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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Material Plasma Exposure eXperiment High Heat Flux Microwave Absorber Design, Manufacture, and Articles Test

The Material Plasma Exposure eXperiment (MPEX) at Oak Ridge National Laboratory is in the final design phase. MPEX will be capable of exposing neutron-irradiated materials to plasmas for the study of plasma-material interaction. This facility will provide information about the complex effects of plasmas on materials and contribute to examining new materials that can withstand high heat fluxes and high ion fluences for future fusion devices. MPEX plasma is heated by 70-GHz or 105-GHz electron Bernstein wave/electron cyclotron heating (ECH), and the high-frequency microwaves are prone to scattering microwave power, which can have detrimental effects, especially on diagnostic components. A large portion of the injected ECH power is expected to be absorbed by plasma, but the remainder requires that microwave absorbers be placed immediately upstream and downstream of the ECH launcher to minimize stray microwaves leaving the ECH region. These microwaves can inadvertently heat components that cannot be shielded or otherwise protected. The microwave absorber design is based on an array of pyramid-shaped ceramic tiles brazed to a water-cooled explosion-bonded heat sink and a stainless steel plate to produce one tile module. Computational fluid dynamics and structural analyses were performed to optimize and validate the design. Multiple test coupons were produced to validate the process for brazing the two different tile materials to the Glidcop AL-15 baseplate. The articles were tested to evaluate the reliability and thermal performance through exposure to an electron beam with a heat flux of up to 1.5 MW/m2. Nondestructive testing was performed before and after testing to identify voids or separations that may have been introduced by the high heat flux. This paper discusses the details of high heat flux microwave absorber design, manufacturing details and associated challenges, and test results, demonstrating the effectiveness of the proposed design.

Hussain, Aftab↗
NASA NTRS2011

Monitoring Delamination of Thermal Barrier Coating During Interrupted High-Heat Flux Laser Testing Using Upconversion Luminescence Imaging

Upconversion luminescence imaging of thermal barrier coatings (TBCs) has been shown to successfully monitor TBC delamination progression during interrupted furnace cycling. However, furnace cycling does not adequately model engine conditions where TBC-coated components are subjected to significant heat fluxes that produce through-thickness temperature gradients that may alter both the rate and path of delamination progression. Therefore, new measurements are presented based on luminescence imaging of TBC-coated specimens subjected to interrupted high-heat-flux laser cycling exposures that much better simulate the thermal gradients present in engine conditions. The TBCs tested were deposited by electron-beam physical vapor deposition (EB-PVD) and were composed of 7wt% yttria-stabilized zirconia (7YSZ) with an integrated delamination sensing layer composed of 7YSZ co-doped with erbium and ytterbium (7YSZ:Er,Yb). The high-heat-flux exposures that produce the desired through-thickness thermal gradients were performed using a high power CO2 laser operating at a wavelength of 10.6 microns. Upconversion luminescence images revealed the debond progression produced by the cyclic high-heat-flux exposures and these results were compared to that observed for furnace cycling.

Eldridge, Jeffrey I.↗
NASA NTRS2007

High-Heat-Flux Cyclic Durability of Thermal and Environmental Barrier Coatings

Advanced ceramic thermal and environmental barrier coatings will play an increasingly important role in future gas turbine engines because of their ability to protect the engine components and further raise engine temperatures. For the supersonic vehicles currently envisioned in the NASA fundamental aeronautics program, advanced gas turbine engines will be used to provide high power density thrust during the extended supersonic flight of the aircraft, while meeting stringent low emission requirements. Advanced ceramic coating systems are critical to the performance, life and durability of the hot-section components of the engine systems. In this work, the laser and burner rig based high-heat-flux testing approaches were developed to investigate the coating cyclic response and failure mechanisms under simulated supersonic long-duration cruise mission. The accelerated coating cracking and delamination mechanism under the engine high-heat-flux, and extended supersonic cruise time conditions will be addressed. A coating life prediction framework may be realized by examining the crack initiation and propagation in conjunction with environmental degradation under high-heat-flux test conditions.

Zhu, Dongming↗
DOE OSTI2024

Development of a Hybrid Single/Two-Phase Capillary-Based Micro-Cooler Using Copper Inverse Opals Wick with Silicon 3D Manifold for High-Heat-Flux Cooling Application: Preprint

Previously, two-phase capillary-based cooling from narrow (200-1,000 micrometer) heater-bridge copper inverse opal (CIO) wicks with heat flux levels exceeding 1,400 watts per square cm with a low superheat of approximately 10 degrees C was demonstrated. Here, we demonstrate the area scaling of the proposed technology to large-area micro-cooler for the high-heat-flux cooling of microprocessors and power electronics. We developed a hybrid single/two-phase micro-cooler that relies on capillary wicking in 25-micrometer-thick CIOs with an open channel silicon 3D-manifold for liquid delivery and vapor extraction, to achieve a high heat flux of approximately 400 watts per square cm over a heated area of 1 square cm. For the range of inlet water (21 degrees C water temperature) flowrates from 5 to 60 mL per min, we achieved total thermal resistances and vapor qualities of 0.68-0.2 square cm Kelvin per watt and 0.55-0.12, respectively. The high heat flux levels are achieved with flowrates that are 10 times smaller than conventional single- or two-phase microchannel cooling technology. The corresponding two-phase thermal resistances are in the range of 0.05 to 0.02 square cm Kelvin per watt with temperature superheat of 8 to 6 degrees C. While the overall performance of the large-area (10 by 10 square millimeter) capillary-based micro-cooler degraded compared to previous demonstration of the technology for a heated area of 5 by 5 square millimeter, preliminary computational fluid dynamics (CFD) modeling indicates that an improved manifold design will be able to achieve comparable performance.

capillary flow↗
DOE OSTI2022

MPEX High Heat Flux Plasma Dump Design, Manufacture, and Articles Test

Here, the Material Plasma Exposure eXperiment (MPEX) device is a steady-state linear plasma device currently in the final design phase at the Oak Ridge National Laboratory. This device will reach ion fluences up to 10 31 m -2 and will be used to expose neutron-irradiated materials to divertor-relevant plasmas and to study the effects of plasma-material interactions. These studies will elucidate the complex effects of plasmas with divertor candidate materials capable of withstanding high heat flux and high fluences for next-generation fusion devices. Bidirectional plasma will be generated using a high-power (200 kW) helicon source. Plasma will be confined by superconducting magnets. The last plasma-facing component on the upstream side of the MPEX device is the dump, which has been designed to intercept plasma and energetic particles. The dump will have a total heat load of 9.2 kW. A copper alloy (Glidcop AL-15) was selected for use in the water-cooled flange design because of its high thermal conductivity, its retaining strength at elevated temperatures, and its ability to be used in the high-temperature braze joints used in this application. Titanium-zirconium-molybdenum (TZM) tiles are brazed to the Glidcop AL-15 flange using high-temperature braze alloy. External water-cooling channels are used on the dump flange to prevent water leakage inside the vacuum space. This article discusses the details of the high heat flux dump design, including the computational fluid dynamics (CFD) and structural analyses performed to validate the design to meet the operational requirements of the MPEX device.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Design and Analysis of High Heat Flux Plasma-Facing Components for NSTX Upgrade

The National Spherical Tokamak Experiment (NSTX) upgrade (NSTX-U) requirements lead to enhanced heat loads on plasma-facing components (PFCs) especially in the divertor regions, where normal heat flux density can reach up to 8 MW/m 2 . For these high heat flux (HHF) regions, the PFCs were redesigned, to use castellations which relieved the thermal stresses associated with high incident heat flux. Another design feature of HHF PFCs is the absence of front face mounting holes which create localized areas of high temperature and thermal stress concentrations. Optimized shaping of the front face of the HHF PFCs eliminates regions where the front face is perpendicular to the heat flux direction during normal helicity operation and spreads the heat load. A unique mechanism was designed to connect PFC tiles to the NSTX-U center stack casing using locking features accessible from the low heat flux regions. Isotropic graphite was selected as the HHF PFC tile material. Initial tile design parameters were accessed using analytical expressions for pulsed heat flux loading. A working prototype of the locking mechanism was created during the initial stages of the design to prove the concept performance. This article presents an overview of the divertor HHF PFC design and the results of the thermal and structural analyses performed using ANSYS software. The results of the analyses cover normal operating conditions and disruptions which impose electromagnetic (EM) loads from eddy and halo currents. The 3-D, transient, nonlinear analyses took into account the temperature-dependent properties of the materials, friction interfaces between the parts, and variable electric properties of the parts and interfaces. The results confirm that the HHF PFC tiles remain within the allowable limits for the loads defined by the NSTX-U Recovery Project. In addition, tolerance stack up analyses were performed to ensure tile performance in the worst possible assembly configuration. Finally, the design process was completed successfully, and the NSTX HHF PFC tiles are currently in the production phase.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Design, fabrication, and testing of a water-cooled tungsten-foam high-heat flux plasma-facing module

Here, we present a comprehensive study detailing the design, fabrication and testing a new modular “finger” component, featuring a hexagonal tungsten foam armor tile bonded to the top surface of the water-cooled finger unit. The mechanical, thermal, and particle transport properties of the tungsten foam armor were determined for a wide range of porosity and cell size, and then combined in an equivalent solid material with “effective” properties suitable for large-scale simulations. A series of 3-D multiphysics simulations for coupled thermal and mechanical behavior of the “finger” module are used to optimize the design before fabrication. The simulation results show that, for the expected experimental conditions, a safe range of heat flux and foam porosity is possible for both water-cooling and helium-cooling. Based on these multiphysics simulations, an optimum finger cooling module has been fabricated at Ultramet, Inc. A series of experiments were designed to study the thermomechanical performance of the “finger” unit under steady-state and transient thermal loading at surface heat flux up to 16 MW/m 2 in the High Energy Flux Test facility (HEFTY) at UCLA. Testing conditions included low-power, steady-state plasma exposure at 6 MW/m 2 , followed by severe high heat flux cycles at 16 MW/m 2 . Results of these tests are explained through comparisons with multiphysics simulations. To eliminate the effects of thermomechanical damage carried out on a module on its thermo-mechanical response on a subsequent test, three different yet identically designed and fabricated finger modules were tested. The results show that the current design is capable of cooling the walls of fusion devices at surface heat flux up to 6 MW/m 2 without failure, and that the failure heat flux limit is below 16 MW/m 2 .

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1993

Hypersonic engine component experiments in high heat flux, supersonic flow environment

A major concern in advancing the state-of-the-art technologies for hypersonic vehicles is the development of an aeropropulsion system capable of withstanding the sustained high thermal loads expected during hypersonic flight. Even though progress has been made in the computational understanding of fluid dynamics and the physics/chemistry of high speed flight, there is also a need for experimental facilities capable of providing a high heat flux environment for testing component concepts and verifying/calibrating these analyses. A hydrogen/oxygen rocket engine heat source was developed at the NASA Lewis Research Center as one element in a series of facilities at national laboratories designed to fulfill this need. This 'Hot Gas Facility' is capable of providing heat fluxes up to 450 w/sq cm on flat surfaces and up to 5,000 w/sq cm at the leading edge stagnation point of a strut in a supersonic flow stream. Gas temperatures up to 3050 K can also be attained. Two recent experimental programs conducted in this facility are discussed. The objective of the first experiment is to evaluate the erosion and oxidation characteristics of a coating on a cowl leading edge (or strut leading edge) in a supersonic, high heat flux environment. Macrophotographic data from a coated leading edge model show progressive degradation over several thermal cycles at aerothermal conditions representative of high Mach number flight. The objective of the second experiment is to assess the capability of cooling a porous surface exposed to a high temperature, high velocity flow environment and to provide a heat transfer data base for a design procedure. Experimental results from transpiration cooled surfaces in a supersonic flow environment are presented.

Gladden, Herbert J.↗
NASA NTRS1988

A high heat flux experiment for verification of thermostructural analysis

A major concern in advancing the state of the art technologies for hypersonic vehicles is the development of an aeropropulsion system capable of handling the high heat fluxes during flight. The leading edges of such systems must not only tolerate the maximum heating rates, but must also minimize distortions to the flow field due to excessive blunting and/or thermal warping of the compression surface to achieve the high inlet performance required. A combined analytical and experimental effort to study the aerothermodynamic loads on actively cooled structures for hypersonic applications was established. A hydrogen/oxygen rocket engine was modified to establish a high enthalpy high heat flux environment. The facility provides heat flux levels from about 200 up to 10000 Btu/sq ft/sec. Cross flow and parallel flow regeneratively cooled model can be tested and analyzed by using cooling fluids of water and hydrogen. Results are presented of the experiment and the characteristics of the Hot Gas Test Facility. The predicted temperature results of the cross flow model are compared with the experimental data on the first monolithic specimens and are found to be in good agreement. Thermal stress analysis results are also presented.

Gladden, Herbert J.↗
NASA NTRS1988

A high heat flux experiment for verification of thermostructural analysis

A major concern in advancing the state of the art technologies for hypersonic vehicles is the development of an aeropropulsion system capable of handling the high heat fluxes during flight. The leading edges of such systems must not only tolerate the maximum heating rates, but must also minimize distortions to the flow field due to excessive blunting and/or thermal warping of the conmpression surface to achieve the high inlet performance required. A combined analytical and experimental effort to study the aerothermodynamic loads on actively cooled structures for hypersonic applications was established. A hydrogen/oxygen rocket engine was modified to establish a high enthalpy high heat flux environment. The facility provides heat flux levels from about 200 up to 10000 Btu/sq ft/sec. Cross flow and parallel flow regeneratively cooled model can be tested and analyzed by using cooling fluids of water and hydrogen. Results are presented of the experiment and the characteristics of the Hot Gas Test Facility. The predicted temperature results of the cross flow model are compared with the experimental data on the first monolithic specimens and are found to be in good agreement. Thermal stress analysis results are also presented.

Gladden, H. J.↗
NASA NTRS2011

Monitoring Delamination of Thermal Barrier Coatings During Interrupted High-Heat-Flux Laser Testing using Luminescence Imaging

This presentation showed progress made in extending luminescence-base delamination monitoring to TBCs exposed to high heat fluxes, which is an environment that much better simulates actual turbine engine conditions. This was done by performing upconversion luminescence imaging during interruptions in laser testing, where a high-power CO2 laser was employed to create the desired heat flux. Upconverison luminescence refers to luminescence where the emission is at a higher energy (shorter wavelength) than the excitation. Since there will be negligible background emission at higher energies than the excitation, this methods produces superb contrast. Delamination contrast is produced because both the excitation and emission wavelengths are reflected at delamination cracks so that substantially higher luminescence intensity is observed in regions containing delamination cracks. Erbium was selected as the dopant for luminescence specifically because it exhibits upconversion luminescence. The high power CO2 10.6 micron wavelength laser facility at NASA GRC was used to produce the heat flux in combination with forced air backside cooling. Testing was performed at a lower (95 W/sq cm) and higher (125 W/sq cm) heat flux as well as furnace cycling at 1163C for comparison. The lower heat flux showed the same general behavior as furnace cycling, a gradual, "spotty" increase in luminescence associated with debond progression; however, a significant difference was a pronounced incubation period followed by acceleration delamination progression. These results indicate that extrapolating behavior from furnace cycling measurements will grossly overestimate remaining life under high heat flux conditions. The higher heat flux results were not only accelerated, but much different in character. Extreme bond coat rumpling occurred, and delamination propagation extended over much larger areas before precipitating macroscopic TBC failure. This indicates that under the higher heat flux (and surface & interface temperatures), the TBC was more tolerant of damage. The main conclusions were that high heat flux conditions can not only accelerate TBC debond progression but can also grossly alter the pathway of delamination.

Eldridge, Jeffrey I.↗
DOE OSTI2024

Development of a Hybrid Single/Two-Phase Capillary-Based Micro-Cooler using Copper Inverse Opals Wick with Silicon 3D Manifold for High-Heat-Flux Cooling Application

Previously, we reported two-phase capillary-based cooling using narrow (200 to 1000 ..mu..m) heater bridge copper inverse opal (CIO) wicks with heat flux level of 1400 Wcm -2 and superheat ~ 10 degrees C. Here, we demonstrate the area scaling of the proposed technology to a large-area micro-cooler for high-heat-flux cooling of microprocessors and power electronics. We developed a hybrid single/two-phase micro-cooler that relies on capillary-wicking in a 25-..mu..m-thick CIO with an open silicon microchannel 3D-manifold for liquid delivery and vapor extraction, achieving a high heat flux ~ 400 Wcm -2 over a heated area of 10 x 10 mm 2 . For a range of inlet water flowrates from 5 to 60 g(min) -1 , we achieved total thermal resistances and vapor qualities of 0.68 cm 2 degrees CW -1 to 0.2 cm 2 degrees CW -1 and 0.55 to 0.12, respectively. The flowrates are 10x smaller than those of conventional single- or two-phase microchannel cooling technology. The corresponding two-phase thermal resistances ranges from 0.05 to 0.02 cm 2 degrees CW -1 with temperature superheat of 8 to 6 degrees C, respectively. While the overall performance of the large-area (10 x 10 mm 2 ) capillary-based micro-cooler degraded compared to the previous demonstration of the technology for a heated area of 5 x 5 mm 2 , however, preliminary CFD modeling indicates that an improved manifold design will be able to achieve comparable performance.

capillary flow↗
NASA NTRS1993

High Heat Flux Facility

This video gives an overview of the High Heat Flux Facility being built at Stennis Space Center in conjunction with Wright-Patterson Air Force Base. This facility will simulate flight heat conditions and will be used to test engine and materials for the National Aerospace Plane.

Source record↗
NASA NTRS2000

Investigation of Instabilities and Heat Transfer Phenomena in Supercritical Fuels at High Heat Flux and Temperatures

A series of heated tube experiments was performed to investigate fluid instabilities that occur during heating of supercritical fluids. In these tests, JP-7 flowed vertically through small diameter tubes at supercritical pressures. Test section heated length, diameter, mass flow rate, inlet temperature, and heat flux were varied in an effort to determine the range of conditions that trigger the instabilities. Heat flux was varied up to 4 BTU/sq in./s, and test section wall temperatures reached as high as 1950 F. A statistical model was generated to explain the trends and effects of the control variables. The model included no direct linear effect of heat flux on the occurrence of the instabilities. All terms involving inlet temperature were negative, and all terms involving mass flow rate were positive. Multiple tests at conditions that produced instabilities provided inconsistent results. These inconsistencies limit the use of the model as a predictive tool. Physical variables that had been previously postulated to control the onset of the instabilities, such as film temperature, velocity, buoyancy, and wall-to-bulk temperature ratio, were evaluated here. Film temperatures at or near critical occurred during both stable and unstable tests. All tests at the highest velocity were stable, but there was no functional relationship found between the instabilities and velocity, or a combination of velocity and temperature ratio. Finally, all of the unstable tests had significant buoyancy at the inlet of the test section, but many stable tests also had significant buoyancy forces.

Linne, Diane L.↗
NASA NTRS1977

Evaluation of three thermal protection systems in a hypersonic high-heating-rate environment induced by an elevon deflected 30 deg

Three thermal protection systems proposed for a hypersonic research airplane were subjected to high heating rates in the Langley 8 foot, high temperature structures tunnel. Metallic heat sink (Lockalloy), reusable surface insulation, and insulator-ablator materials were each tested under similar conditions. The specimens were tested for a 10 second exposure on the windward side of an elevon deflected 30 deg. The metallic heat sink panel exhibited no damage; whereas the reusable surface insulation tiles were debonded from the panel and the insulator-ablator panel eroded through its thickness, thus exposing the aluminum structure to the Mach 7 environment.

Taylor, A. H.↗
NASA NTRS2005

GRCop-84: A High Temperature Copper-based Alloy For High Heat Flux Applications

While designed for rocket engine main combustion chamber liners, GRCop-84 (Cu-8 at.% Cr-4 at.% Nb) offers potential for high heat flux applications in industrial applications requiring a temperature capability up to approximately 700 C (1292 F). GRCop-84 is a copper-based alloy with excellent elevated temperature strength, good creep resistance, long LCF lives and enhanced oxidation resistance. It also has a lower thermal expansion than copper and many other low alloy copper-based alloys. GRCop-84 can be manufactured into a variety of shapes such as tubing, bar, plate and sheet using standard production techniques and requires no special production techniques. GRCop-84 forms well, so conventional fabrication methods including stamping and bending can be used. GRCop-84 has demonstrated an ability to be friction stir welded, brazed, inertia welded, diffusion bonded and electron beam welded for joining to itself and other materials. Potential applications include plastic injection molds, resistance welding electrodes and holders, permanent metal casting molds, vacuum plasma spray nozzles and high temperature heat exchanger applications.

Ellis, David L.↗
NASA NTRS1990

A unique high heat flux facility for testing hypersonic engine components

A major concern in advancing the state-of-the-art technologies for hypersonic vehicles is the development of an aeropropulsion system capable of withstanding high thermal loads expected during hypersonic flights. Consequently, there is a need for experimental facilities capable of providing a high heat flux environment for testing compound concepts and verifying analyses. A hydrogen/oxygen rocket engine was developed to provide a high enthalpy/high heat flux environment for component evaluation. This Hot Gas Facility is capable of providing heat fluxes ranging from 200 (on flat surfaces) up to 8000 Btu per sq ft per sec (at a leading edge stagnation point). Gas temperatures up to 5500 R can be attained as well as Reynolds numbers up to 360,000 per ft. Test articles such as cowl leading edges, transpiration-cooled seals, fuel injectors, and cooled panel concepts can be evaluated with gaseous hydrogen as coolant. This facility and its configuration and test capabilities are discussed. Results from flow characterization experiments are also shown and their implications considered.

Melis, Matthew E.↗
NASA NTRS1987

High heat transfer oxidizer heat exchanger design and analysis

The RL10-2B engine, a derivative of the RL10, is capable of multimode thrust operation. This engine operates at two low thrust levels: tank head idle (THI), which is approximately 1 to 2% of full thrust, and pumped idle (PI), which is 10% of full thrust. Operation at THI provides vehicle propellant settling thrust and efficient engine thermal conditioning; PI operation provides vehicle tank pre-pressurization and maneuver thrust for low-g deployment. Stable combustion of the RL10-2B engine during the low thrust operating modes can be accomplished by using a heat exchanger to supply gaseous oxygen to the propellant injector. The oxidizer heat exchanger (OHE) vaporizes the liquid oxygen using hydrogen as the energy source. The design, concept verification testing and analysis for such a heat exchanger is discussed. The design presented uses a high efficiency compact core to vaporize the oxygen, and in the self-contained unit, attenuates any pressure and flow oscillations which result from unstable boiling in the core. This approach is referred to as the high heat transfer design. An alternative approach which prevents unstable boiling of the oxygen by limiting the heat transfer is referred to as the low heat transfer design and is reported in Pratt & Whitney report FR-19135-2.

Kmiec, Thomas D.↗