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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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The active Heat Rejection System designed for Mars Pathfinder was modified for the Mars Exploration Rover mission and will be used to remove excess heat from the Rover electronics during the cruise part of the mission. This paper addresses the lessons learned from the performance testing, and potential changes to improve the HRS performance.
A thermal design concept of attaching the thermoelectric cooler (TEC) hot side directly to the radiator and maximizing the number of TECs to cool multiple detectors in space is presented. It minimizes the temperature drop between the TECs and radiator. An ethane constant conductance heat pipe transfers heat from the detectors to a TEC cold plate which the cold side of the TECs is attached to. This thermal design concept minimizes the size of TEC heat rejection systems. Hence it reduces the problem of accommodating the radiator within a required envelope. It also reduces the mass of the TEC heat rejection system. Thermal testing of a demonstration unit in vacuum verified the thermal performance of the thermal design concept.
Effect of mission attitude timelines on consumables requirements for proposed shuttle orbiter heat rejection systems
Robust assembly and integration technologies are critically needed for the manufacturing of heat rejection system (HRS) components for current and future space exploration missions. Active metal brazing and adhesive bonding technologies are being assessed for the bonding of titanium to high conductivity Carbon-Carbon composite sub components in various shapes and sizes. Currently a number of different silver and copper based active metal brazes and adhesive compositions are being evaluated. The joint microstructures were examined using optical microscopy, and scanning electron microscopy (SEM) coupled with energy dispersive spectrometry (EDS). Several mechanical tests have been employed to ascertain the effectiveness of different brazing and adhesive approaches in tension and in shear that are both simple and representative of the actual system and relatively straightforward in analysis. The results of these mechanical tests along with the fractographic analysis will be discussed. In addition, advantages, technical issues and concerns in using different bonding approaches will also be presented.
This is the first time in unmanned spacecraft history that an active heat rejection system of this type has been used on a long duration spacecraft mission.
The use of a rotary fluid management device (RFMD) and shear flow condenser for two-phase fluid management in microgravity organic Rankine cycle (ORC) applications is examined. A prototype of the proposed Space Station ORC heat rejection system was constructed to evaluate the performance of the inventory control method. The design and operation of the RFMD, shear flow condenser, and inventory control fluid accumulator are described. A schematic diagram of the ORC, RFMD, and condenser, and a functional diagram of the heat rejection system for the ORC are presented.
High temperature adhesives with good thermal conductivity, mechanical performance, and long term durability are crucial for the assembly of heat rejection system components for space exploration missions. In the present study, commercially available adhesives were used to bond high conductivity carbon-carbon composites to titanium sheets. Bonded pieces were also exposed to high (530 to 600 Kelvin for 24 hours) and low (liquid nitrogen 77K for 15 minutes) temperatures to evaluate the integrity of the bonds. Results of the microstructural characterization and tensile shear strengths of bonded specimens will be reported. The effect of titanium surface roughness on the interface microstructure will also be discussed.
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.
The critical evaluation and subsequent redesign of the power conversion subsystem of the spacecraft are covered. As part of that evaluation and redesign, prototype heat pipe components for the heat rejection system were designed fabricated and tested. Based on the results of these tests in conjunction with changing mission requirements and changing energy conversion devices, new system designs were investigated. The initial evaluation and redesign was based on state-of-the-art fabrication and assembly techniques for high temperature liquid metal heat pipes and energy conversion devices. The hardware evaluation demonstrated the validity of several complicated heat pipe geometries and wick structures, including an annular-to-circular transition, bends in the heat pipe, long heat pipe condensers and arterial wicks. Additionally, a heat pipe computer model was developed which describes the end point temperature profile of long radiator heat pipes to within several degrees celsius.
The Mars Science Laboratory (MSL) rover was launched on an Atlas V on November 26, 2011. Preparations were carried out prior to launch in order to closeout the spacecraft's complex heat rejection system (HRS), which consists of two mechanically pumped CFC-11 fluid loops. The first HRS loop, onboard the Curiosity rover, was fully integrated, filled with CFC-11, and successfully operated prior to launch pad operations; however, the second thermal loop, called the cruise HRS loop, required final mechanical and thermal integration activities to occur while on the launch pad in order to accommodate the last minute installation of the rover's Multi-Mission Radioisotope Thermoelectric Generator (MMRTG) power source. In order to prevent overheating of propellant tanks and critical avionics equipment buried deep within the spacecraft's aeroshell, the MMRTG needed to be pre-cooled using a separate non-flight mechanically pumped fluid loop prior to and during the final closeout and subsequent startup of the flight loop. This paper outlines the various steps that took place to safely install the MMRTG while carefully transitioning from the pre-cooling operation to the final startup and operation of the flight cruise HRS loop. Temperature data of the launch pad thermal transition from the ground support loop activity to the final flight loop operation is presented. Some background development of the ground support loop and lessons learned are also discussed. This successful launch pad integration activity required a close-knit coordination between NASA KSC, JPL, the Department of Energy, Idaho National Labs, Pratt and Whitney Rocketdyne Inc., Teledyne Technologies Inc., ULA, and Advanced Thermal Sciences Corp.
A preliminary design study of a conceptual 6000-megawatt open-cycle gas-core nuclear rocket engine system was made. The engine has a thrust of 196,600 newtons (44,200 lb) and a specific impulse of 4400 seconds. The nuclear fuel is uranium-235 and the propellant is hydrogen. Critical fuel mass was calculated for several reactor configurations. Major components of the reactor (reflector, pressure vessel, and waste heat rejection system) were considered conceptually and were sized.
The joining of metal tubes to composite plates is required for heat-rejection components in several space applications. Currently a number of different braze compositions are being evaluated as to their effectiveness. Such tube-plate configurations cannot be represented by traditional methods of testing, e.g., lap joints. The joined region is not between two flat surfaces, but rather between a flat surface and a curved surface. Therefore, several tests have been employed to ascertain the effectiveness of the different braze approaches in tension and in shear that are both simple and representative of the actual system and relatively straightforward in analysis. The results of these "tube tests" will be discussed for the three different braze compositions, Cu-ABA, Ti-Cu-Sil, and Ti-Cu-Ni. In addition, fracture analysis of the failed joints was performed and offers insights into the cause of joint failure and the distinctions which need to be made between the "strength" of a joint versus the "load carrying ability" of a joint.
Results of an analytical study investigating the application of capillary pumping to the heat rejection loop of an advanced Rankine cycle power conversion system are presented. The feasibility of the concept of capillary pumping as an alternate to electromagnetic pumping is analytically demonstrated. Capillary pumping is shown to provide a potential for weight and electrical power saving and reliability through the use of redundant systems. A screen wick pump design with arterial feed lines was analytically developed. Advantages of this design are high thermodynamic and hydrodynamic efficiency, which provide a lightweight easily packaged system. Operational problems were identified which must be solved for successful application of capillary pumping. The most important are the development of start up and shutdown procedures, and development of a means of keeping noncondensibles from the system and of earth-bound testing procedures.
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Two different heat pipe radiator elements, one intended for use with the power conversion subsystem of the NASA funded nuclear electric propulsion (NEP) spacecraft, and one intended for use with the DOE funded space power advanced reactor (SPAR) system were tested and evaluated. The NEP stainless steel/sodium heat pipe was 4.42 meters long and had a 1 cm diameter. Thermal performance testing at 920 K showed a non-limited power level of 3560 watts, well in excess of the design power of 2600 watts. This test verified the applicability of screen arteries for use in long radiator heat pipes. The SPAR titanium/potassium heat pipe was 5.5 meters long and had a semicircular crossection with a 4 cm diameter. Thermal performance testing at 775 K showed a maximum power level of 1.86 kW, somewhat short of the desired 2.6 kW beginning of life design requirement. The reduced performance was shown to be the result of the inability of the evaporator wall wick (shot blasted evaporator wall) to handle the required liquid flow.
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Performing extravehicular activity (EVA) at various locations of the lunar surface presents thermal challenges that exceed those experienced in space flight to date. The lunar Portable Life Support System (PLSS) cooling unit must maintain thermal conditions within the space suit and reject heat loads generated by the crewmember and the PLSS equipment. The amount of cooling required varies based on the lunar location and terrain due to the heat transferred between the suit and its surroundings. A study has been completed which investigated the resources required to provide cooling under various lunar conditions, assuming three different thermal technology categories: 1. Spacesuit Water Membrane Evaporator (SWME) 2. Subcooled Phase Change Material (SPCM) 3. Radiators with and without heat pumps Results from the study are presented that show mass and power impacts on the cooling system as a function of the location and terrain on the lunar surface. Resources (cooling equipment mass and consumables) are greater at the equator and inside sunlit craters due to the additional heat loads on the cooling system. While radiator and SPCM technologies require minimal consumables, they come with carry-weight penalties and have limitations. A wider investigation is recommended to determine if these penalties and limitations are offset by the savings in consumables.