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NASA NTRS2003

Aeroheating Thermal Model Correlation for Mars Global Surveyor (MGS) Solar Array

The Mars Global Surveyor (MGS) Spacecraft made use of aerobraking to gradually reduce its orbit period from a highly elliptical insertion orbit to its final science orbit. Aerobraking produces a high heat load on the solar arrays, which have a large surface area exposed to the airflow and relatively low mass. To accurately model the complex behavior during aerobraking, the thermal analysis needed to be tightly coupled to the spatially varying, time dependent aerodynamic heating. Also, the thermal model itself needed to accurately capture the behavior of the solar array and its response to changing heat load conditions. The correlation of the thermal model to flight data allowed a validation of the modeling process, as well as information on what processes dominate the thermal behavior. Correlation in this case primarily involved detailing the thermal sensor nodes, using as-built mass to modify material property estimates, refining solar cell assembly properties, and adding detail to radiation and heat flux boundary conditions. This paper describes the methods used to develop finite element thermal models of the MGS solar array and the correlation of the thermal model to flight data from the spacecraft drag passes. Correlation was made to data from four flight thermal sensors over three of the early drag passes. Good correlation of the model was achieved, with a maximum difference between the predicted model maximum and the observed flight maximum temperature of less than 5%. Lessons learned in the correlation of this model assisted in validating a similar model and method used for the Mars Odyssey solar array aeroheating analysis, which were used during onorbit operations.

Amundsen, Ruth M.↗

DOE OSTI2022

It's All About the Envelope: Prioritizing Envelope Upgrades for Electrification of Cold Climate Homes

Building decarbonization via electrification on a clean grid is the most promising climate solution proposed to date for the building sector. In cold climate zones, building electrification will be driven in large part by moving from natural gas space heating to cold climate heat pumps (CCHPs). CCHPs are commercially available today, including economical cold climate air source heat pumps (ccASHPs). But there's one big problem - wide-scale adoption of ccASHPs will dramatically increase winter peak electricity demand, even with the highest efficiency ccASHP products. Furthermore, cold climate space heating loads will drive unprecedented electric system peaks during the lowest periods of renewable generation and are likely to overwhelm existing distribution systems. This scenario is avoidable by coupling electrification with building envelope upgrades to reduce peak heating loads. This paper presents a model, built from home energy audit and research data sets, that quantifies the above challenges. Results demonstrate how weatherization efforts coupled with additional high-performance envelope upgrade measures can prepare the building stock for electrification and show the benefit these measures can bring to future utility operations. Much of this envelope upgrade work is cost-effective, according to conservative cost-benefit testing and program successes to date, and is coupled with substantial non-energy benefits. However, persistent market barriers have made scaling of envelope retrofit work challenging for decades, suggesting additional policy support is required. Lessons learned from previous policy experience, combined with new technology and administrative support, create exciting potential for this decarbonization climate solution.

air sealing↗

NASA NTRS2014

Simulation for Prediction of Entry Article Demise (SPEAD): an Analysis Tool for Spacecraft Safety Analysis and Ascent/Reentry Risk Assessment

For the purpose of performing safety analysis and risk assessment for a probable offnominal suborbital/orbital atmospheric reentry resulting in vehicle breakup, a synthesis of trajectory propagation coupled with thermal analysis and the evaluation of node failure is required to predict the sequence of events, the timeline, and the progressive demise of spacecraft components. To provide this capability, the Simulation for Prediction of Entry Article Demise (SPEAD) analysis tool was developed. This report discusses the capabilities, modeling, and validation of the SPEAD analysis tool. SPEAD is applicable for Earth or Mars, with the option for 3 or 6 degrees-of-freedom (DOF) trajectory propagation. The atmosphere and aerodynamics data are supplied in tables, for linear interpolation of up to 4 independent variables. The gravitation model can include up to 20 zonal harmonic coefficients. The modeling of a single motor is available and can be adapted to multiple motors. For thermal analysis, the aerodynamic radiative and free-molecular/continuum convective heating, black-body radiative cooling, conductive heat transfer between adjacent nodes, and node ablation are modeled. In a 6- DOF simulation, the local convective heating on a node is a function of Mach, angle-ofattack, and sideslip angle, and is dependent on 1) the location of the node in the spacecraft and its orientation to the flow modeled by an exposure factor, and 2) the geometries of the spacecraft and the node modeled by a heating factor and convective area. Node failure is evaluated using criteria based on melting temperature, reference heat load, g-load, or a combination of the above. The failure of a liquid propellant tank is evaluated based on burnout flux from nucleate boiling or excess internal pressure. Following a component failure, updates are made as needed to the spacecraft mass and aerodynamic properties, nodal exposure and heating factors, and nodal convective and conductive areas. This allows the trajectory to be propagated seamlessly in a single run, inclusive of the trajectories of components that have separated from the spacecraft. The node ablation simulates the decreasing mass and convective/reference areas, and variable heating factor. A built-in database provides the thermo-mechanical properties of For the purpose of performing safety analysis and risk assessment for a probable offnominal suborbital/orbital atmospheric reentry resulting in vehicle breakup, a synthesis of trajectory propagation coupled with thermal analysis and the evaluation of node failure is required to predict the sequence of events, the timeline, and the progressive demise of spacecraft components. To provide this capability, the Simulation for Prediction of Entry Article Demise (SPEAD) analysis tool was developed. This report discusses the capabilities, modeling, and validation of the SPEAD analysis tool. SPEAD is applicable for Earth or Mars, with the option for 3 or 6 degrees-of-freedom (DOF) trajectory propagation. The atmosphere and aerodynamics data are supplied in tables, for linear interpolation of up to 4 independent variables. The gravitation model can include up to 20 zonal harmonic coefficients. The modeling of a single motor is available and can be adapted to multiple motors. For thermal analysis, the aerodynamic radiative and free-molecular/continuum convective heating, black-body radiative cooling, conductive heat transfer between adjacent nodes, and node ablation are modeled. In a 6- DOF simulation, the local convective heating on a node is a function of Mach, angle-ofattack, and sideslip angle, and is dependent on 1) the location of the node in the spacecraft and its orientation to the flow modeled by an exposure factor, and 2) the geometries of the spacecraft and the node modeled by a heating factor and convective area. Node failure is evaluated using criteria based on melting temperature, reference heat load, g-load, or a combination of the above. The failure of a liquid propellant tank is evaluated based on burnout flux from nucleate boiling or excess internal pressure. Following a component failure, updates are made as needed to the spacecraft mass and aerodynamic properties, nodal exposure and heating factors, and nodal convective and conductive areas. This allows the trajectory to be propagated seamlessly in a single run, inclusive of the trajectories of components that have separated from the spacecraft. The node ablation simulates the decreasing mass and convective/reference areas, and variable heating factor. A built-in database provides the thermo-mechanical properties of

Ling, Lisa↗

NASA NTRS1992

Space Station Freedom main truss thermal analysis

The main truss structure of the Permanently Manned Capability configuration of the Space Station Freedom is analyzed in order to evaluate orbital heating loads and determine the temperature distributions and temperature gradients in the structure. The results are to be utilized in a thermal/structure analysis in the determination of thermal stresses and deflections in the truss members caused by solar heating loads and by shadowing of the truss members by other segments of the Space Station as it moves around the orbit. A SINDA thermal finite different model and a TRASYS radiation interchange model of the truss were generated automatically from a NASTRAN finite element structural model. The analysis yielded transient temperature distribution in the truss structure around the orbit, indicating large temperature gradients in the structure.

Warren, Andrew H.↗

NASA NTRS2015

Pressure Profiles in a Loop Heat Pipe Under Gravity Influence

During the operation of a loop heat pipe (LHP), the viscous flow induces pressure drops in various elements of the loop. The total pressure drop is equal to the sum of pressure drops in vapor grooves, vapor line, condenser, liquid line and primary wick, and is sustained by menisci at liquid and vapor interfaces on the outer surface of the primary wick in the evaporator. The menisci will curve naturally so that the resulting capillary pressure matches the total pressure drop. In ground testing, an additional gravitational pressure head may be present and must be included in the total pressure drop when LHP components are placed in a non-planar configuration. Under gravity-neutral and anti-gravity conditions, the fluid circulation in the LHP is driven solely by the capillary force. With gravity assist, however, the flow circulation can be driven by the combination of capillary and gravitational forces, or by the gravitational force alone. For a gravity-assist LHP at a given elevation between the horizontal condenser and evaporator, there exists a threshold heat load below which the LHP operation is gravity driven and above which the LHP operation is capillary force and gravity co-driven. The gravitational pressure head can have profound effects on the LHP operation, and such effects depend on the elevation, evaporator heat load, and condenser sink temperature. This paper presents a theoretical study on LHP operations under gravity neutral, anti-gravity, and gravity-assist modes using pressure diagrams to help understand the underlying physical processes. Effects of the condenser configuration on the gravitational pressure head and LHP operation are also discussed.

0000↗

NASA NTRS2015

Pressure Profiles in a Loop Heat Pipe under Gravity Influence

During the operation of a loop heat pipe (LHP), the viscous flow induces pressure drops in various elements of the loop. The total pressure drop is equal to the sum of pressure drops in vapor grooves, vapor line, condenser, liquid line and primary wick, and is sustained by menisci at liquid and vapor interfaces on the outer surface of the primary wick in the evaporator. The menisci will curve naturally so that the resulting capillary pressure matches the total pressure drop. In ground testing, an additional gravitational pressure head may be present and must be included in the total pressure drop when LHP components are placed in a non-planar configuration. Under gravity-neutral and anti-gravity conditions, the fluid circulation in the LHP is driven solely by the capillary force. With gravity assist, however, the flow circulation can be driven by the combination of capillary and gravitational forces, or by the gravitational force alone. For a gravity-assist LHP at a given elevation between the horizontal condenser and evaporator, there exists a threshold heat load below which the LHP operation is gravity driven and above which the LHP operation is capillary force and gravity co-driven. The gravitational pressure head can have profound effects on the LHP operation, and such effects depend on the elevation, evaporator heat load, and condenser sink temperature. This paper presents a theoretical study on LHP operations under gravity-neutral, anti-gravity, and gravity-assist modes using pressure diagrams to help understand the underlying physical processes. Effects of the condenser configuration on the gravitational pressure head and LHP operation are also discussed.

Thermal Control Systems↗

NASA NTRS1974

Shuttle active thermal control system development testing. Volume 1: Overall summary

A summary is given of a series of thermal vacuum tests designed to support the development of the orbiter active thermal control system (ATCS) and included testing of a wide heat load range modular radiator system (MRS) configured to the March 1973 orbiter baseline system, a candidate weight reducing radiator/water cooling system, and a smaller radiator system with a high performance radiator coating. The tests verified the performance of the baseline system and obtained detailed design information for application of a wide heat load range modular radiator system to the orbiter. The two candidate ATCS weight reducing designs have undergone extensive concept verification testing and their system operating characteristics have been determined in sufficient detail for application to the orbiter. Design information has been obtained for an integrated radiator/water cooling system that provides for vehicle heat rejection as well as water management of the excess fuel cell water. Processing techniques have been developed and verified for the application of a high performance thermal control coating to large radiator areas subjected to a temperature range of -280 F to +160 F.

Howell, H. R.↗

DOE OSTI2025

STORM: Scrape-off layer turbulence in tokamak fusion reactors

The scrape-off layer of a tokamak fusion reactor carries the plasma exhaust from the hot core plasma to the material surfaces of the reactor vessel. The heat loads imposed by the exhaust are a critical limit on the performance of fusion power plants. Turbulent transport of the plasma regulates the width of the scrape-off layer plasma and must be modelled to understand the intensity of these heat loads. STORM is a plasma turbulence code capable of simulating three dimensional turbulence across the full scrape-off layer of a tokamak fusion reactor, using a drift reduced, collisional fluid model. STORM uses mostly finite difference schemes, with a staggered grid in the direction parallel to the magnetic field. We describe the model, geometry and initialisation options used by STORM, as well as the numerical methods, which are implemented using the BOUT++ plasma simulation framework. BOUT++ has been enhanced alongside the development of STORM, providing better support for staggered grid methods. We summarise these enhancements, including a detailed explanation of the parallel derivative methods, which underwent a major update for version 4 of BOUT++.

BOUT++↗

NASA NTRS2007

Effects of Gravity on Start-up of a Miniature Loop Heat Pipe with Multiple Evaporators and Multiple Condensers

This paper describes an experimental study on the effect of gravity on the start-up of a miniature loop heat pipe (MLHP) with two evaporators and two condensers. Each evaporator has an outer diameter of 9 mm and has its own integral compensation chamber (CC). The MLHP was placed under five configurations where the relative elevation and tilt among the loop components were varied. The four well-known initial conditions between the evaporator and CC prior to the LHP start-up were created in this experimental study through combinations of: 1) the test configuration; 2) the method of preconditioning the loop prior to start-up, and 3) the heat load distribution among the evaporators. A total of 165 start-ups were conducted under the five test configurations. All of these start-ups were successful. However, the effect of gravity on start-up transients was clearly seen under otherwise the same heat load distribution and sink temperatures. An analytical model was used to simulate the MLHP transient behaviors, and the model predictions agreed very well with the experimental results.

Ku, Jentung↗

NASA NTRS1991

Cold-tip off-state conduction loss of miniature Stirling cycle cryocoolers

For redundant miniature Stirling-cycle cryocoolers in space applications, the off-state heat conduction down the coldfinger of one cooler is a parasitic heat load on the other coolers. At JPL, a heat flow transducer specifically designed to measure this load has been developed, and measurements have been performed on the coldfinger of a British Aerospace 80 K Stirling cooler with the tip temperature ranging between 40 and 170 K. Measurements have also been made using a transient warmup technique, where the warmup rates of the coldtip under various applied heat loads are used to determine the static conduction load. There is a difference between the results of these two methods, and these differences are discussed with regard to the applicability of the transient warmup method to a nonoperating coldfinger.

Kotsubo, V.↗

DOE OSTI2025

Comprehensive analysis of disruption mitigation methods using gas and pellet-like injections in ITER-like Tokamaks

Abstract Inert-gas shielding could be an effective mechanism for protection of plasma facing surfaces (PFS) against plasma particles impact and photon radiation heat loads during transient events in fusion devices. Neutral gas injection is one promising way to mitigate erosion of tokamak components and contamination. The objective of this work is to study and optimize mitigation methods using neutral gas and pellet-like injections to decrease the heat load to the divertor surfaces and to prevent vaporization of the various internal surfaces due to transient events in ITER-like devices. The integrated self-consistent models implemented in the HEIGHTS package was used for detailed analysis of the potential secondary plasma generation from the injected inert gas, its radiative characteristics, and shielding effectiveness. We varied the density, size, and location of an argon gas cloud to minimize the disruption energy deposited into the divertor components. We also investigated innovative ways for minor changes in ITER-like internal design to mitigate disruptions. We found the optimum parameters to fully protect ITER tokamak surfaces from erosion and vaporization during plasma instabilities. This preliminary analysis showed that using Ar gas injection methods could lead to enhancement in components lifetime in ITER-like and future DEMO devices with minor design changes.

Science & Technology - Other Topics↗

NASA NTRS2001

An Experimental Study of the Operating Temperature in a Loop Heat Pipe with Two Evaporators and Two Condensers

This paper presents a comprehensive experimental study of the loop operating temperature in a loop heat pipe (LHP) which has two parallel evaporators and two parallel condensers. In a single evaporator LHP, it is well known that the loop operating temperature is a function of the heat load, the sink temperature and the ambient temperature. The objective of the present study emphasizes on the stability of the loop operating temperature and parameters that affects the loop operation. Tests results show that the loop operating temperature is a function of the total system heat load, sink temperature, ambient temperature, and beat load distribution between the two evaporators. Under most conditions, only one compensation chamber (CC) contains two-phase fluid and controls the loop operating temperature, and the other CC is completely filled with liquid. Moreover, as the test condition changes, control of the loop operating temperature often shifted from one CC to another. In spite of complex interactions between various components, the test loop has demonstrated very robust operation even during fast transients.

Ku, Jentung↗

DOE OSTI2022

Economic viability of using thermal energy storage for flexible carbon capture on natural gas power plants

Fossil fuel-based power plants generate 80% of the electricity in the United States and provide a reliable generation source for both base and peak power demands. These plants are expected to adapt to changes in environmental policies that will require carbon management with carbon capture and storage (CCS) representing a possible solution. Current solvent-based CCS has a detrimental impact on a power plant's performance due to large heat loads required for carbon capture solvent regeneration. This parasitic load restricts the power plant's output and operation flexibility. Therefore, this study evaluates the feasibility of using thermal storage technologies for natural gas combined cycle (NGCC) power plants coupled with CCS to minimize the impact of solvent regeneration and enable the plant to operate at peak power output. Thermal storage can minimize the impact of CCS on the power plant by providing the heat load required for solvent regeneration during times of peak demand which will allow the plant to operate unrestricted and at full power. In total, fifteen unique thermal storage configurations were evaluated from three thermal storage categories: Brayton cycle heat pump, vapor compression heat pump, and heat recovery steam generator steam extraction for storage. The viability of these systems was determined by evaluating each configuration on thousands of real-world Locational Marginal Pricing (LMP) profiles from the New York Independent System Operator and California Independent System Operator electricity markets using a techno-economic analysis. Afterwards, results were compared to the performance of a base power plant (NGCC with CCS and no thermal storage) to determine the impact of thermal storage on power plant economics. Overall, six of the thermal storage configurations performed better than base CCS enabled power plant on between 11.5% and 38.7% of the LMP signals evaluated. The best performing configuration was a vapor compression heat pump that used flue gas as the working fluid and had both hot and cold thermal storage units. This configuration performed better than the base CCS power plant on 38.7% of the LMP profiles. The results of this study show thermal storage can mitigate the economic impact of carbon capture solvent regeneration on NGCC power plants. Discussion focuses on the impact of electricity pricing on the optimal thermal storage system, the advantages and disadvantages of the systems evaluated, and identifies limitations with the study.

25 ENERGY STORAGE↗

NASA NTRS1972

Techniques associated with thermal-vacuum testing of the OAO-C heat pipes

The mechanical problems associated with testing the two high-heat load pipes are discussed. One of these pipes was tested three times before being accepted. The first test resulted in the discovery of non-condensable hydrogen gas, which prevented the pipe from functioning properly. The second test was a repeat of the first, to see if all the gas had been removed. The third test was to see if any changes had occurred to the pipe as a result of saddle modifications. Saddle modifications were necessary because the epoxy binding agent between the saddles and the pipe had decomposed during the testing. The test problems discussed deal with the specially designed heat-removal devices, the mobile tilt table, the table position indicator, and the heat input mechanisms, all of which were necessary to conduct a high-heat load, thermal-vacuum test. The final results showed that the techniques used were adequate for thermal-vacuum testing of heat pipes.

Marshburn, J. P.↗

NASA NTRS1973

Study and development of a cryogenic heat exchanger for life support systems

A prototype cryogenic heat exchanger for removal of waste heat from a spacecraft environmental control life support system was developed. The heat exchanger uses the heat sink capabilities of the cryogenic propellants and, hence, can operate over all mission phases from prelaunch to orbit, to post landing, with quiescent periods during orbit. A survey of candidate warm fluids resulted in the selection of E-2, a fluorocarbon compound, because of its low freezing point and high boiling point. The final design and testing of the heat exchanger was carried out, however, using Freon-21, which is similar to E-2 except for its low boiling point. This change was motivated by the desire for cost effectiveness of the experimental program. The transient performance of the heat exchanger was demonstrated by an analog simulation of the heat sink system. Under the realistic transient heat load conditions (20 sec ramp from minimum to maximum Freon-21 inlet temperature), the control system was able to maintain the warm fluid outlet temperature within + or - 3 F. For a 20-sec ramp from 0 F to -400 F in the hydrogen inlet temperature, at maximum heat load, the warm fluid outlet temperature was maintained within + or - 7 F.

Soliman, M. M.↗

NASA NTRSDate not supplied

Extreme Environment Hot Fire Durability of Post-Processed Additively Manufactured GRCop-Alloy Combustion Chambers in LOX/Hydrogen and LOX/Methane

Extreme environment survivability of metal additive manufactured (AM) GRCop-alloy thrust chambers has been demonstrated in different bi-propellants at near stoichiometric and even oxygen rich combustion. GRCop-alloy chambers tested at NASA Marshall Space Flight Center (MSFC) have accumulated over 26,000 seconds of hot fire duration and over 500 starts. These chambers are produced using an AM process called laser powder bed fusion (L-PBF). A major feature of this process is high wall surface roughness which can be customized in post processing to leverage various performance advantages. Post-processing can include heat treatment, final machining, polishing, and welding and is key to hardware survivability in extreme environments. Surface finish enhancement techniques were applied to the hot wall and coolant channels to reduce the overall total heat load to the chamber walls. Performance optimization of various thrust class TCA’s is a strategic technology goal of NASA MSFC. Three different chamber geometries using cryogenic methane and de-ionized water as coolants were hot fire tested to obtain their life cycle, pressure drop, and heat load performances. Several 1.2K lbf LOX/H2 chambers, 1K lbf LOX/CH4 chambers, and 7K lbf LOX/CH4 chambers were tested. All post-processed configurations performed remarkably well when subjected to extreme hot fire test conditions. Streaking and blanching due to localized oxygen rich conditions were observed on some test articles in their as-built surface finish state. However, this is actually a function of the injector mixing and only serves to further establish the durability of L-PBF GRCop-alloy thrust chambers. Several different polishing techniques were applied to the hot wall and integrated coolant channels prior to hot fire testing and their performances assessed. Overall, AM produced GRCop chambers are extremely reliable, durable, and customizable to the desired performance metrics.

grcop↗

NASA NTRS2011

Spacecraft Radiator Freeze Protection Using a Regenerative Heat Exchanger

An active thermal control system architecture has been modified to include a regenerative heat exchanger (regenerator) inboard of the radiator. Rather than using a radiator bypass valve a regenerative heat exchanger is placed inboard of the radiators. A regenerator cold side bypass valve is used to set the return temperature. During operation, the regenerator bypass flow is varied, mixing cold radiator return fluid and warm regenerator outlet fluid to maintain the system setpoint. At the lowest heat load for stable operation, the bypass flow is closed off, sending all of the flow through the regenerator. This lowers the radiator inlet temperature well below the system set-point while maintaining full flow through the radiators. By using a regenerator bypass flow control to maintain system setpoint, the required minimum heat load to avoid radiator freezing can be reduced by more than half compared to a radiator bypass system.

Ungar, Eugene K.↗

DOE OSTI2021

Controlling the size of non-axisymmetric magnetic footprints using resonant magnetic perturbations

The structure of the non-axisymmetric heat load distribution at the divertor plates is determined not only by the toroidal but also from the poloidal spectrum of non-axisymmetric field perturbations. Whether they are intrinsic, like error fields, or they are applied through 3D coils, the non-axisymmetric fields produce complex 3D edge magnetic topologies (footprints) that alter the properties of the heat and particle flux distributions on the divertor target plates. In this manuscript, a study of the impact of applied 3D field poloidal spectrum on the footprint size and structure is done for the DIII-D tokamak using the resistive MHD code M3D-C1 coupled with the field line tracing code TRIP3D. To resolve the impact of the poloidal spectrum of the magnetic perturbation, the relative phase of the two rows of in-vessel 3D coils used to produce both a n = 2 and a n = 3 perturbation is varied, where n is the toroidal harmonic of the magnetic perturbation. This shows that the largest footprint is predicted when the relative phase of the two rows is close to zero, which is also where the resonant coupling with the plasma is maximized. These results suggest that it will be challenging to decouple the footprint size from the requisite resonant coupling for RMP–ELM control. The correlation between the measured heat load and particle flux distributions at the outer divertor plates in DIII-D and the magnetic measurements is in good agreement with the predicted dependence of the magnetic footprint size on the amplitude of the resonant component of the plasma response.

3D fields↗