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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

Metallization for Yb14MnSb11-Based Thermoelectric Materials

Thermoelectric materials provide a means for converting heat into electrical power using a fully solid-state device. Power-generating devices (which include individual couples as well as multicouple modules) require the use of ntype and p-type thermoelectric materials, typically comprising highly doped narrow band-gap semiconductors which are connected to a heat collector and electrodes. To achieve greater device efficiency and greater specific power will require using new thermoelectric materials, in more complex combinations. One such material is the p-type compound semiconductor Yb14MnSb11 (YMS), which has been demonstrated to have one of the highest ZT values at 1,000 C, the desired operational temperature of many space-based radioisotope thermoelectric generators (RTGs). Despite the favorable attributes of the bulk YMS material, it must ultimately be incorporated into a power-generating device using a suitable joining technology. Typically, processes such as diffusion bonding and/or brazing are used to join thermoelectric materials to the heat collector and electrodes, with the goal of providing a stable, ohmic contact with high thermal conductivity at the required operating temperature. Since YMS is an inorganic compound featuring chemical bonds with a mixture of covalent and ionic character, simple metallurgical diffusion bonding is difficult to implement. Furthermore, the Sb within YMS readily reacts with most metals to form antimonide compounds with a wide range of stoichiometries. Although choosing metals that react to form high-melting-point antimonides could be employed to form a stable reaction bond, it is difficult to limit the reactivity of Sb in YMS such that the electrode is not completely consumed at an operating temperature of 1,000 C. Previous attempts to form suitable metallization layers resulted in poor bonding, complete consumption of the metallization layer or fracture within the YMS thermoelement (or leg).

Firdosy, Samad↗
NASA NTRS2004

Thermal Energy Conversion Branch

The Thermal Energy Conversion Branch (5490) leads the way in designing, conducting, and implementing research for the newest thermal systems used in space applications at the NASA Glenn Research Center. Specifically some of the most advanced technologies developed in this branch can be broken down into four main areas: Dynamic Power Systems, Primary Solar Concentrators, Secondary Solar Concentrators, and Thermal Management. Work was performed in the Dynamic Power Systems area, specifically the Stirling Engine subdivision. Today, the main focus of the 5490 branch is free-piston Stirling cycle converters, Brayton cycle nuclear reactors, and heat rejection systems for long duration mission spacecraft. All space exploring devices need electricity to operate. In most space applications, heat energy from radioisotopes is converted to electrical power. The Radioisotope Thermoelectric Generator (RTG) already supplies electricity for missions such as the Cassini Spacecraft. The focus of today's Stirling research at GRC is aimed at creating an engine that can replace the RTG. The primary appeal of the Stirling engine is its high system efficiency. Because it is so efficient, the Stirling engine will significantly reduce the plutonium fuel mission requirements compared to the RTG. Stirling is also being considered for missions such as the lunar/Mars bases and rovers. This project has focused largely on Stirling Engines of all types, particularly the fluidyne liquid piston engine. The fluidyne was developed by Colin D. West. This engine uses the same concepts found in any type of Stirling engine, with the exception of missing mechanical components. All the working components are fluid. One goal was to develop and demonstrate a working Stirling Fluidyne Engine at the 2nd Annual International Energy Conversion Engineering Conference in Providence, Rhode Island.

Bielozer, Matthew C.↗
NASA NTRS1992

Making Conductive, Compliant Heat-Transfer Pads

Composite copper/tungsten pads developed for use in thermoelectric generators. Pads thermally and electrically conductive and compliant enough to accommodate large mismatches in thermal expansion between different parts. Each pad consists of tungsten fibers in copper matrix interconnecting pair of tungsten face sheets.

Douglas, Lawrence E.↗
NASA NTRS1982

Computer modeling of thermoelectric generator performance

Features of the DEGRA 2 computer code for simulating the operations of a spacecraft thermoelectric generator are described. The code models the physical processes occurring during operation. Input variables include the thermoelectric couple geometry and composition, the thermoelectric materials' properties, interfaces and insulation in the thermopile, the heat source characteristics, mission trajectory, and generator electrical requirements. Time steps can be specified and sublimation of the leg and hot shoe is accounted for, as are shorts between legs. Calculations are performed for conduction, Peltier, Thomson, and Joule heating, the cold junction can be adjusted for solar radition, and the legs of the thermoelectric couple are segmented to enhance the approximation accuracy. A trial run covering 18 couple modules yielded data with 0.3% accuracy with regard to test data. The model has been successful with selenide materials, SiGe, and SiN4, with output of all critical operational variables.

Chmielewski, A. B.↗
NASA NTRS1972

Long term tests of a SNAP-19 thermoelectric generator.

Results of tests performed on a SNAP 19 thermoelectric generator, SN-20. The SN-20 generator was tested for approximately 37,000 hours using electrical heating to simulate the heat released by isotope decay. After 27,000 hours of operation the output power from the generator decreased to approximately 1/3 of the beginning of life value while the internal resistance increased by a factor of 5. Analysis of the test results, confirmed by preliminary metallographic examination, indicated that the output power degradation was the result of excessive sublimation of the thermoelectric material and loss of the hot junction bond due to the depletion of the internal cover gas. This also resulted in excessive junction temperatures. Comparison is made with the behavior observed from the two flight generators and a tentative conclusion is advanced as to the reason for their failure.

Rouklove, P.↗
NASA NTRS2009

Compatibility of Segments of Thermoelectric Generators

A method of calculating (usually for the purpose of maximizing) the power-conversion efficiency of a segmented thermoelectric generator is based on equations derived from the fundamental equations of thermoelectricity. Because it is directly traceable to first principles, the method provides physical explanations in addition to predictions of phenomena involved in segmentation. In comparison with the finite-element method used heretofore to predict (without being able to explain) the behavior of a segmented thermoelectric generator, this method is much simpler to implement in practice: in particular, the efficiency of a segmented thermoelectric generator can be estimated by evaluating equations using only hand-held calculator with this method. In addition, the method provides for determination of cascading ratios. The concept of cascading is illustrated in the figure and the definition of the cascading ratio is defined in the figure caption. An important aspect of the method is its approach to the issue of compatibility among segments, in combination with introduction of the concept of compatibility within a segment. Prior approaches involved the use of only averaged material properties. Two materials in direct contact could be examined for compatibility with each other, but there was no general framework for analysis of compatibility. The present method establishes such a framework. The mathematical derivation of the method begins with the definition of reduced efficiency of a thermoelectric generator as the ratio between (1) its thermal-to-electric power-conversion efficiency and (2) its Carnot efficiency (the maximum efficiency theoretically attainable, given its hot- and cold-side temperatures). The derivation involves calculation of the reduced efficiency of a model thermoelectric generator for which the hot-side temperature is only infinitesimally greater than the cold-side temperature. The derivation includes consideration of the ratio (u) between the electric current and heat-conduction power and leads to the concept of compatibility factor (s) for a given thermoelectric material, defined as the value of u that maximizes the reduced efficiency of the aforementioned model thermoelectric generator.

Snyder, G. Jeffrey↗
NASA NTRS2002

The synthesis of CaZn2Sb2 and its thermoelectric properties

CaZn2Sb2 was prepared and examined for use as a hightemperature thermoelectric material. It has a high Seebeck coefficient and high electrical conductivity-comparable to B-Zn4Sb3. These two properties are vital in determining the ability of the compound to change heat into electricity isentropically.

thermoelectric power generation segmented↗
NASA NTRS1980

Electric energy production by particle thermionic-thermoelectric power generators

Thermionic-thermoelectric power generators, composed of a thin layer of porous, low work function material separating a heated emitter electrode and a cooler collector electrode, have extremely large Seebeck coefficients of over 2 mV/K and can provide significant output power. Preliminary experiments with 20-micron thick (Ba Sr Ca)O coatings, limited by evaporative loss to temperatures below 1400 K, have yielded short circuit current densities of 500 mA/sq cm and power densities of 60 mW/ sq cm. Substantially more output is expected with cesium-coated refractory oxide particle coatings operating at higher temperatures. Practical generators will have thermal-to-electrical efficiencies of 10 to 20%. Further increases can be gained by cascading these high-temperature devices with lower temperature conventional thermoelectric generators.

Oettinger, P. E.↗
NASA NTRS1986

Brush-Type Connectors for Thermoelectric Elements

Wire brushes used to connect positive and negative legs of semiconductor thermoelectric generators to power leads and heat sources and sinks. Brushes are flexible thermal and electrical conductors that readily accommodate expansion and contraction of legs with changing temperature. Thus, direct conductive coupling between heat source and sink allowed, in contrast to older and less efficient method of having to couple radiatively to accommodate thermal expansion.

Wood, C.↗
NASA NTRS1985

Thermally-Rechargeable Electrochemical Cell

Proposed liquid-sodium/sulfur electrochemical cell recharged by heat, rather than electric generator. Concept suitable for energy storage for utilites, mobile electronic equipment, and solar thermoelectric power systems. Sodium ions driven across membrane with aid of temperature differential.

Richter, R.↗
NASA NTRS2011

CO2 Insulation for Thermal Control of the Mars Science Laboratory

The National Aeronautics and Space Administration (NASA) is sending a large (>850 kg) rover as part of the Mars Science Laboratory (MSL) mission to Mars in 2011. The rover's primary power source is a Multi-Mission Radioisotope Thermoelectric Generator (MMRTG) that generates roughly 2000 W of heat, which is converted to approximately 110 W of electrical power for use by the rover electronics, science instruments, and mechanism-actuators. The large rover size and extreme thermal environments (cold and hot) for which the rover is designed for led to a sophisticated thermal control system to keep it within allowable temperature limits. The pre-existing Martian atmosphere of low thermal conductivity CO2 gas (8 Torr) is used to thermally protect the rover and its components from the extremely cold Martian environment (temperatures as low as -130 deg C). Conventional vacuum based insulation like Multi Layer Insulation (MLI) is not effective in a gaseous atmosphere, so engineered gaps between the warm rover internal components and the cold rover external structure were employed to implement this thermal isolation. Large gaps would lead to more thermal isolation, but would also require more of the precious volume available within the rover. Therefore, a balance of the degree of thermal isolation achieved vs. the volume of rover utilized is required to reach an acceptable design. The temperature differences between the controlled components and the rover structure vary from location to location so each gap has to be evaluated on a case-by-case basis to arrive at an optimal thickness. For every configuration and temperature difference, there is a critical thickness below which the heat transfer mechanism is dominated by simple gaseous thermal conduction. For larger gaps, the mechanism is dominated by natural convection. In general, convection leads to a poorer level of thermal isolation as compared to conduction. All these considerations play important roles in the optimization process. A three-step process was utilized to design this insulation. The first step is to come up with a simple, textbook based, closed-form equation assessment of gap thickness vs. resultant thermal isolation achieved. The second step is a more sophisticated numerical assessment using Computational Fluid Dynamics (CFD) software to investigate the effect of complicated geometries and temperature contours along them to arrive at the effective thermal isolation in a CO2 atmosphere. The third step is to test samples of representative geometries in a CO2 filled chamber to measure the thermal isolation achieved. The results of these assessments along with the consistency checks across these methods leads to the formulation of design-guidelines for gap implementation within the rover geometry. Finally, based on the geometric and functional constraints within the real rover system, a detailed design that accommodates all these factors is arrived at. This paper will describe in detail this entire process, the results of these assessments and the final design that was implemented.

CO2↗
NASA NTRS2002

A study of hear sink performance in air and soil for use in a thermoelectric energy harvesting device

A suggested application of a thermoelectric generator is to exploit the natural temperature difference between the air and the soil to generate small amounts of electrical energy. Since the conversion efficiency of even the best thermoelectric generators available is very low, the performance of the heat sinks providing the heat flow is critical. By providing a constant heat input to various heat sinks, field tests of their thermal conductances in soil and in air were performed. Aprototype device without a thermoelectric generator was constructed, buried, and monitored to experimentally measure the heat flow achievable in such a system. Theoretical considerations for design and selection of improved heat sinks are also presented. In particular, the method of shape factoranalysis is used to give rough estimates and upper bounds for the thermal conductance of a passive heat sink buried in soil.

Thermoelectric power generation↗
NASA NTRS2013

Performance of the Mechanically Pumped Fluid Loop Rover Heat Rejection System Used for Thermal Control of the Mars Science Laboratory Curiosity Rover on the Surface of Mars

The challenging range of landing sites for which the Mars Science Laboratory Rover was designed, required a rover thermal management system that is capable of keeping temperatures controlled across a wide variety of environmental conditions. On the Martian surface where temperatures can be as cold as -123 C and as warm as 38 C, the Rover relies upon a Mechanically Pumped Fluid Loop (MPFL) Rover Heat Rejection System (RHRS) and external radiators to maintain the temperature of sensitive electronics and science instruments within a -40 C to +50 C range. The RHRS harnesses some of the waste heat generated from the Rover power source, known as the Multi Mission Radioisotope Thermoelectric Generator (MMRTG), for use as survival heat for the rover during cold conditions. The MMRTG produces 110 Watts of electrical power while generating waste heat equivalent to approximately 2000 Watts. Heat exchanger plates (hot plates) positioned close to the MMRTG pick up this survival heat from it by radiative heat transfer and supply it to the rover. This design is the first instance of use of a RHRS for thermal control of a rover or lander on the surface of a planet. After an extremely successful landing on Mars (August 5), the rover and the RHRS have performed flawlessly for close to an earth year (half the nominal mission life). This paper will share the performance of the RHRS on the Martian surface as well as compare it to its predictions.

Mars↗
NASA NTRS2013

CFD Analysis for Assessing the Effect of Wind on the Thermal Control of the Mars Science Laboratory Curiosity Rover

The challenging range of landing sites for which the Mars Science Laboratory Rover was designed, requires a rover thermal management system that is capable of keeping temperatures controlled across a wide variety of environmental conditions. On the Martian surface where temperatures can be as cold as -123 C and as warm as 38 C, the rover relies upon a Mechanically Pumped Fluid Loop (MPFL) Rover Heat Rejection System (RHRS) and external radiators to maintain the temperature of sensitive electronics and science instruments within a -40 C to 50 C range. The RHRS harnesses some of the waste heat generated from the rover power source, known as the Multi Mission Radioisotope Thermoelectric Generator (MMRTG), for use as survival heat for the rover during cold conditions. The MMRTG produces 110 W of electrical power while generating waste heat equivalent to approximately 2000 W. Heat exchanger plates (hot plates) positioned close to the MMRTG pick up this survival heat from it by radiative heat transfer. Winds on Mars can be as fast as 15 m/s for extended periods. They can lead to significant heat loss from the MMRTG and the hot plates due to convective heat pick up from these surfaces. Estimation of this convective heat loss cannot be accurately and adequately achieved by simple textbook based calculations because of the very complicated flow fields around these surfaces, which are a function of wind direction and speed. Accurate calculations necessitated the employment of sophisticated Computational Fluid Dynamics (CFD) computer codes. This paper describes the methodology and results of these CFD calculations. Additionally, these results are compared to simple textbook based calculations that served as benchmarks and sanity checks for them. And finally, the overall RHRS system performance predictions will be shared to show how these results affected the overall rover thermal performance.

wind↗
NASA NTRS1990

Thermoelectric power conversion in space

A radiatively-heated multicouple for use in the next generation of radioisotope thermoelectric generator (RTG) will employ 20 individual couples within a single cell, so that 40 n- and p-semiconductor legs will be interconnected in series. At the hot end of the RTG, the legs will be electrically interconnected using silicon molybdenum; on the cold side, the legs are interconnected by tungsten. The entire cell is then mechanically attached to a radiator, which conducts heat away and radiates it into space. Deep-space applications will use RTGs developed for vacuum operation; thermoelectric converter power systems using a unicouple configuration have flown on such missions as Pioneers 10 and 11, which used lead telluride thermoelectric converters, and Voyagers I and II, which used silicon germanium-based thermoelectrics.

Awaya, Henry I.↗
NASA NTRS2005

Making the Most of Waste Energy

The Thermo-Mechanical Systems Branch at NASA s Glenn Research Center is responsible for planning and conducting research efforts to advance thermal systems for space, aerospace, and non-aerospace applications. Technological areas pertain to solar and thermal energy conversion. For example, thermo-mechanical systems researchers work with gas (Stirling) and liquid/vapor (Rankine) systems that convert thermal energy to electrical power, as well as solar dynamic power systems that concentrate sunlight to electrical power. The branch s development of new solar and thermal energy technologies is propelling NASA s missions deep into unfamiliar territories of space. Solar dynamic power systems are actively improving the health of orbiting satellites, giving them longer life and a stronger radiation tolerance, thus, creating less need for on-orbit maintenance. For future missions, NASA may probe even deeper into the mysterious cosmos, with the adoption of highly efficient thermal energy converters that have the potential to serve as the source of onboard electrical power for satellites and spacecraft. Research indicates that these thermal converters can deliver up to 5 times as much power as radioisotope thermoelectric generators in use today, for the same amount of radioisotope. On Earth, energy-converting technologies associated with NASA s Thermo-Mechanical Systems Branch are being used to recover and transform low-temperature waste heat into usable electric power, with a helping hand from NASA.

Source record↗
NASA NTRS1973

An evaluation of some special techniques for nuclear waste disposal in space

A preliminary examination is reported of several special ways for space disposal of nuclear waste material which utilize the radioactive heat in the waste to assist in the propulsion for deep space trajectories. These include use of the wastes in a thermoelectric generator (RTG) which operates an electric propulsion device and a radioisotope - thermal thruster which uses hydrogen or ammonia as the propellant. These propulsive devices are compared to the space tug and the space tug/solar electric propulsion combination for disposal of waste on a solar system escape trajectory. Such comparisons indicate that the waste-RTG approach has considerable potential provided the combined specific mass of the waste container - RTG system does not exceed approximately 150 kg/kw sub e. Several exploratory numerical calculations have been made for high earth orbit and Earth escape destinations.

Mackay, J. S.↗
NASA NTRS1972

Design point characteristics of a 500 - 2500 watt isotope-Brayton power system.

An analytical study was conducted to investigate the potential performance characteristics of an isotope-Brayton space power system at electric power levels from 500 to 2500 W. Utilization of the Pu 238 heat source, or capsule, being developed for the Multi-Hundred Watt Radioisotope Thermoelectric Generator was assumed. A single-loop system design concept was selected. The design concept and results of first-order tradeoff studies of the effects of major system parameters on system performance are presented. Results of the study indicate the potential for high system efficiency and high specific power over the entire power range.

Barna, G. J.↗