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NASA NTRSDate not supplied

Rapid Development of Instrument Thermal Models: Perspectives and Guidelines from NASA Goddard’s Instrument Design Laboratory

The Instrument Design Laboratory (IDL), part of NASA Goddard Space Flight Center’s Integrated Design Center (IDC), is a concurrent and collaborative environment which allows for rapid development of science instrumentation concepts within the span of less than two weeks. Science goals set by a Principal Investigator from government, industry or academia are translated into engineering requirements, from which a team of engineers spanning multiple disciplines use an established study process and a suite of analysis tools to work towards an instrument point design. As part of this process, a staff thermal engineer is tasked with designing a thermal control system which meets all incoming thermal requirements, while iterating real-time with other subsystems to ensure compatibility and functionality as a completed system. Thermal engineers on spaceflight projects typically have weeks or months to develop thermal models. However, the severe time limitation in this conceptual study setting makes thermal design particularly difficult, as rapid thermal modeling solely over the span of a few days is required to develop the instrument thermal design and understand the performance over its intended mission, especially if the instrument concept contains multiple thermal challenges such as dynamic environments or high heat dissipating components. In this paper, the authors provide a condensed guide for the most efficient ways to develop thermal models and conduct thermal analysis within the span of one-to-two weeks, as informed by decades of design experience and best practices in the IDL. The authors also focus on quick methods for determining worst-case thermal environments, deciding which modeling details are essential at this early phase, and quantifying the engineering resources necessary for thermal control. This paper concludes with specific thermal design tips for different instrument types across the electromagnetic spectrum.

Kan Yang↗

NASA NTRS2003

SWIFT BAT Loop Heat Pipe Thermal System Characteristics and Ground/Flight Operation Procedure

The SWIFT Burst Alert Telescope (BAT) Detector Array has a total power dissipation of 208 W. To meet the stringent temperature gradient and thermal stability requirements in the normal operational mode, and heater power budget in both the normal operational and safehold modes, the Detector Array is thermally well coupled to eight constant conductance heat pipes (CCHPs) embedded in the Detector Array Plate (DAP), and two loop heat pipes (LHPs) transport heat fiom the CCHPs to a radiator. The CCHPs have ammonia as the working fluid and the LHPs have propylene as the working fluid. Precision heater controllers, which have adjustable set points in flight, are used to control the LHP compensation chamber and Detector Array XA1 ASIC temperatures. The radiator has the AZ-Tek AZW-LA-II low-alpha white paint as the thermal coating and is located on the anti-sun side of the spacecraft. This paper presents the characteristics, ground operation and flight operation procedures of the LHP thermal system.

Choi, Michael K.↗

NASA NTRS1989

The effect of ballooning modes on thermal transport and magnetic field diffusion in the solar corona

Presently favored mechanisms of coronal heating (current sheet dissipation and Alfven wave resonant heating) deposit heat in thin layers. Classical thermal conduction cannot explain how heat is transported across the magnetic field. If heating occurs in thin layers, large pressure gradients can be created which can give rise to ballooning modes. These instabilities are caused by the pressure gradient and the curvature of the magnetic field, and are stabilized by magnetic tension. The modes are broad band in wavelength and should produce turbulence. A mixing length expression for the turbulent heat transport shows that it is more than adequate to rapidly convect heat into much broader layers. Furthermore, the turbulent resistivity implies that heating occurs over most of the width of these broadened layers. The broadening also implies that much shorter time scales are required for heating. The beta values in the corona suggest that 1-10 turbulent layers are formed in typical loop or arch structures.

Strauss, H. R.↗

NASA NTRS2003

Conducting the Heat

Heat conduction plays an important role in the efficiency and life span of electronic components. To keep electronic components running efficiently and at a proper temperature, thermal management systems transfer heat generated from the components to thermal surfaces such as heat sinks, heat pipes, radiators, or heat spreaders. Thermal surfaces absorb the heat from the electrical components and dissipate it into the environment, preventing overheating. To ensure the best contact between electrical components and thermal surfaces, thermal interface materials are applied. In addition to having high conductivity, ideal thermal interface materials should be compliant to conform to the components, increasing the surface contact. While many different types of interface materials exist for varying purposes, Energy Science Laboratories, Inc. (ESLI), of San Diego, California, proposed using carbon velvets as thermal interface materials for general aerospace and electronics applications. NASA s Johnson Space Center granted ESLI a Small Business Innovation Research (SBIR) contract to develop thermal interface materials that are lightweight and compliant, and demonstrate high thermal conductance even for nonflat surfaces. Through Phase II SBIR work, ESLI created Vel-Therm for the commercial market. Vel-Therm is a soft, carbon fiber velvet consisting of numerous high thermal conductivity carbon fibers anchored in a thin layer of adhesive. The velvets are fabricated by precision cutting continuous carbon fiber tows and electrostatically flocking the fibers into uncured adhesive, using proprietary techniques.

Source record↗

DOE OSTI2024

Power Electronics Thermal Management

The 2017 Electrical and Electronics Technical Team Roadmap [1] proposes aggressive research and development targets aimed at improving power electronics technology to enable the mass-market penetration of electric-drive vehicles. Achieving these aggressive targets will require a decrease in cost (year 2025 cost target: $2.70/kW) and an increase in power density (year 2025 power density target: 100 kW/L) as compared with current on-road technology. Replacing traditional silicon device-based components with more efficient and higher-temperature wide-bandgap (WBG) semiconductor device-based components will enable increased power density. However, meeting the power density target will also require innovative thermal management solutions to increase the heat fluxes dissipated and allow for compact electronics packaging.

ADVANCED PROPULSION SYSTEMS↗

NASA NTRS1988

Shock structure in classical magnetohydrodynamics

How the structure of coplanar MHD fast and slow shocks depends upon the relative magnitudes of the dissipation coefficients contained in classical magnetohydrodynamics is examined. An asymptotic method is used in which the scale lengths for resistivity, thermal conduction, and viscosity are widely separated, and the qualitative dependence of the shock solutions upon the ordering of the scales is studied. Upper limit Mach numbers for both fast and slow shocks are defined at which resistivity and thermal conduction taken together can provide all the shock dissipation and at which viscosity is not needed.

Kennel, Charles F.↗

NASA NTRS1979

Thermal control canister

An apparatus for maintaining a heat dissipating load at a substantially constant temperature, and more particularly, to such an apparatus where in variable conductance heat pipes control the radiating area of a radiator is described.

Ollendorf, S.↗

DOE OSTI2020

Beryllium Oxide (BeO) Handbook

Beryllium oxide (BeO) is an oxide ceramic material. BeO ceramics provide thermal conductivity second only to diamond among electrically insulating materials, dissipating nearly 300 W/mK at room temperature. This property leads to electronic applications for BeO. BeO has a thermal expansion coefficient intermediate between gallium arsenide and refractory metal composites. Its low dielectric constant (6.7) and low loss index (0.0012 at 1 MHz) permits electrical circuit performance at high frequencies. It is employed as a window material for high frequency microwave applications. BeO is very stable under oxidizing and reducing high temperature and high humidity environments, unlike nitrides which will decompose to their oxide equivalent. Similar to beryllium metal, BeO acts as a scatterer of neutrons and is used as a neutron moderator material in nuclear reactor applications. The largest use of BeO is as the raw material for the manufacture of beryllium-copper alloys, followed closely as the raw material for conversion to beryllium metal. Most of the research performed on BeO was conducted in the 1960’s and 1970’s. 75% of the references cited in this Handbook are from the time period 1960-1980. Up to 1995, there were three commercial sources of BeO: Materion Corporation, Eagle-Picher, and Ceradyne Corporation. However, since 1995 Eagle-Picher and Ceradyne no longer supply BeO commercial products. Thus, the only current commercial source of BeO materials is Materion Corporation.

36 MATERIALS SCIENCE↗

NASA NTRS1979

Melting of Io by tidal dissipation

The resonant structure of Io leads to forced eccentricities that are considerably larger than the free values. Although still modest by all standards, these forced eccentricities coupled with the enormous tides induced by Jupiter lead to magnitudes of tidal dissipation that are large enough to completely dominate the thermal history of Io. In the present paper, the forced eccentricities are calculated and then substituted into an expression for the total tidal dissipation. The results point to the possibility that the dissipation of tidal energy in Io may have melted a major fraction of Io's mass.

Peale, S. J.↗

NASA NTRS2019

Safe, High Power/Voltage Battery Module Design Challenges

NASA seeks to demonstrate a path for achieving safe, high power, and high performing Li-ion battery designs for the purpose of establishing design guidelines for our aeronautic and spacecraft applications. Safe means passively resistant to thermal runaway propagation of any single cell catastrophic thermal runaway. High power means capable of 3C continuous discharge without overheating. High performing means achieving > 160 Wh/kg, 200 Wh/L. The biggest challenge has been balancing a high flux light weight path for cell heat dissipation during the high rate discharge that minimizes thermal gradients between cells and also protects adjacent cells from the heat load of thermal runaway cell. Our solution includes an oscillating heat pipe spine that contacts every 18650 cell in the pack and careful cell design selection to maximize the range of initial temperatures conditions where the battery can safely complete the 3C discharge.

Thermal runaway↗

NASA NTRS2012

Development of the GPM Observatory Thermal Vacuum Test Model

A software-based thermal modeling process was documented for generating the thermal panel settings necessary to simulate worst-case on-orbit flight environments in an observatory-level thermal vacuum test setup. The method for creating such a thermal model involved four major steps: (1) determining the major thermal zones for test as indicated by the major dissipating components on the spacecraft, then mapping the major heat flows between these components; (2) finding the flight equivalent sink temperatures for these test thermal zones; (3) determining the thermal test ground support equipment (GSE) design and initial thermal panel settings based on the equivalent sink temperatures; and (4) adjusting the panel settings in the test model to match heat flows and temperatures with the flight model. The observatory test thermal model developed from this process allows quick predictions of the performance of the thermal vacuum test design. In this work, the method described above was applied to the Global Precipitation Measurement (GPM) core observatory spacecraft, a joint project between NASA and the Japanese Aerospace Exploration Agency (JAXA) which is currently being integrated at NASA Goddard Space Flight Center for launch in Early 2014. From preliminary results, the thermal test model generated from this process shows that the heat flows and temperatures match fairly well with the flight thermal model, indicating that the test model can simulate fairly accurately the conditions on-orbit. However, further analysis is needed to determine the best test configuration possible to validate the GPM thermal design before the start of environmental testing later this year. Also, while this analysis method has been applied solely to GPM, it should be emphasized that the same process can be applied to any mission to develop an effective test setup and panel settings which accurately simulate on-orbit thermal environments.

Yang, Kan↗

DOE OSTI2024

A variational phase-field framework for thermal softening and dynamic ductile fracture

A variational phase field model for dynamic ductile fracture is presented. Here, the model is designed for elasto-viscoplastic materials subjected to rapid deformations in which the effects of heat generation and material softening are dominant. The variational framework allows for the consistent inclusion of plastic dissipation in the heat equation as well as thermal softening. It employs a coalescence function to degrade fracture energy during regimes of high plastic flow. A variationally consistent form of the Johnson–Cook model is developed for use with the framework. Results from various benchmark problems in dynamic ductile fracture are presented to demonstrate capabilities. In particular, the ability of the model to regularize shear band formation and subsequent damage evolution in two- and three-dimensional problems is demonstrated. Importantly, these phenomena are naturally captured through the underlying physics without the need for phenomenological criteria such as stability thresholds for the onset of shear band formation.

42 ENGINEERING↗

NASA NTRS2008

Optical Coating Performance and Thermal Structure Design for Heat Reflectors of JWST Electronic Control Unit

The James Webb Space Telescope (JWST) consists of an infrared-optimized Optical Telescope Element (OTE) that is cooled down to 40 degrees Kelvin. A second adjacent component to the OTE is the Integrated Science Instrument Module, or ISIM. This module includes the electronic compartment, which provides the mounting surfaces and ambient thermally controlled environment for the instrument control electronics. Dissipating the 200 watts generated from the ISIM structure away from the OTE is of paramount importance so that the spacecraft's own heat does not interfere with the infrared light detected from distant cosmic sources. This technical challenge is overcome by a thermal subsystem unit that provides passive cooling to the ISIM control electronics. The proposed design of this thermal radiator consists of a lightweight structure made out of composite materials and low-emittance metal coatings. In this paper, we will present characterizations of the coating emittance, bidirectional reflectance, and mechanical structure design that will affect the performance of this passive cooling system.

Quijada, Manuel A.↗

DOE OSTI2020

Device-Level Multidimensional Thermal Dynamics With Implications for Current and Future Wide Bandgap Electronics

Researchers have been extensively studying wide-bandgap (WBG) semiconductor materials such as gallium nitride (GaN) with an aim to accomplish an improvement in size, weight, and power of power electronics beyond current devices based on silicon (Si). However, the increased operating power densities and reduced areal footprints of WBG device technologies result in significant levels of self-heating that can ultimately restrict device operation through performance degradation, reliability issues, and failure. Typically, self-heating in WBG devices is studied using a single measurement technique while operating the device under steady-state direct current measurement conditions. However, for switching applications, this steady-state thermal characterization may lose significance since the high power dissipation occurs during fast transient switching events. Therefore, it can be useful to probe the WBG devices under transient measurement conditions in order to better understand the thermal dynamics of these systems in practical applications. In this work, the transient thermal dynamics of an AlGaN/GaN high electron mobility transistor (HEMT) were studied using thermoreflectance thermal imaging and Raman thermometry. Also, the proper use of iterative pulsed measurement schemes such as thermoreflectance thermal imaging to determine the steady-state operating temperature of devices is discussed. These studies are followed with subsequent transient thermal characterization to accurately probe the self-heating from steady-state down to submicrosecond pulse conditions using both thermoreflectance thermal imaging and Raman thermometry with temporal resolutions down to 15 ns.

42 ENGINEERING↗

NASA NTRS2009

Heat rejection sublimator

A sublimator includes a sublimation plate having a thermal element disposed adjacent to a feed water channel and a control point disposed between at least a portion of the thermal element and a large pore substrate. The control point includes a sintered metal material. A method of dissipating heat using a sublimator includes a sublimation plate having a thermal element and a control point. The thermal element is disposed adjacent to a feed water channel and the control point is disposed between at least a portion of the thermal element and a large pore substrate. The method includes controlling a flow rate of feed water to the large pore substrate at the control point and supplying heated coolant to the thermal element. Sublimation occurs in the large pore substrate and the controlling of the flow rate of feed water is independent of time. A sublimator includes a sublimation plate having a thermal element disposed adjacent to a feed water channel and a control point disposed between at least a portion of the thermal element and a large pore substrate. The control point restricts a flow rate of feed water from the feed water channel to the large pore substrate independent of time.

Dingell, Charles W.↗

NASA NTRS1980

Ring connection for porous combustor wall panels

A gas turbine engine combustor assembly of unique configuration has an outer wall made up of a plurality of axially extending multi-layered porous metal panels joined together at butt joints therebetween by a reinforcing and heat dissipation ring and a unique weld configuration to prevent thermal erosion of the ends of the porous metal panels at the butt joints; the combustor further including a unique inner wall made up of a plurality of like axially extending multi-layered porous metal panels joined at butt joints by a reinforcing and heat dissipation ring on the inner surface of the inner wall panels and an improved butt weld joint that prevents thermal erosion of the ends of the porous metal inner wall panels.

Verdouw, Albert J.↗

NASA NTRS1988

On the prediction of the behavior of the velocity, temperature and humidity fields above a thermally stratified air-water interface

A turbulent kinetic energy-dissipation (k-epsilon) model is employed to numerically simulate the behavior of the mean velocity, temperature and humidity fields, along with such second-order statistics as Reynolds stresses, turbulent heat and mass transfer correlation, and bulk transfer coefficients in the boundary layer above wind-generated laboratory waves. The k and epsilon equations have been properly modified to account for thermal stratification, the presence of free surface, and favorable pressure gradient effects. Predictions are compared with available data.

Papadimitrakis, Yiannis A.↗

DOE OSTI2020

Analytic investigation of combined effects of anisotropic thermal transport and energetic particles on stability of resistive plasma resistive wall mode

The combined effects of anisotropic thermal transport and trapped energetic particles (EPs) on the stability of the resistive plasma resistive wall mode (RPRWM) are investigated by an energy-principle based analytical model. The results qualitatively confirm that of a recent toroidal modeling study [Bai et al., Phys. Plasmas 27, 072502 (2020)], in which the thermal transport can stabilize the RPPWM depending on the parameters of both the plasma equilibrium and energetic particles. The analytical model predicts a complete stabilization of the RPRWM in highly resistive plasmas, at sufficiently high EPs’ pressure, and finite plasma flow. The stabilizing effect of thermal transport originates from its enhancement of energy dissipations associated with both the resistive layer and the trapped energetic particles.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗