Results for “Thermal modeling and analysis” — Page 16

NASA NTRSDate not supplied

Pterodactyl: Aerodynamic and Aerothermal Modeling for a Symmetric Deployable Earth Entry Vehicle with Flaps

NASA’s Pterodactyl project has investigated a deployable atmospheric entry vehicle integrated with a flap control system that provides precision targeting during reentry. The control system consists of eight flaps mounted at the edge of a heatshield that can deflect in and out of the flow. An aerodynamic and aerothermodynamic analysis process was developed for preliminary vehicle design and aerodynamic database generation using engineering and CFD tools with varying levels of fidelity. The objective of this analysis was to: 1) understand the inherent aerodynamics, 2) provide an aerodynamics database for stability and control analysis, and 3) provide qualitative and quantitative aeroheating analysis for Thermal Protection System modeling of the flaps. A high fidelity Euler code, Cart3D, was used to resolve complex flow features such as secondary shocks and shock impingement. A wide range of supersonic (Mach 2) and hypersonic Mach numbers (up to Mach 40) were tested with an Earth atmosphere model. A process was developed to utilize the adaptive volume mesh generator utility of the perfect gas model of Cart3D to create meshes with high cell efficiency and numerical stability prior to running a 2nd order accurate solution with a real gas model. High-fidelity aerothermal CFD simulations were performed using US3D to further improve the aerothermal analysis on hypersonic flow around a complex entry vehicle shape including viscosity, chemical reactions of air species, vibrational energy, and catalytic surface reactions. In this process, it was found that the flap control system provided multi-axis control that can be utilized for entry precision targeting. Additionally, the Pterodactyl vehicle can achieve up to a trim L/D of 0.2. Finally, the increased fidelity of the aerothermal heating environments revealed that the shear stress contributes to increasing the heating on the flaps.

Deployable Entry Vehicle↗

NASA NTRSDate not supplied

Pterodactyl: Aerodynamic and Aerothermal Modeling for a Symmetric Deployable Earth Entry Vehicle with Flaps

NASA’s Pterodactyl project has investigated a deployable atmospheric entry vehicle integrated with a flap control system that provides precision targeting during reentry. The control system consists of eight flaps mounted at the edge of a heatshield that can deflect in and out of the flow. An aerodynamic and aerothermodynamic analysis process was developed for preliminary vehicle design and aerodynamic database generation using engineering and CFD tools with varying levels of fidelity. The objective of this analysis was to: 1) understand the inherent aerodynamics, 2) provide an aerodynamics database for stability and control analysis, and 3) provide qualitative and quantitative aeroheating analysis for Thermal Protection System modeling of the flaps. A high fidelity Euler code, Cart3D, was used to resolve complex flow features such as secondary shocks and shock impingement. A wide range of supersonic (Mach 2) and hypersonic Mach numbers (up to Mach 40) were tested with an Earth atmosphere model. A process was developed to utilize the adaptive volume mesh generator utility of the perfect gas model of Cart3D to create meshes with high cell efficiency and numerical stability prior to running a 2nd order accurate solution with a real gas model. High-fidelity aerothermal CFD simulations were performed using US3D to further improve the aerothermal analysis on hypersonic flow around a complex entry vehicle shape including viscosity, chemical reactions of air species, vibrational energy, and catalytic surface reactions. In this process, it was found that the flap control system provided multi-axis control that can be utilized for entry precision targeting. Additionally, the Pterodactyl vehicle can achieve up to a trim L/D of 0.2. Finally, the increased fidelity of the aerothermal heating environments revealed that the shear stress contributes to increasing the heating on the flaps.

Deployable Entry Vehicle↗

NASA NTRS1999

Thermal Analysis of the X-38 Aft Fin During Re-Entry

This document contains the details of the thermal analysis of the X-38 aft fin during re-entry. This analysis was performed in order to calculate temperature response of the aft fin components. This would be provided as input to a structural analysis and would also define the operating environment for the electromechanical actuator (EMA). The calculated structural temperature response would verify the performance of the thermal protection system (TPS). The geometric representation of the aft fin was derived from an I-DEAS finite element model that was used for structural analysis. The thermal mass network model was derived from the geometric representation.

Hong, Andrew E.↗

NASA NTRS2020

Thermal system and environmental testing of the Mars Helicopter

The Mars Helicopter will be a technology demonstration conducted during the Mars 2020 mission. The primary mission objective is to achieve several 90-second flights demonstrating the feasibility of heavier than air flight on Mars and capture visible light images via forward and nadir mounted cameras. These flights could possibly provide reconnaissance data for sampling site selection for other Mars surface missions. A solar array and batteries for flight operations, imaging, communications, and survival heating power the Helicopter. The thermal design is driven by minimizing survival heater energy while maintaining compliance with allowable flight temperatures in a variable thermal environment. Due to the small size of the Helicopter and its complex geometries, along with the fact that it operates with very low power and small margins in the extreme Mars environment, additional care had to be paid while planning thermal tests and designing the thermal system. The first section of the paper describes the evolution of the thermal system of the Mars Helicopter. After the first thermal vacuum test of the engineering model, the thermal team has conducted a partial effect analysis on the thermal design components that had a major impact on the system performance. Several design choices derived by analysis and test have been made to meet the energy allocation and the temperature requirements. These changes included increased gas gaps to reduce gas conduction, low emissivity coatings for internal components, blanket implementation, optimization of wire routing and fine-tuning of surface operations to optimize waste heat recovery. The second part of the paper describes the flight model thermal vacuum test and the subsequent thermal model correlation necessary to confirm the fidelity of the analysis results.

Pauken, Michael↗

NASA NTRS1984

Steady internal flow and aerodynamic loads analysis of shuttle thermal protection system

An analytical model for calculation of ascent steady state tile loading was developed and validated with wind tunnel data. The analytical model is described and results are given. Results are given for loading due to shocks and skin friction. The analysis included calculation of internal flow (porous media flow and channel flow) to obtain pressures and integration of the pressures to obtain forces and moments on an insulation tile. A heat transfer program was modified by using analogies between heat transfer and fluid flow so that it could be used for internal flow calculation. The type of insulation tile considered was undensified reusable surface insulation (RSI) without gap fillers, and the location studied was the lower surface of the orbiter. Force and moment results are reported for parameter variations on surface pressure distribution, gap sizes, insulation permeability, and tile thickness.

Petley, D. H.↗

DOE OSTI2023

Characterization of Fe-6Si Soft Magnetic Alloy Produced by Laser-Directed Energy Deposition Additive Manufacturing

Abstract Commercial electrical steels, Fe-Si alloys with < 4 wt.% Si, are inexpensive and efficient materials for electrical power conversion. Further efficiency improvements require increasing the silicon concentration to 6 wt.%, at which point the material becomes brittle and difficult to form by conventional rolling and sheet fabrication methods. Additive manufacturing stands to overcome challenges with commercial manufacturing techniques by leveraging near-net-shape fabrication. The wide array of process conditions provides additive manufacturing with increased flexibility, enabling control over the microstructure and mechanical properties. This work explores the microstructures and magnetic properties of ring-shaped Fe-Si alloys produced using concentric and cross-hatch tool paths on a laser-directed energy deposition additive manufacturing system. Concentric-built samples exhibit elongated grain structures while cross-hatch-built samples comprise lower aspect ratio grain structures. Thermal finite element analysis simulations model the stress conditions produced by the different scan path geometries. Microhardness measurements probe the mechanical properties as a function of anneal temperature, providing a qualitative understanding of the intergranular defect density. Soft magnetic properties measured under quasistatic and AC conditions show frequency- and microstructure-dependent coercivity and permeability. Finally, analysis of the core loss quantifies how the build strategies and thermal treatments influence efficiency in electrical power conversion applications. Understanding the influences of scan path geometry and thermal treatment provides a pathway towards application of additively manufactured soft magnetic materials.

Adamczyk, Jesse M.↗

NASA NTRS2010

Mineralogy and Thermal Properties of V-Type Asteroid 956 Elisa: Evidence for Diogenitic Material from the Spitzer IRS (5-35 Micrometers) Spectrum

We present the thermal infrared (5-35 micrometer) spectrum of 956 Elisa as measured by the Spitzer Infrared Spectrograph ("IRS"; Houck,1.R. et .11. [20041. Astrophys, 1. SuppL 154, 18-24) together with new ground-based lightcurve data and near-IR spectra. From the visible lightcurve photometry, we determine a rotation period of 16.494 +/- 0.001 h, identify the rotational phase of the Spitzer observations, and estimate the visible absolute magnitude (Hv) at that rotational phase to be 12.58 +/- 0.04. From radiometric analysis of the thermal flux spectrum, we find that at the time of observation 956 Elisa had a projected radius of 5.3 +/- 0.4 km with a visible albedo pv = 0.142+/- 0.022, significantly lower than that of the prototype V-type asteroid, 4 Vesta. (This corresponds to a radius of 5.2 +/- 0.4 km at lightcurve mean.) Analysis with the standard thermal model (STM) results in a sub-solar temperature of 292.3 +/- 2.8 K and beaming parameter eta = 1.16 +/- 0.05. Thermophysical modeling places a lower limit of 20 J m(exp -2)K(exp -1)s(exp -1/2) on the thermal inertia of the asteroid's surface layer (if the surface is very smooth) but more likely values fall between 30 and 150 J m(exp -2)K(exp -1)s(exp -1/2) depending on the sense of rotation. The emissivity spectrum, calculated by dividing the measured thermal flux spectrum by the modeled thermal continuum, exhibits mineralogically interpretable spectral features within the 9-12 micrometer reststrahlen band, the 15-16.5 micrometer Si-O-Si stretching region, and the 16-25 micrometer reststrahlen region that are consistent with pyroxene of diogenitic composition: extant diogenitic pyroxenes fall within the narrow compositional range W0(sub 2+/-1)En(sub 74+/-2)Fs(sub 24+/-1). Spectral deconvolution of the 9-12 micrometer reststrahlen features indicates that up to approximately 20% olivine may also be present, suggesting an olivine-diogenite-like mineralogy. The mid-IR spectrum is inconsistent with non-cumulate eucrite as the major component on the surface of 956 Elisa, although cumulate eucrite material may be present at abundances lower than that of the diogenite component. Analysis of new near-IR spectra of 956 Elisa with the Modified Gaussian Model (MGM; Sunshine, J,M., Pieters, C.M., Pratt, S.F.[1990]. J. Geophys. Res, 95 (May), 6955-6966) results in two pyroxene compositions: 75% magnesian low-Ca pyroxene and 25% high-Ca pyroxene. High-Ca pyroxene is not evident in the mid-IR data, but may belong to a component that is underrepresented in the mid-IR spectrum either because of its spatial distribution on the asteroid or because of its particle size. High-Ca pyroxenes that occur as exsolution lamellae may also be more evident spectrally in the NIR than in the mid-IR. In any case, we find that the mid-IR spectrum of 956 Elisa is dominated by emission from material of diogenite- like composition, which has very rarely been observed among asteroids.

Lim, Lucy F.↗

NASA NTRS2017

Thermal Modeling of Mars Ground for Surface Missions

Thermal analysis packages are capable of including ground temperature effects for orbital and surface thermal analyses. In particular, Thermal Desktop® offers the option of specifying ground temperatures as a function of time for planetary surface modeling. While suitable for many cases, this approach is not sufficient if an object has local interactions with the ground that could significantly affect the ground temperature. Ground modeling is necessary for the Mars 2020 rover thermal design and analysis since shadowing and heat dissipation from the rover’s Multi-Mission Radioisotope Thermoelectric Generator (MMRTG) can result in significant temperature deviations of the local ground. The Mars 2020 thermal team is explicitly modeling the Martian ground so that these local temperature effects can be captured. The upper portion of the ground is modeled, and material and optical properties of the ground are varied in order to match data collected from orbiting science instruments. Atmospheric surface temperature, sky temperatures, and solar loads from a Mars General Circulation Model (GCM) are used as boundary conditions, resulting in a ground surface temperature profile consistent with the GCM predictions. The rover model is then placed on this modeled ground so that the effects of shadowing and MMRTG dissipation on the ground temperature can be captured.

Farias, Edgardo↗

NASA NTRS2001

Thermal Analysis of Next Generation Space Telescope (NGST) Mirrors During Optical Testing in the X-Ray Calibration Facility (XRCF)

The Next Generation Space Telescope (NGST) program and industry partners are developing extremely lightweight mirror designs. NGST development mirrors are being tested at Marshall Space Flight Center. Target temperature for development mirror testing is 35 K. Conduction and radiation are not sufficient to conduct thermal vacuum testing in a reasonable time. Helium gas is injected into the vacuum chamber to accelerate temperature transitions during testing. Free-molecular conduction can be modeled by adapting present thermal analysis techniques.

Page, Tim↗

NASA NTRS1985

Dendritic solidification. I - Analysis of current theories and models. II - A model for dendritic growth under an imposed thermal gradient

A critical review of the present dendritic growth theories and models is presented. Mathematically rigorous solutions to dendritic growth are found to rely on an ad hoc assumption that dendrites grow at the maximum possible growth rate. This hypothesis is found to be in error and is replaced by stability criteria which consider the conditions under which a dendrite tip advances in a stable fashion in a liquid. The important elements of a satisfactory model for dendritic solidification are summarized and a theoretically consistent model for dendritic growth under an imposed thermal gradient is proposed and described. The model is based on the modification of an analysis due to Burden and Hunt (1974) and predicts correctly in all respects, the transition from a dendritic to a planar interface at both very low and very large growth rates.

Laxmanan, V.↗

NASA NTRS2002

A Modified Wall Matching Treatment to Account for Local Solid to Fluid Thermal Coupling

The wall-matching methodology of Wilcox is modified to include a solid-wall, thermal-conduction model. This coupled fluid-thermal-structure model is derived assuming that the wall thermal-structure behavior is locally one-dimensional and that structural deformations, due to thermally induced stresses, are not significant. The one-dimensional coupled fluid-thermal-structure model is derived such that the wall temperature is removed as an independent boundary condition variable. The one-dimensional coupled fluid-thermal-structure model is also derived for the general case of an arbitrary mixture of thermally prefect gases and a wall of arbitrary thickness and conductivity by using a compressible, streamwise-pressure-gradient-corrected, wall-matching function and Fourier's law of heat conduction. The resulting model was implemented in the VULCAN CFD code as a new boundary condition type. VULCAN was then used to simulate a two-dimensional Mach 6 wind tunnel facility nozzle flow to demonstrate/validate the one-dimensional coupled fluid-thermal-structure model. The nozzle internal-wall surface temperature and heat transfer distributions computed using the one-dimensional coupled fluid-thermal-structure model are compared to wall temperature and heat transfer distributions from an iterative multi-dimensional analysis obtained by coupling the VULCAN CFD code and the MSC/NASTRAN-thermal code. The one-dimensional coupled fluid-thermal-structure model analysis is shown to be very robust and in excellent agreement with the multi-dimensional iteratively coupled analysis. It is also shown that the one-dimensional analysis can be used as an initial guess for the multi-dimensional iteratively coupled analysis.

White, Jeffery A.↗

NASA NTRS2002

A Modified Wall Matching Treatment to Account for Local Solid to Fluid Thermal Coupling

The wall-matching methodology of Wilcox is modified to include a solid-wall, thermal-conduction model. This coupled fluid-thermal-structure model is derived assuming that the wall thermal-structure behavior is locally one-dimensional and that structural deformations, due to thermally induced stresses, are not significant. The one-dimensional coupled fluid-thermal-structure model is derived such that the wall temperature is removed as an independent boundary condition variable. The one-dimensional coupled fluid-thermal-structure model is also derived for the general case of an arbitrary mixture of thermally prefect gases and a wall of arbitrary thickness and conductivity by using a compressible, streamwise-pressure-gradient-corrected, wall-matching function and Fourier's law of heat conduction. The resulting model was implemented in the VULCAN CFD code as a new boundary condition type. VULCAN was then used to simulate a two-dimensional Mach 6 wind tunnel facility nozzle flow to demonstrate/validate the one-dimensional coupled fluid-thermal-structure model. The nozzle internal-wall surface temperature and heat transfer distributions computed using the one-dimensional coupled fluid-thermal-structure model are compared to wall temperature and heat transfer distributions from an iterative multi-dimensional analysis obtained by coupling the VULCAN CFD code and the MSC/NASTRAN-thermal code. The one-dimensional coupled fluid-thermal-structure model analysis is shown to be very robust and in excellent agreement with the multi-dimensional iteratively coupled analysis. It is also shown that the one-dimensional analysis can be used as an initial guess for the multi-dimensional iteratively coupled analysis.

White, Jeffery A.↗

NASA NTRS1995

RTE: A computer code for Rocket Thermal Evaluation

The numerical model for a rocket thermal analysis code (RTE) is discussed. RTE is a comprehensive thermal analysis code for thermal analysis of regeneratively cooled rocket engines. The input to the code consists of the composition of fuel/oxidant mixture and flow rates, chamber pressure, coolant temperature and pressure. dimensions of the engine, materials and the number of nodes in different parts of the engine. The code allows for temperature variation in axial, radial and circumferential directions. By implementing an iterative scheme, it provides nodal temperature distribution, rates of heat transfer, hot gas and coolant thermal and transport properties. The fuel/oxidant mixture ratio can be varied along the thrust chamber. This feature allows the user to incorporate a non-equilibrium model or an energy release model for the hot-gas-side. The user has the option of bypassing the hot-gas-side calculations and directly inputting the gas-side fluxes. This feature is used to link RTE to a boundary layer module for the hot-gas-side heat flux calculations.

Naraghi, Mohammad H. N.↗

NASA NTRS1976

Thermal design and analysis of a hydrogen-burning wind tunnel model of an airframe-integrated scramjet

An aerodynamic model of a hydrogen burning, airframe integrated scramjet engine has been designed, fabricated, and instrumented. This model is to be tested in an electric arc heated wind tunnel at an altitude of 35.39 km (116,094 ft.) but with an inlet Mach number of 6 simulating precompression on an aircraft undersurface. The scramjet model is constructed from oxygen free, high conductivity copper and is a heat sink design except for water cooling in some critical locations. The model is instrumented for pressure, surface temperature, heat transfer rate, and thrust measurements. Calculated flow properties, heat transfer rates, and surface temperature distributions along the various engine components are included for the conditions stated above. For some components, estimates of thermal strain are presented which indicate significant reductions in plastic strain by selective cooling of the model. These results show that the 100 thermal cycle life of the engine was met with minimum distortion while staying within the 2669 N (600 lbf) engine weight limitation and while cooling the engine only in critical locations.

Guy, R. W.↗

NASA NTRS2011

Ascent Heating Thermal Analysis on Spacecraft Adaptor Fairings

When the Crew Exploration Vehicle (CEV) is launched, the spacecraft adaptor (SA) fairings that cover the CEV service module (SM) are exposed to aero heating. Thermal analysis is performed to compute the fairing temperatures and to investigate whether the temperatures are within the material limits for nominal ascent aeroheating case. The ascent heating is analyzed by using computational fluid dynamics (CFD) and engineering codes at Marshall Space Flight Center. The aeroheating environment data used for this work is known as Thermal Environment 3 (TE3) heating data. One of the major concerns is with the SA fairings covering the CEV SM and the SM/crew launch vehicle (CLV) flange interface. The TE3 heating rate is a function of time, wall temperature, and the spatial locations. The implementation of the TE3 heating rate as boundary conditions in the thermal analysis becomes challenging. The ascent heating thermal analysis on SA fairings and SM/CLV flange interface are performed using two commercial software packages: Cullimore & Ring (C&R) Thermal Desktop (TD) 5.1 and MSC Patran 2007r1 b. TD is the pre-and post-processor for SINDA, which is a finite-difference-based solver. In TD, the geometry is built and meshed, the boundary conditions are defined, and then SINDA is used to compute temperatures. MSC Pthermal is a finite-element- based thermal solver. MSC Patran is the pre- and post-processor for Pthermal. Regarding the boundary conditions, the convection, contact resistance, and heat load can be imposed in different ways in both programs. These two software packages are used to build the thermal model for the same analysis to validate each other and show the differences in the modeling details.

Wang, Xiao Yen↗

DOE OSTI2022

COMPASS-U Global Heat Balance Calculations

COMPASS-U is a medium size, high magnetic field experimental tokamak (R = 0.9 m, B t = 5 T, and I p = 2 MA), built at the Institute of Plasma Physics, Czech Academy of Sciences (IPP-CAS). This global heat balance calculation for COMPASS-U was done at Princeton Plasma Physics Laboratory (PPPL). Based on our previous experience of building global thermal model for National Spherical Torus Experiment-Upgrade (NSTX-U) at PPPL, this 2-D global thermal model geometry represents a typical cross section of COMPASS-U machine. The model includes thermal radiation, conduction, and convection among components and also between the machine and outer environment. Helium gas heating/cooling was modeled with fluid element and surface element. This model was used to calculate component temperatures and heat distribution during heat up, cryogenic cool down, normal operation, and fault operation scenarios. Definition of 14 main thermal scenarios was provided by IPP-CAS. First nine are normal operation scenarios. Scenarios #10–#14 are fault scenarios. Results of thermal scenario #5 will be given and discussed in this article, including peak temperatures, temperature ratcheting, energy distribution, and required cooling power.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Advanced multimaterial shape optimization methods as applied to advanced manufacturing of wind turbine generators

Abstract Currently, many utility‐scale wind turbine generator original equipment manufacturers are dependent on imported rare earth permanent magnets, which are susceptible to market risks from cost instability. To lower the production costs of these generators and stay competitive in the market, several small wind manufacturers are pursuing continuous improvements to both generator design and manufacturing. However, traditional design and manufacturing methods have yielded marginal improvements in wind power performance. This work presents novel methods to redesign a baseline 15‐kW wind turbine generator with reduced rare‐earth permanent magnets by leveraging cutting‐edge three‐dimensional (3D) printed polymer‐bonded permanent magnets and steel. Symmetric, asymmetric, and multimaterial‐magnet parametrization methods are introduced for shape optimization. We extend the symmetric and asymmetric methods to the back iron in the stator to further investigate the impact and opportunities for performance improvements with lesser active materials. We employ a design‐of‐experiments approach with parametric computer‐aided design for shape generation and evaluate different designs by magneto‐thermal modeling and finite‐element analysis. We use adaptive sampling technique to identify better performing designs with lesser magnet mass, higher efficiency, and lower cogging torque when compared with the baseline generator. Asymmetric pole designs resulted in a magnet mass in the range of 4.77–5.37 kg, which was 27%–35% lighter than the baseline generator, suggesting that a new design freedom exists that can be enabled by advanced manufacturing, such as 3D printing. Shaping the back iron in the stator resulted in material savings in electrical steel of up to 14.62 kg, which was 20% lighter than the baseline stator. We conducted a structural analysis to evaluate an optimized asymmetric rotor design from the point of view of mechanical integrity and air‐gap stiffness. The magnetically optimal shape profile was shown as having a positive impact on the radial stiffness, and an optimal solution was discovered to reduce the structural mass by nearly 30 kg, which was 29% lighter than the baseline.

17 WIND ENERGY↗

DOE OSTI2026

Thermal Management for a Novel Non-Heavy Rare-Earth Interior Permanent Magnet Machine

The work presents a thermal management solution for a novel non-heavy rare-earth permanent magnet machine being developed at Oak Ridge National Laboratory. The motor has been designed to minimize losses while maximizing performance for a range of speeds and power ratings. The novel motor design reduces rare-earth magnet usage, thereby avoiding supply chain issues. The motor component heat losses are established for operating windows and desired performance. These heat losses, along with windage losses, are being used to develop cooling solutions for different components of this machine. A novel thermal management solution for stators and rotors has been developed, and progress is presented in this paper. The stator cooling is achieved with the help of water-ethylene glycol flowing over the finned aluminum stator jacket, and rotor cooling with automatic transmission fluid passing through novel channels designed in the rotor laminations. The attempt is to establish effective cooling of the stator winding, laminations, and rotor magnets. A 3D conjugate heat transfer model has been developed for overall thermal analysis to establish a down- selected thermal management solution for the machine. The model, in addition to estimated component heat losses, includes windage losses and its impact on rotor and stator cooling. Overall, the work presents a workable thermal solution for the interior permanent magnet machine with potential for further improvements. Future work will involve establishing end winding and refinement of other end parts of the machine with the aim of establishing a robust thermal management solution. The work will also focus on different shapes (e.g., round, non-round, presence of wedges) of rotor-stator gaps and investigate windage losses and their impact on thermal management for higher rotational speeds for the machine.

30 DIRECT ENERGY CONVERSION↗