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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 271 records · Page 15

Induction brazing at the Kennedy Space Center

A description of the joint design, materials, equipment, qualification testing, inspection methods, and applications involved in performing induction brazing on hyperbolic propellants tubing at Kennedy Space Center. Induction brazing is a form of brazing in which the energy is transmitted to the workpiece by electrical induction; the eddy currents generated in the metal produce heat by resistance losses. Since induction heating is fast and highly localized, undesirable heat effects are minimized and the resulting braze is of high quality.

Clautice, W. E.↗

Dynamic Discharge Arc Driver

A computer program using nonlinear RLC circuit analysis was developed to accurately model the electrical discharge performance of the Ames 1-MJ energy storage and arc-driver system. Solutions of circuit parameters are compared with experimental circuit data and related to shock speed measurements. Computer analysis led to the concept of a Dynamic Discharge Arc Driver (DDAD) capable of increasing the range of operation of shock-driven facilities. Utilization of mass addition of the driver gas offers a unique means of improving driver performance. Mass addition acts to increase the arc resistance, which results in better electrical circuit damping with more efficient Joule heating, producing stronger shock waves. Preliminary tests resulted in an increase in shock Mach number from 34 to 39 in air at an initial pressure of 2.5 torr.

Dannenberg, R. E.↗

Characterization of NTD germanium and ion-implanted Si bolometers at 0.3K and 0.1K

Bolometer elements were built and tested using NTD germanium and ion-implanted Si thermometer elements. The thermal links were made using aluminum wires and NbC(x)N(y) coated carbon fibers. The temperature dependence of the detector resistance, lead thermal conductivity, and heat capacity were measured. The dependence of the detector resistance on applied electric field was also measured. This, combined with the current-voltage curve for the detector, allowed the calculation of the detector responsivity. Known amounts of energy were deposited into the detector by allowing X-rays from the decay of Fe-55 to be thermalized in the detector. In the best-measured case, the predicted pulse height/measured height was 1.04 + or - .05. The noise at frequencies above 25 Hz in the NTD Ge was near that predicted by thermodynamics. The noise below 25 Hz has a 1/f character and may be in the carbon fiber/bolometer junction. The implanted detectors show some 1/f noise which depends on the total thermometer volume. Comparison between noise measurements and theory will be presented.

Moseley, H.↗

Using In-Situ Deposition of Metallic Thin Films on Mars to Monitor Atmospheric H20

We describe the use of a novel sensor, designed to characterize the reactive nature of the Martian atmosphere, to also characterize the instantaneous abundance of atmospheric H,O. The sensor deposits, in situ, a thin silver film onto a sapphire substrate and monitors oxidation by measuring resistance of the Ag film during both deposition and subsequent oxidation [1,2]. . The evaporation source is placed in the center of a hollow, open-ended tube. On flash heating the source, evaporated metallic silver rapidly reacts with oxidizing gases in the tube, depositing on the tube walls as a resisitive Ag oxide film. Unoxidized silver deposits over the Ag oxides, once the oxidizing gases in the vicinity of the source have been consumed. Since the ends of the tube are open, atmospheric gases in the tube cause a time delay as the evaporated silver initially reacts with the available O2, and H2O; once oxidizing gases in the tube are significantly depleted, a silver film closes the chemiresistor circuit. In principle this operation mode provides a repeatable measure of the variable H2O abundance, since O2, levels are constant in the atmosphere. To explore the utility of the instrument as an H2O sensor, predict its behavior, and identify possible failure modes, we developed a numerical model of the instrument, and exercised it for Mars conditions. The model predicts the behavior of the electrical circuit, the temperature dependence of resistivity for each component, and the resultant Joule heating. The model balances Joule heating against radiation, sensible heat loss to ambient CO2, and, latent heat loss from sublimating Ag. The flux of Ag atoms from the source is tracked continuously. In the gas phase, the number density of Ag, O2, and H2O is calculated, along with their reaction rates on collision. The model suggests that Ag substantially depletes H2O only near the center of the tube. The model supports the hypothesis that the onset of high conductivity between the A u electrodes is a function of the H2O abundance in the ambient gas, but only to a limit; when H2O abundances are buffered at or above 240K (an H2O abundance that would not have occurred on Mars), metallic Ag never deposits in excess of Ago, and the circuit does not close. A significant difference in the Mars simulation is that the Ag source sublimates more quickly, primarily because of differences in sensible heat fluxes from the source. This allows subsequent heating of the W filament used to support the Ag source. Had the originally-designed experimental sequence been carried out on Mars, the filament might have melted, making subsequent investigations impossible.

Zent, A. P.↗

Comparison of Thermal Management Approaches for Integrated Traction Drives in Electric Vehicles

The continuous push to increase power densities of electric vehicle (EV) traction drive systems necessitates combining electric motor and power electronics into one unit. A single, compact traction drive unit with fewer interconnecting components also facilitates fast, automated assembly of electric vehicles, driving production costs down and enabling wider adoption of EVs. There are a number of challenges associated with the integration of power electronics with the electric machine, including thermal management of the combined traction drive system. However, one important benefit of integration from the thermal management system perspective is the potential for using a single fluid loop instead of two separate cooling systems for the electric machine and the power electronics/inverter. This paper reviews several integration approaches and, employing finite element analysis (FEA), compares thermal management solutions for the combined electric machine and power electronics systems. Namely, three different scenarios are modeled: (1) independent component (motor and power electronics) cooling, which is compared to the combined cooling system approach for (2) radially and (3) axially integrated power electronics modules into the motor enclosure. Temperature distributions for selected thermal loads and thermal resistances from the key heat-generating components to the cooling fluid are compared for each scenario.

47 OTHER INSTRUMENTATION↗

Spatiotemporal Thermal Coupling in VO 2 Device Arrays

Correlated oxides such as VO 2 exhibit an electrically driven insulator–metal transition (IMT) that underlies their promise for neuromorphic and memory devices. Yet the IMT is not a uniform bulk process but a spatiotemporal phenomenon in which local heating nucleates filaments, contracts or dissolves them with the electric field, and couples to the environment. In this work, we directly image the VO 2 IMT dynamics by mid-wave infrared, thermography synchronized with electrical transport, resolving device temperature with micrometer spatial and microsecond temporal resolution. At the single-device level, we capture the full cycle of filament nucleation, contraction, and relaxation during current/voltage-driven resistive switching. At the array level, we show that heat propagates across etched gaps with an effective length scale of ∼131 µm, enabling cooperative behaviors among electrically isolated devices. Short-range distanced devices exhibit mutual filament attraction and sequential dissolution, while long-range distanced devices differentiate into distinct roles: drivers that initiate switching, cooperative responders that undergo assisted self-oscillations, and passive reporters that record the thermal field. Furthermore, these results reframe thermal crosstalk, long regarded as parasitic, as an intrinsic coupling channel and design principle for organizing collective switching behaviors, with direct implications for emergent circuit functionality in neuromorphic and unconventional computing architectures.

coupling↗

Intermetallic Nickel-Titanium Alloys for Oil-Lubricated Bearing Applications

An intermetallic nickel-titanium alloy, NITINOL 60 (60NiTi), containing 60 wt% nickel and 40 wt% titanium, is shown to be a promising candidate material for oil-lubricated rolling and sliding contact applications such as bearings and gears. NiTi alloys are well known and normally exploited for their shape memory behavior. When properly processed, however, NITINOL 60 exhibits excellent dimensional stability and useful structural properties. Processed via high temperature, high-pressure powder metallurgy techniques or other means, NITINOL 60 offers a broad combination of physical properties that make it unique among bearing materials. NITINOL 60 is hard, electrically conductive, highly corrosion resistant, less dense than steel, readily machined prior to final heat treatment, nongalling and nonmagnetic. No other bearing alloy, metallic or ceramic encompasses all of these attributes. Further, NITINOL 60 has shown remarkable tribological performance when compared to other aerospace bearing alloys under oil-lubricated conditions. Spiral orbit tribometer (SOT) tests were conducted in vacuum using NITINOL 60 balls loaded between rotating 440C stainless steel disks, lubricated with synthetic hydrocarbon oil. Under conditions considered representative of precision bearings, the performance (life and friction) equaled or exceeded that observed with silicon nitride or titanium carbide coated 440C bearing balls. Based upon this preliminary data, it appears that NITINOL 60, despite its high titanium content, is a promising candidate alloy for advanced mechanical systems requiring superior and intrinsic corrosion resistance, electrical conductivity and nonmagnetic behavior under lubricated contacting conditions.

DellaCorte, C.↗

Influence of pre-existing defects on thermal transport in nuclear graphite

Nuclear graphite is a critical material in high-temperature nuclear reactors due to its superior thermal and mechanical properties. The manufacturing process leaves multi-scale ‘pre-existing’ defects that can affect thermal transport characteristics. Because these defects are remnant of graphitization temperature, they cannot be thermally annealed. This study employs a non-thermal electron wind force (EWF) annealing technique to avoid this obstacle. 2 min of EWF treatment of the as-received graphite IG-110 at temperatures below 100 °C led up to 67% increase in thermal diffusivity and ~ 35% decrease in electrical resistivity in average. Differential scanning calorimetry also showed similar outcome for specific heat. X-ray diffraction characterization was performed by fitting a bi-modal crystallite size distribution model to reveal the enhancement in crystallinity after the EWF treatment. The findings emphasize the potential of EWF annealing for optimizing thermal performance in nuclear graphite and its implications for reactor efficiency and safety.

Annealing↗

A sharp knife for high temperatures

Electrically heated nickel-chrome-steel alloy knife may be used to cut heat resistant plastic felt and similar materials with relative ease. Blade made of commercially available alloy RA 330 retains edge at temperatures as high as 927 C.

Heisman, R. M.↗

Calorimetry of 25 Ah lithium/thionyl chloride cells

Heat flow measurements of 25-Ah lithium thionyl chloride cells provided a method to calculate an effective thermal potential, E(TP) of 3.907 V. The calculation is useful to determine specific heat generation of this cell chemistry and design. The E(TP) value includes heat generation by electrochemical cell reactions, competitive chemical reactions, and resistance heating at the tabs, connectors, and leads. Heat flow was measured while applying electrical loads to the cell in an isothermal calorimeter set at 0, 20, and 60 C.

Johnson, C. J.↗

Microlith Based Sorber for Removal of Environmental Contaminants

The development of energy efficient, lightweight sorption systems for removal of environmental contaminants in space flight applications is an area of continuing interest to NASA. The current CO2 removal system on the International Space Station employs two pellet bed canisters of 5A molecular sieve that alternate between regeneration and sorption. A separate disposable charcoal bed removes trace contaminants. An alternative technology has been demonstrated using a sorption bed consisting of metal meshes coated with a sorbent, trademarked and patented as Microlith by Precision Combustion, Inc. (PCI); thesemeshes have the potential for direct electrical heating for this application. This allows the bed to be regenerable via resistive heating and offers the potential for shorter regeneration times, reduced power requirement, and net energy savings vs. conventional systems. The capability of removing both CO2 and trace contaminants within the same bed has also been demonstrated. Thus, the need for a separate trace contaminant unit is eliminated resulting in an opportunity for significant weight savings. Unlike the charcoal bed, zeolites for trace contaminant removal are amenable to periodic regeneration. This paper describes the design and performance of a prototype sorber device for simultaneous CO2 and trace contarninant removal and its attendant weight and energy savings.

Roychoudhury, S.↗

Space Fission Propulsion System Development Status

The world's first man-made self-sustaining fission reaction was achieved in 1942. Since then fission has been used to propel submarines, generate tremendous amounts of electricity, produce medical isotopes, and provide numerous other benefits to society. Fission systems operate independently of solar proximity or orientation, and are thus well suited for deep space or planetary surface missions. In addition, the fuel for fission systems (enriched uranium) is virtually non-radioactive. The primary safety issue with fission systems is avoiding inadvertent system start. Addressing this issue through proper system design is straight-forward. Despite the relative simplicity and tremendous potential of space fission systems, the development and utilization of these systems has proven elusive. The first use of fission technology in space occurred 3 April 1965 with the US launch of the SNAP-10A reactor. There have been no additional US uses of space fission systems. While space fission systems were used extensively by the former Soviet Union, their application was limited to earth-orbital missions. Early space fission systems must be safely and affordably utilized if we are to reap the benefits of advanced space fission systems. NASA's Marshall Space Flight Center, working with Los Alamos National Laboratory (LANL), Sandia National Laboratories, and others, has conducted preliminary research related to a Safe Affordable Fission Engine (SAFE). An unfueled core has been fabricated by LANL, and resistance heaters used to verify predicted core thermal performance by closely mimicking heat from fission. The core is designed to use only established nuclear technology and be highly testable. In FY01 an energy conversion system and thruster will be coupled to the core, resulting in an 'end-to-end' nuclear electric propulsion demonstrator being tested using resistance heaters to closely mimic heat from fission. Results of the SAFE test program will be presented. The applicability of a SAFE-powered electric propulsion system to outer planet science missions will also be discussed.

Houts, M.↗

Nondestructive testing of electro thermal devices

This paper describes the results of a recent investigation into 'thermal time constant' nondestructive testing of high reliability electrical fuses. The use of established nondestructive test technology for examining the quality and firing characteristics of electro-explosive devices has been successfully applied to the inspection and prediction of the functional performance of electrical fuses. The technique requires application of a low level current pulse to the electrical fuse with an oscilloscope display of the curve as generated by the temperature coefficient of resistance feedback. The heating curve of temperature vs time is composed of one predominant thermal time constant, which is the product of the test unit's thermal capacity and thermal resistance. It has been found that the quality of the individual electrical fuse, for instance, the relative condition of the critical internal weld or solder joint, can be examined nondestructively.

Earnest, J. E., Jr.↗

Diamond Heat-Spreader for Submillimeter-Wave Frequency Multipliers

The planar GaAs Shottky diode frequency multiplier is a critical technology for the local oscillator (LO) for submillimeter- wave heterodyne receivers due to low mass, tenability, long lifetime, and room-temperature operation. The use of a W-band (75-100 GHz) power amplifier followed by a frequency multiplier is the most common for submillimeter-wave sources. Its greatest challenge is to provide enough input power to the LO for instruments onboard future planetary missions. Recently, JPL produced 800 mW at 92.5 GHz by combining four MMICs in parallel in a balanced configuration. As more power at W-band is available to the multipliers, their power-handling capability be comes more important. High operating temperatures can lead to degradation of conversion efficiency or catastrophic failure. The goal of this innovation is to reduce the thermal resistance by attaching diamond film as a heat-spreader on the backside of multipliers to improve their power-handling capability. Polycrystalline diamond is deposited by hot-filament chemical vapor deposition (CVD). This diamond film acts as a heat-spreader to both the existing 250- and 300-GHz triplers, and has a high thermal conductivity (1,000-1,200 W/mK). It is approximately 2.5 times greater than copper (401 W/mK) and 20 times greater than GaAs (46 W/mK). It is an electrical insulator (resistivity approx. equals 10(exp 15) Ohms-cm), and has a low relative dielectric constant of 5.7. Diamond heat-spreaders reduce by at least 200 C at 250 mW of input power, compared to the tripler without diamond, according to thermal simulation. This superior thermal management provides a 100-percent increase in power-handling capability. For example, with this innovation, 40-mW output power has been achieved from a 250-GHz tripler at 350-mW input power, while the previous triplers, without diamond, suffered catastrophic failures. This breakthrough provides a stepping-stone for frequency multipliers-based LO up to 3 THz. The future work for this design is to apply the high output power from both the 250 and 300 GHz to multiple chains in order to generate milliwatts at 2.3 THz. Using the first generation of results for this innovation, 40 mW of output power were produced from a 240-GHz tripler at 350-mW input power, and 27- mW output power was produced from a 300-GHz tripler at 408-mW input power. This is two times higher than the current state-of-the-art output power capability. A finite-element thermal simulation also shows that 30-microns thick diamond dropped the temperature of the anodes by at least 200 C.

Lin, Robert H.↗

Computer simulation of the Farley-Buneman instability and anomalous electron heating in the auroral ionosphere

The nonlinear saturation of the Farley-Buneman instability in a collisional plasma is studied by a 2 1/2 dimensional electrostatic particle simulation which includes inelastic and elastic collisions of electrons and elastic collision of ions with neutrals. In the simulation, a uniform convection electric field is applied externally so that the relative velocity between the electrons and ions is greater than the ion sound speed and destabilizes the instability. A nonlinear frequency shift from higher to lower frequencies and diffusion of the wave spectrum in two dimensional wave number space are found. It is found that the dominant mechanism for electron heating is due to an enhanced effective electron collision frequency and hence enhanced resistive heating as suggested by Primdahl (1986) and not due to the heating of electrons by the electric field of the waves parallel to the magnetic field. For the ionospheric conditions discussed by Schlegel and St.-Maurice (1981)an anomalous heating rate of about 4 x 10 to the 7th W/cu cm is found.

Machida, S.↗

Metallurgical and Thermal Properties of 57Ni–40Ti–3Hf (wt%)

Selected properties of 57Ni-40Ti-3Hf (wt%) were measured to further develop this material for use in aerospace rolling-element bearings. The average grain size and microindentation hardness of the material at room temperature were 90 μm and 549 HV, respectively. From room temperature to 500 °C, electrical resistivity increased from 8.9×10 –7 to 11.3×10 –7 Ω⋅m, thermal expansion coefficients varied from 1.1×10 –5 to 1.2×10 –5 mm/mm⋅°C, specific heat increased from 0.44 to 0.53 W⋅sec/g⋅K, thermal diffusivity rose from approximately 0.003 to 0.005 cm 2 /sec and thermal conductivity increased from approximately 0.09 to 0.19 W/cm⋅K. The behavior of the material can be explained by well-known metallurgical theory. These results are expected to provide a basis for design and modeling of future aerospace components.

intermetallics↗

Anomalous Resistivity and Electron Heating by Lower Hybrid Drift Waves during Magnetic Reconnection with a Guide Field

The lower hybrid drift wave (LHDW) has been a candidate for anomalous resistivity and electron heating inside the electron diffusion region of magnetic reconnection. In a laboratory reconnection layer with a finite guide field, quasielectrostatic LHDW (ES-LHDW) propagating along the direction nearly perpendicular to the local magnetic field is excited in the electron diffusion region. ES-LHDW generates large density fluctuations ($δn_{\text e}$, about 25% of the mean density) that are correlated with fluctuations in the out-of-plane electric field ($δE_Y$, about twice larger than the mean reconnection electric field). With a small phase difference (~ 30°) between two fluctuating quantities, the anomalous resistivity associated with the observed ES-LHDW is twice larger than the classical resistivity and accounts for 20% of the mean reconnection electric field. After we verify the linear relationship between $δn_{\text e}$ and $δE_Y$, anomalous electron heating by LHDW is estimated by a quasilinear analysis. The estimated electron heating is about 2.6 ± 0.3 MW / m 3 , which exceeds the classical Ohmic heating of about 2.0 ± 0.2 MW / m 3 . This LHDW-driven heating is consistent with the observed trend of higher electron temperatures when the wave amplitude is larger. Finally, presented results provide the first direct estimate of anomalous resistivity and electron heating power by LHDW, which demonstrates the importance of wave-particle interactions in magnetic reconnection.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Diode and protection fuse unit Patent

Single electrical circuit component combining diode, fuse, and blown indicator with elongated tube of heat resistant transparent material

Jenkins, K. H.↗