coefficient, oxygen nonstoichiometry, chemical oxygen surface exchange coefficient, oxygen surface exchange resistance, thermal stress, chemical stress, thermal strain, and chemical strain of the model mixed ionic electronic conducting material 10PCO. The (100)-oriented thin film 10PCO thermal expansion coefficient, thermo-chemical expansion coefficient, oxygen nonstoichiometry, and Young’s modulus (which is essentially constant, at ~200 MPa, over the entire 280–700 °C temperature range in air) measured here were similar to those from other bulk and thin film 10PCO studies. In addition, the measured PCO10 oxygen surface coefficients were in agreement with those reported by other in situ , current collector- free techniques. However, the measured PCO10 oxygen surface exchange coefficients were significantly lower than those obtained from literature studies with large amounts of intentional or inadvertent precious metal surface coverage/contamination (suggesting that uncontaminated (100)-oriented 10PCO may not be a desirable SOFC cathode material). Taken together, this highlighted the advantages of using a sample’s mechanical response, instead of the more traditional electrical response, to probe the electrochemical properties of the ion-exchange materials used in solid oxide fuel cell, solid oxide electrolysis cell, gas-sensing, battery, emission control, water splitting, water purification, and other electrochemically-active devices. For the second approach, a novel silver-nickel brazing method was developed. It was demonstrated that transient porous nickel interlayers, instead of reactive element additions, could be used to promote Ag wetting on yttria stabilized zirconia (YSZ) and produce high-quality YSZ stainless steel (SS) braze joints. Mechanical tests on these reactive-element-free, silver-based SOFC braze joints, both before and after 500 hours of 750°C oxidation in air, showed that the braze and braze interface strength were higher than the underlying YSZ|NiO-YSZ substrate. The microstructural and compositional evolution of SS|Ag-Ni|YSZ braze joints exposed to dual atmosphere (air on one side and 4%H 2 -96%N 2 on the other side) for 300 hours of isothermal 750 °C aging and 300 25°C/min 35-830 °C rapid thermal cycles were compared to a Ag-3CuO braze joint. In contrast to conventional Ag-CuO RAB brazes, the Ag-Ni brazes remained pore free and well bonded, suggesting that Ag-Ni brazes may be more suitable for long term SOFC operation than Ag-CuO brazes. Other applications inspired by the silver-nickel wetting process on various ceramic substrates were also explored. In support of efforts to identify new CuO-free Ag-based brazes, density functional theory and ab initio molecular dynamics calculations were performed to 1) understand silver wetting on YSZ, and 2) identify new oxides to promote silver wetting on YSZ. These simulations found that while the formation of dissolved oxygen clusters within molten silver at the YSZ interface promoted wetting, much greater wetting angle reductions came from the formation of metal oxide interlayers at the Ag-YSZ interface. Through the development of a simple descriptor, many simple metal oxides (single cation) were examined. Unfortunately, their ability to promote Ag wetting were less than that of CuO. However, expanding the search to multi-cation oxides led to several promising candidates, such as CuAlO 2 , CuGaO 2 , and Cu 3 TiO 4 ; all of which are also stable in the reducing SOFC conditions. Depending upon their solubility in molten Ag, these newly-identified oxides could either be pre-applied as wetting promoting interlayers or directly incorporated into Ag to form new reactive air brazes.
The bibliography contains citations concerning the development and testing of ceramic matrix composites for high temperature use. Tests examining effects of the high temperatures on bond strength, thermal degradation, oxidation, thermal stress, thermal fatigue, and thermal expansion properties are referenced. Applications of the composites include space structures, gas turbine and engine components, control surfaces for spacecraft and transatmospheric vehicles, heat shields, and heat exchangers.
Large space structures are capable of large thermal deformations in the space environment. A case of large-scale thermal deformation was observed in the analysis of the Near Earth Asteroid Scout solar sail, with predicted tip displacements of more than one meter in seven-meter booms. Experimental data supports the broad conclusions of the analysis, but shows poor agreement on the details of the thermal deformation. Prediction that is precise enough to drive engineering decisions will require coupled thermal-stress analysis with features that are not found in current multiphysics codes. This paper describes a simple method for stepwise coupling between commercial nonlinear stress analysis software and radiative thermal analysis software. Results are presented for a round stainless steel tube, which is a common case in existing literature.
By using the theory we developed in the early 1970s, a broad range of phenomena is considered for an optical surface of a solid body that is exposed to radiation arbitrarily varying in time and producing temperature fields, thermoelastic stresses and thermal deformations on the surface layer. The examination is based on the relations (which are similar to Duhamel's integral formula from the theory of heat conduction) between the quantities characterising the thermal stress state in any nonstationary regimes of energy input into a solid. A peculiar feature of the analysis of the thermal stress state in this case consists in the fact that this relation comprises time as a parameter, which in turn is a consequence of incoherence of the quasi-stationary problem of thermoelasticity. This phenomenon is particularly important for the optics of high-power, high-pulse repetition rate lasers, which are being actively developed. In the review, we have recently published in Laser Physics, the thermal stress state of a solid is analysed. In this state, time is treated as an independent variable used in differentiation. Such an approach greatly reduces the applicability of the method. The review published contains data on the use of capillary porous structures made of various materials with different degrees of the surface development. Moreover, such structures can be efficiently employed to increase the heat exchange at a temperature below the boiling point of the coolant. In the present review we discuss the dependences of the limiting laser intensities on the duration of a pulse or a pulse train, corresponding to the three stages of the state of the reflecting surface and leading to unacceptable elastic deformations of the surface, to the plastic yield of the material accompanied by the formation of residual stresses and to the melting of the surface layer. We also analyse the problem of heat exchange in the surface layer with a liquid metal coolant pumped through it. The theoretical estimates are compared with the experimental data. We discuss the issues related to the technology of fabrication of power optics elements based on materials with a porous structure, of lightweight highly stable large optics based on highly porous materials, multi-layer honeycomb structures and silicon carbide, as well as problems of application of physical and technical fundamentals of power optics in modern cutting-edge technology. (invited paper)
Heat transfer, thermal stresses, and thermal buckling analyses were performed on the unconventional wing structures of a Hyper-X hypersonic flight research vehicle (designated as X-43) subjected to nominal Mach 7 aerodynamic heating. A wing midspan cross section was selected for the heat transfer and thermal stress analyses. Thermal buckling analysis was performed on three regions of the wing skin (lower or upper); 1) a fore wing panel, 2) an aft wing panel, and 3) a unit panel at the middle of the aft wing panel. A fourth thermal buckling analysis was performed on a midspan wing segment. The unit panel region is identified as the potential thermal buckling initiation zone. Therefore, thermal buckling analysis of the Hyper-X wing panels could be reduced to the thermal buckling analysis of that unit panel. "Buckling temperature magnification factors" were established. Structural temperature-time histories are presented. The results show that the concerns of shear failure at wing and spar welded sites, and of thermal buckling of Hyper-X wing panels, may not arise under Mach 7 conditions.
Multiple stressors in the spaceflight environment, including microgravity and radiation, have the potential to alter microbial pathogenesis and virulence characteristics. Understanding how these and other factors may exacerbate the risk of infectious disease for astronauts is important to ensure the success of the mission. One understudied question in our assessment of infectious disease risk is the contribution carbon dioxide (CO2) at atmospheric concentrations higher than would be observed in terrestrial settings. Previous terrestrial studies have shown altered gene expression, selective bacterial inhibition, increased growth and diversity, and increased antibiotic resistance of bacterial communities individually and in biofilms when exposed to increased levels of CO2. While many of these findings are based on levels of CO2 higher than would be found during spaceflight exploration missions, the potential for subtle changes in CO2 levels to exacerbate infectious disease risks warrants an evaluation of pathogen responses to spaceflight CO2 conditions. To address this question, we are evaluating the effects of elevated atmospheric CO2 on microbial concentration, diversity, and pathogenesis-related characteristics using medically significant microorganisms cultured at CO2 levels representing terrestrial atmospheric concentration (≈0.04 %), ISS elevated concentration (0.4 %), and an unexpectedly elevated concentration (1 %) to represent a worst-case scenario. To determine if microbial responses to these CO2 concentrations may be exacerbated in response to the spaceflight environment, microorganisms are being cultured under static conditions and both spaceflight analogue and control conditions using the Rotating Wall Vessel (RWV) bioreactor (Synthecon, Houston, TX). For these studies, we will evaluate the response of Staphylococcus aureus, Streptococcus pneumoniae, and Enterobacter aerogenes, which are opportunistic bacterial pathogens that are of medical significance and have been or are likely to be found aboard human-inhabited spacecraft. Bacteria will be evaluated individually and together as a consortium. The following Specific Aims are be investigated: Aim 1. Characterize the growth, diversity, and pathogenesis-related stress responses of medically significant microorganisms grown under multiple CO2 concentrations under static growth in a liquid medium. Stress responses include acid stress, oxidative stress, and thermal stress. Aim 2. Characterize the growth, diversity, and pathogenesis-related stress responses of medically significant microorganisms grown under multiple CO2 concentrations in both spaceflight analogue and control conditions. Stress responses include acid stress, oxidative stress, and thermal stress.
A three-dimensional flux-based thermal analysis method has been developed and its capability is demonstrated by predicting the transient nonlinear temperature response of a swept cowl leading edge subjected to intense three-dimensional aerodynamic heating. The predicted temperature response from the transient thermal analysis is used in a linear elastic structural analysis to determine thermal stresses. Predicted thermal stresses are compared with those obtained from a two-dimensional analysis which represents conditions along the chord where maximum heating occurs. Results indicate a need for a three-dimensional analysis to predict accurately the leading edge thermal stress response.
The work presents the development of new algorithms for calculating the fraction of thermal energy dissipated during the irradiation on the inner surface of pores. On the basis of these algorithms, the simulation of heat transfer in three-layered systems was carried out taking into account the dissipation of thermal energy in specimens having different porosity. We have performed quantitative estimates of the portion of dissipating thermal energy and its influence on the distribution of thermal stresses in thermal barrier coating systems. It was demonstrated that the presence of pores with a large internal surface area in the intermediate layer material enables two-fold decrease of the internal thermal stresses.
Thermal changes in tensile stresses and strains in bolt and in corresponding compressive stresses and strains in bolted material estimated more accurately by use of equations incorporating two refinements over previous equations. Elasticity of bolted material and radial thermal expansion also taken into account. Refined equations improve design and analysis of bolted joints assembled at one temperature (e.g., room temperature) and in which specified minimum tension must be maintained (and/or specified maximum tension not exceeded) at higher or lower operational temperature.
To complement the effectiveness of ceramic materials and the applicability to turbine engine applications, a parametric study using the finite element method was carried out. This study conducted thorough analyses of a thermal-barrier-coated silicon nitride (Si3N4) plate specimen with cooling channels, where its thermal conductivity was verified in an attempt to minimize the thermal stresses and reach an optimal rate of stress. The thermal stress profile was generated for specimens with circular and square cooling channels. Lower stresses were reported for a higher magnitude of thermal conductivity and in particular for the circular cooling channel arrangement. Contour plots for the stresses and the temperature are presented and discussed.
A fracture mechanics damage methodology to predict edge delamination is described. The methodology accounts for residual thermal stresses, cyclic thermal stresses, and cyclic mechanical stresses. The modeling is based on the classical lamination theory and a sublaminate theory. The prediction methodology determines the strain energy release rate, G, at the edge of a laminate and compares it with the fatigue and fracture toughness of the composite. To verify the methodology, isothermal static tests at 23, 125, and 175 C and tension-tension fatigue tests at 23 and 175 C were conducted on laminates. The material system used was a carbon/bismaleimide, IM7/5260. Two quasi-isotropic layups were used. Also, 24 ply unidirectional double cantilever beam specimens were tested to determine the fatigue and fracture toughness of the composite at different temperatures. Raising the temperature had the effect of increasing the value of G at the edge for these layups and also to lower the fatigue and fracture toughness of the composite. The static stress to edge delamination was not affected by temperature but the number of cycles to edge delamination decreased.
BEST3D is advanced engineering software system for three-dimensional thermal and stress analyses, particularly of components of hot sections of gas-turbine engines. Utilizes boundary element method, offering, in many situations, more accuracy, efficiency, and ease of use than finite element method. Performs engineering analyses of following types: elastic, heat transfer, plastic, forced vibration, free vibration, and transient elastodynamic. Written in FORTRAN 77.
Numerical data for plane thermal stresses in isotropic elastic square plate bounded by edge stiffeners and under symmetric temperature distributions
Finite-element thermal stress modeling at the glass-ceramic to metal (GCtM) interface was conducted assuming heterogeneous glass-ceramic microstructure. The glass-ceramics were treated as composites consisting of high expansion silica crystalline phases dispersed in a uniform residual glass. Interfacial stresses were examined for two types of glass-ceramics. One was designated as SL16 glass -ceramic, owing to its step-like thermal strain curve with an overall coefficient of thermal expansion (CTE) at 16 ppm/ºC. Clustered Cristobalite is the dominant silica phase in SL16 glass-ceramic. The other, designated as NL16 glass-ceramic, exhibited clusters of mixed Cristobalite and Quartz and showed a near-linear thermal strain curve with a same CTE value.
Finite-element analysis (FEA) modal results of 3C-SiC lateral resonant devices anchored to a Si substrate are presented as resonant frequency versus temperature. The suspended elements are etched from a 2 micron, 3C-SiC film grown at 1600 K on a 500 micron-thick, Si substrate. The analysis includes, temperature-dependent properties, shape change due to volume expansion with temperature, and thermal stress caused by differential thermal expansion of different materials. Two designs are considered: type I has anchor locations close to the geometric centroid and a small shuttle; type 11 has a large shuttle with anchors far from the centroid, The resonant frequency decreases approximately 3.5% over a 1000 K temperature increase for the type-I device, and behaves according to theory. The resonant frequency of the type-11 device decreases by 2% over the first 400 K, then rises slightly over the remaining 600 K. This device deviates from theory because of the high thermal stress induced in the beams. The thermal stress is caused by the differential thermal expansion of the suspended element relative to the substrate. The results show that the device geometry must be properly chosen if the resonant frequency of that device will be used to calculate the temperature coefficient of Young's modulus. These results apply only to resonators of one material on a substrate of a different material.
Biaxial prestressing in ceramic plates under nonuniform thermal stress for damage reduction study