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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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Transient thermal simulation of Apollo spacecraft and ECS.
Apollo spacecraft command module analytical thermal model, discussing correlation of model with test data
Advanced Drying Cycle Simulator Thermal Response to Commercial Drying Conditions
The purpose of this report is to document updates on testing of the apparatus built to simulate commercial drying procedures for spent nuclear fuel at the Nuclear Energy Work Complex at Sandia National Laboratories. Validation of the extent of water removal in a dry spent nuclear fuel storage system based on drying procedures used at nuclear power plants is needed to close existing technical gaps. Operational conditions leading to incomplete drying may have potential impacts on the fuel, cladding, and other components in the system during subsequent storage and disposal. A general lack of data suitable for model validation of commercial nuclear canister drying processes necessitates well-designed investigations of drying process efficacy and water retention that incorporate relevant physics and well-controlled boundary conditions. This report documents testing updates for the Advanced Drying Cycle Simulator (ADCS). This apparatus was built to simulate commercial drying procedures and quantify the amount of residual water remaining in a pressurized water reactor (PWR) fuel assembly after drying. The ADCS was constructed with a prototypic 17×17 PWR fuel skeleton and waterproof heater rods to simulate decay heat. These waterproof heaters are the next generation design to heater rods developed and tested at Sandia National Laboratories in FY20. This report describes preliminary testing of the ADCS through measurement and analysis of the thermal response of the system to a subset of commercial drying conditions that exclude the introduction of water, namely simulated decay heats and pressures relevant to commercial drying. This test series, referred to as a “dry” test series in this report, spans three uniform waterproof heater rod powers (representing spent fuel decay heats), four helium fill pressures, and six vacuum levels. This test series was conducted to cover the range of expected ADCS testing conditions for upcoming “wet” testing, where water will be introduced and a simulated commercial drying cycle will be performed. The dry test conditions were derived from the commercial drying conditions seen in the High Burnup Demonstration and the vacuum drying conditions chosen for a smaller scale Dashpot Drying Apparatus tested at Sandia National Laboratories in FY22. For a given uniform power and pressure/vacuum level, the ADCS was operated at constant power and pressure and allowed to reach steady state conditions. The thermal data obtained from these tests were analyzed, and the results can inform computational models built to simulate commercial drying processes by providing baseline thermal data prior to the introduction of water. Following the preliminary dry tests, a test plan for the ADCS will be developed to implement a drying procedure that begins with the introduction of water to the system and is based on measurements from the drying process used for the High Burnup Demonstration Project. While applying power to the simulated fuel rods, this procedure is expected to consist of filling the ADCS vessel with water, draining the water with applied pressure and multiple helium blowdowns, evacuating additional water with a vacuum drying sequence at successively lower pressures, and backfilling the vessel with helium. Additional investigations are expected to feature failed fuel rod simulators with engineered cladding defects and guide tubes with obstructed dashpots to challenge the drying system with multiple water retention sites. The data from these investigations is expected to inform the efficacy of commercial drying operations through the quantification of residual water in a prototypic-length dry storage canister.
A unique approach to space thermal simulation
The Space Systems Lab of McDonnell Douglas developed several innovative techniques to perform the DELTA Star System thermal vacuum test. Test design constraints included an accelerated test schedule and an ambitious test plan focusing on cyclic absorbed orbital flux simulation. Test design and fabrication was completed in only 4 months, producing a 21 zone computer modeled refectorless lamp array system. Array zone control was based on discreet absorbed flux measurements, provided by adiabatic coupons conceived to eliminate the need for conventional radiometers. Test requirements, methodology, and test thermal model flight data correlation are presented.
Electro-Thermal Simulation Studies of SiC Junction Diodes Containing Screw Dislocations Under High Reverse-Bias Operation
The objective of this work was to conduct a modeling study of SiC P-N junction diodes operating under high reverse biased conditions. Analytical models and numerical simulation capabilities were to be developed for self-consistent electro-thermal analysis of the diode current-voltage (I-V) characteristics. Data from GRC indicate that screw dislocations are unavoidable in large area SiC devices, and lead to changes in the SiC diode electrical response characteristics under high field conditions. For example, device instability and failures linked to internal current filamentation have been observed. The physical origin of these processes is not well understood, and quantitative projections of the electrical behavior under high field and temperature conditions are lacking. Thermal calculations for SiC devices have not been reported in the literature either. So estimates or projections of peak device temperatures and power limitations do not exist. This numerical study and simulation analysis was aimed at resolving some of the above issues. The following tasks were successfully accomplished: (1) Development of physically based models using one- and two-dimensional drift-diffusion theory for the transport behavior and I-V characteristics; (2) One- and two-dimensional heat flow to account for internal device heating. This led to calculations of the internal temperature profiles, which in turn, were used to update the electrical transport parameters for a self-consistent analysis. The temperature profiles and the peak values were thus obtainable for a given device operating condition; (3) Inclusion of traps assumed to model the presence of internal screw dislocations running along the longitudinal direction; (4) Predictions of the operating characteristics with and without heating as a function of applied bias with and without traps. Both one and two-dimensional cases were implemented; (5) Assessment of device stability based on the operating characteristics. The presence of internal non-uniformities, particularly filamentary structures, was probed and demonstrated; (6) Cause and physical origins of filamentary behavior and unstable I-V characteristics were made transparent; (7) It was demonstrated that diodes containing defects would be more prone to thermal breakdown associated with the temperature dependent decrease in the thermal conductivity; and (8) Finally, negative differential resistance (S-shaped NDR) which can potential lead to device instability and filamentary behavior was shown to occur for diodes containing a line of defects such as could be associated with a screw dislocation line.
A Computational Methodology for Simulating Thermal Loss Testing of the Advanced Stirling Convertor
Convertor and generator testing is carried out in tests designed to characterize convertor performance when subjected to environments intended to simulate launch and space conditions. The value of net heat input must be known in order to calculate convertor efficiency and to validate convertor performance. Specially designed test hardware was used to verify and validate a two step methodology for the prediction of net heat input. This lessons learned from these simulations have been applied to previous convertor simulations. As heat is supplied to the convertors, electric power is produced and measured. Net heat input to the convertor is one parameter that will contribute to the calculation of efficiency. This parameter is not measured directly. Insulation Loss. Determine the current status of the thermal conductivity of the micro-porous insulation. - Match heat source and hot end temperatures. - Match temperature difference across Kaowool insulation
15-Foot Lunar Simulation Thermal Vacuum Chamber
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A representative-sandwich model for simultaneously coupled mechanical-electrical-thermal simulation of a lithium-ion cell under quasi-static indentation tests
The safety behavior of lithium-ion batteries under external mechanical crush is a critical concern, especially during large scale deployment. We previously presented a sequentially coupled mechanical-electrical-thermal modeling approach for studying mechanical abuse induced short circuit. Here in this work, we study different mechanical test conditions and examine the interaction between mechanical failure and electrical-thermal responses, by developing a simultaneous coupled mechanical-electrical-thermal model. The present work utilizes a single representative-sandwich (RS) to model the full pouch cell with explicit representations for each individual component such as the active material, current collector, separator, etc. Anisotropic constitutive material models are presented to describe the mechanical properties of active materials and separator. The model predicts accurately the force-strain response and fracture of battery structure, simulates the local failure of separator layer, and captures the onset of short circuit for lithium-ion battery cell under sphere indentation tests with three different diameters. Electrical-thermal responses to the three different indentation tests are elaborated and discussed. Lastly, numerical studies are presented to show the potential impact of test conditions on the electrical-thermal behavior of the cell after the occurrence of short circuit.
A Computational Methodology for Simulating Thermal Loss Testing of the Advanced Stirling Convertor
The U.S. Department of Energy (DOE) and Lockheed Martin Space Systems Company (LMSSC) have been developing the Advanced Stirling Radioisotope Generator (ASRG) for use as a power system for space science missions. This generator would use two highefficiency Advanced Stirling Convertors (ASCs), developed by Sunpower Inc. and NASA Glenn Research Center (GRC). The ASCs convert thermal energy from a radioisotope heat source into electricity. As part of ground testing of these ASCs, different operating conditions are used to simulate expected mission conditions. These conditions require achieving a particular operating frequency, hot end and cold end temperatures, and specified electrical power output for a given net heat input. In an effort to improve net heat input predictions, numerous tasks have been performed which provided a more accurate value for net heat input into the ASCs, including the use of multidimensional numerical models. Validation test hardware has also been used to provide a direct comparison of numerical results and validate the multi-dimensional numerical models used to predict convertor net heat input and efficiency. These validation tests were designed to simulate the temperature profile of an operating Stirling convertor and resulted in a measured net heat input of 244.4 W. The methodology was applied to the multi-dimensional numerical model which resulted in a net heat input of 240.3 W. The computational methodology resulted in a value of net heat input that was 1.7 percent less than that measured during laboratory testing. The resulting computational methodology and results are discussed.
Mechanical-Electrochemical-Thermal Simulation of Lithium-Ion Cells
Models capture the force response for single-cell and cell-string levels to within 15%-20% accuracy and predict the location for the origin of failure based on the deformation data from the experiments. At the module level, there is some discrepancy due to poor mechanical characterization of the packaging material between the cells. The thermal response (location and value of maximum temperature) agrees qualitatively with experimental data. In general, the X-plane results agree with model predictions to within 20% (pending faulty thermocouples, etc.); the Z-plane results show a bigger variability both between the models and test-results, as well as among multiple repeats of the tests. The models are able to capture the timing and sequence in voltage drop observed in the multi-cell experiments; the shapes of the current and temperature profiles need more work to better characterize propagation. The cells within packaging experience about 60% less force under identical impact test conditions, so the packaging on the test articles is robust. However, under slow-crush simulations, the maximum deformation of the cell strings with packaging is about twice that of cell strings without packaging.
Thermal simulation of the EIC HSR interconnect module - RF fingers
The Electron Ion Collider (EIC) Hadron Storage Ring (HSR) will reuse most of the existing superconducting magnets from the RHIC storage ring. However, the existing beam vacuum chamber and stripline BPMs will not be compatible with the planned EIC hadron bunches that will have a 3x higher intensity and be 10x shorter, and some operational scenarios with large radial offsets of the beam in the vacuum chamber. To address these challenges, a copper coated beam screen will be implemented, the existing RHIC stripline BPMs will be shielded and an interconnect module design, including new BPM will be installed adjacent to the existing BPMs. A thermal analysis of the new arc BPM interconnect housing has been conducted to assess the heating caused by beam induced resistive wall heating and electron cloud heating. An analysis of the BPM module has been made and reported separately. This report will focus on the other side of the interconnect module, containing the RF fingers.
Thermal simulation of the HSR arc BPM Module for EIC
The Electron Ion Collider (EIC) Hadron Storage Ring (HSR) will reuse most of the existing superconducting magnets from the RHIC storage ring. However, the existing stripline beam position monitors (BPM) used for RHIC will not be compatible with the planned EIC hadron beam parameters that include higher intensity, shorter bunches, and some operational scenarios with large radial offsets of the beam in the vacuum chamber. To address these challenges, the existing RHIC stripline BPMs will be shielded, and a new BPM design using button pick-ups and integrated in a new vacuum interconnect/bellows assembly that will be installed adjacent to the existing BPMs. A thermal analysis of the new arc BPM housing and button pick-up design has been conducted to assess the effects caused by beam induced resistive wall heating and signal propagation through the button pick-up cables for several operational scenarios. This report will describe the analysis results to quantify the heat transfer and temperature distribution that can be expected on the new HSR cryogenic arc BPM housings, button pick-ups, and cryo-signal cables.
3DThesis (3D THErmal Simulation Software)
There is a need for a way to simulate the heat transfer conditions for the entire layer of a build (both temperature and solidification gradient and velocity). CFD models could do this but those may take months to finish a simulation. The solution is an adaptive integration scheme for a analytic, conduction-only approach for a volumetric Gaussian heat source. Because this is analytic, it also allows increased functionality as well. 3DThesis can simulate heat transfer conditions for a volumetric Gaussian heat source moving in an arbitrary path at a point in time. This allows for the calculation of discrete snapshots of the temperature field or even the final solidification gradients and velocities.
Aerodynamic thermal simulation system. Part 2: System controls (instruction manual)
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Aerodynamic thermal simulation system. Part 3: Related reference material (instruction manual)
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Special problems of the thermal simulation of HELIOS experiment E6: Test results compared with flight data
The maximum solar energy (16 Solar Constants) irradiating experiment orifice E6 intermittently during the mission of space probe HELIOS has been reproduced in a High Intensity Component Test Facility. A detailed comparison is given between test results and flight data evaluation.
Development of an Emulation-simulation Thermal Control Model for Space Station Application
Analysis techniques to evaluate the effects of changing thermal loads and the methods utilized to control temperature distributions in the orbital space station are essential. Analysis techniques including a user-friendly computer program, were developed which should prove useful in thermal design and system analysis of the the space station. The program uses a data base and user input to compute costs, sizes, and power requirements for individual components and complete systems. User input consists of selecting mission parameters, selecting thermal acquisition configurations, transport systems and distances, and thermal rejection configurations.