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NASA's Platform for Cross-Disciplinary Microchannel Research

A team from the Structural Biology group located at the NASA Marshall Space Flight Center in Huntsville, Alabama is developing a platform suitable for cross-disciplinary microchannel research. The original objective of this engineering development effort was to deliver a multi-user flight-certified facility for iterative investigations of protein crystal growth; that is, Iterative Biological Crystallization (IBC). However, the unique capabilities of this facility are not limited to the low-gravity structural biology research community. Microchannel-based research in a number of other areas may be greatly accelerated through use of this facility. In particular, the potential for gas-liquid flow investigations and cellular biological research utilizing the exceptional pressure control and simplified coupling to macroscale diagnostics inherent in the IBC facility will be discussed. In conclusion, the opportunities for research-specific modifications to the microchannel configuration, control, and diagnostics will be discussed.

Son, Sang Young

Development, Fabrication, and Testing of a Liquid/Liquid Microchannel Heat Exchanger for Constellation Spacecrafts

Microchannel technology can be incorporated into heat exchanger designs to decrease the mass and volume of space hardware. The National Aeronautics and Space Administration at the Johnson Space Center (NASA JSC) partnered with Pacific Northwest National Laboratories (PNNL) to develop a liquid/liquid microchannel heat exchanger that has significant mass and volume savings without sacrificing thermal and pressure drop performance. PNNL designed the microchannel heat exchanger to the same performance design requirements of a conventional plate and fin liquid/liquid heat exchanger; 3 kW duty with inlet temperatures of 26 C and 4 C. Both heat exchangers were tested using the same test parameters on a test apparatus and performance data compared.

Hawkins-Reynolds, Ebony

Performance Characterization of a Microchannel Liquid/Liquid Heat Exchanger Throughout an Extended Duration Life Test

Liquid/Liquid Heat Exchangers (L/L HX) are an integral portion of any spacecraft active thermal control system. For this study the X-38 L/L HX was used as a baseline. As detailed in a previous ICES manuscript, NASA paired with Pacific Northwest National Laboratory to develop a Microchannel L/L HX (MHX). This microchannel HX was designed to meet the same performance characteristics as the aforementioned X-38 HX. The as designed Microchannel HX has a 26% and 60% reduction in mass and volume, respectively. Due to the inherently smaller flow passages the design team was concerned about fouling affecting performance during extended missions. To address this concern, NASA has developed a test stand and is currently performing an 18 month life test on the MHX. This report will detail the up-to-date performance of the MHX during life testing.

Sheth, Rubik B.

Fluid & Thermal Analysis of a Manifold Microchannel Heat Sink

A three-dimensional (3-D) numerical model has been developed to study the fluid flow and heat transfer through a manifold-microchannel (MMC) heat sink, a microfluidic cooling system designed as a heat dissipation solution for compact, high-powered electronic systems. An MMC consists of a 3-D manifold structure that distributes working fluid through alternating inlet and outlet manifold channels that guide the fluid to and from the microchannels, shortening the flow length and thereby, reducing the pressure drop across the system. Wide bandgap semiconductors such as silicon carbide (SiC) are increasingly utilized due to their ability to enable smaller electronic devices and components to operate more efficiently at higher frequencies. These semiconductors can greatly benefit from the MMC, which can extract all the heat produced by compact, high-powered electronics, enabling them to achieve optimal performance. The MMC also utilizes an embedded cooling approach which allows for fabrication directly within SiC-based electronics, resulting in significant mass and weight savings and lower thermal resistance than conventional heat sink designs. This paper outlines the methods used to conduct fluid and thermal analysis of different MMC configurations for flow parameters such as flow rate and inlet flow conditions. This study involves both steady state and transient thermal analysis as a gradually increasing heat flux is applied to the system over time, which is representative of the heat dissipation from the electronics over a given period. Results from the analysis show that the MMC is capable of effectively dissipating heat flux of ~100 W/cm2 while maintaining considerably low pressure drop (< 1 kPa) and thermal resistance (< 1 K/W) for certain single-phase working fluids.

manifold microchannel

Fluid & Thermal Analysis of a Manifold Microchannel Heat Sink

A three-dimensional (3-D) numerical model has been developed to study the fluid flow and heat transfer through a manifold-microchannel (MMC) heat sink, a microfluidic cooling system designed as a heat dissipation solution for compact, high-powered electronic systems. An MMC consists of a 3-D manifold structure that distributes working fluid through alternating inlet and outlet manifold channels that guide the fluid to and from the microchannels, shortening the flow length and thereby, reducing the pressure drop across the system. Wide bandgap semiconductors such as silicon carbide (SiC) are increasingly utilized due to their ability to enable smaller electronic devices and components to operate more efficiently at higher frequencies. These semiconductors can greatly benefit from the MMC, which can extract all the heat produced by compact, high-powered electronics, enabling them to achieve optimal performance. The MMC also utilizes an embedded cooling approach which allows for fabrication directly within SiC-based electronics, resulting in significant mass and weight savings and lower thermal resistance than conventional heat sink designs. This paper outlines the methods used to conduct fluid and thermal analysis of different MMC configurations for flow parameters such as flow rate and inlet flow conditions. This study involves both steady state and transient thermal analysis as a gradually increasing heat flux is applied to the system over time, which is representative of the heat dissipation from the electronics over a given period. Results from the analysis show that the MMC is capable of effectively dissipating heat flux of ~100 W/cm2 while maintaining considerably low pressure drop (< 1 kPa) and thermal resistance (< 1 K/W) for certain single-phase working fluids.

manifold microchannel

Evaluating Microchannel Heat Exchanger Lifetime for Concentrating Solar Power Applications FY24Q4 (RPPR-1)

Microchannel heat exchanger technology is being pursued for next generation CSP concepts for primary power cycle heat addition and power cycle heat recuperation due to the high heat transfer coefficients and pressure containment advantages of small sCO 2 channels. The economics of future CSP plants as dictated by the SETO 2020 or 2030 targets depend on a heat exchanger with a 30-year lifetime (resisting creep, fatigue, corrosion, erosion) and operational characteristics such as fast ramping and the ability to withstand thermal shock. However, the lifetime and operational limits of microchannel heat exchangers operating at high-temperatures, particularly those constructed from high-nickel alloys, are not well known. This uncertainty has resulted in heat exchanger vendors not being able to accurately forecast heat exchanger lifetime as required by customers, specify operational limits as required by process engineers to prevent premature heat exchanger failure, or overdesign heat exchanger which leads to higher cost than necessary. Our goal is to evaluate heat exchanger lifetime and operational limits for the manufacturing and prototype design for next-generation CSP heat exchanger technology through a combination of collecting experimental data and modeling studies.

14 SOLAR ENERGY

Evaluating Microchannel Heat Exchanger Lifetime for Concentrating Solar Power Applications Research Performance Progress Report (RPPR-1)

Microchannel heat exchanger technology is being pursued for next generation CSP concepts for primary power cycle heat addition and power cycle heat recuperation due to the high heat transfer coefficients and pressure containment advantages of small sCO 2 channels. The economics of future CSP plants as dictated by the SETO 2020 or 2030 targets depend on a heat exchanger with a 30-year lifetime (resisting creep, fatigue, corrosion, erosion) and operational characteristics such as fast ramping and the ability to withstand thermal shock. However, the lifetime and operational limits of microchannel heat exchangers operating at high temperatures, particularly those constructed from high-nickel alloys, are not well known. This uncertainty has resulted in heat exchanger vendors not being able to accurately forecast heat exchanger lifetime as required by customers, specify operational limits as required by process engineers to prevent premature heat exchanger failure, or overdesign heat exchanger which leads to higher cost than necessary.

14 SOLAR ENERGY

Ultraviolet spectrograph using microchannel plates

An ultraviolet spectrograph was constructed using double microchannel plates as detectors at the focal plane. The photoelectron pulses were located one at a time by measuring the charge division to the ends of a resistor strip behind the microchannel plates. The system worked to 20,000 counts/sec and gave resolution exceeding 100 elements.

Lawrence, G. M.

Optimization of the performance of a tandem microchannel plate detector as a function of interplate spacing and voltage

The effect of varying the size of the gap voltage and spacing on the performance of a tandem pair of microchannel plates (MCP) is investigated. Results show that increasing the voltage in the gap increases the gain of the pair and also produces a narrower Gaussian pulse-height distribution, although beyond a critical voltage the gain of the channel plate pair is found to plateau. A model is developed which explains the nonlinear gain behavior of individual microchannels and the behavior of the electron cloud emitted from the first MCP as it spreads out between the two MCPs and hits the surface of the second. The model calculates the plateau voltage as a function of the gap size, the gain of each MCP, and the diameter of the channels, and is found to show good agreement with the observed results. It is concluded that interplate gaps of up to several millimeters can be accommodated without a significant degradation in pulse-height distribution.

Rogers, D.

Microchannel intensified electrography

Although electrography is an attractive electronic imaging technique, it suffers at low light levels from limitations imposed by microphotometer and emulsion grain noise. The use of microchannel intensification allows individual photoelectron events to be unambiguously detected and measured, with little loss of achievable resolution. A series of quantitative studies have been conducted to determine the gains in detectivity and SNR yielded by the use of this technique, through microphotometry and computer analysis of images identical or similar to laboratory light sources, by means of both unintensified and microchannel-intensified electromagnetic Schmidt cameras. Applications of the technique to far-UV wide field imaging and nebular spectrograph experiments are described.

Heckathorn, H. M.

Electronic readout systems for microchannel plates

The modes of operation of position-sensitive electronic readout systems which use high-gain microchannel plate (MCP) electron multipliers are described, and their performance characteristics, along with those of the MCP, are compared. Among the structures presented are the wedge-and-strip, Codacon, and multilayer coincidence-anode MAMA (Multimode Microchannel Array) arrays. Spatial resolution of 25 x 25 sq microns (coincidence anode arrays) is achieved with an array format of 256 x 1024 pixels. On the basis of the performance data it is concluded that the readout systems using only conducting electrodes offer the best performance characteristics.

Timothy, J. G.

A position sensitive microchannel photomultiplier for ultraviolet space astronomy

The 25-mm microchannel-plate, position-sensitive UV astronomy photomultiplier tube presented is intended for the EOM-1 Spacelab Mission's FAUST payload and conducts wide-field imaging surveys in the VUV over the 1400-1800-A range. The sealed detector encompasses a CsI photocathode deposited on the inner surface of a MgF2 window, a stack of microchannel plates, and a wedge-and-strip two-dimensional position-sensing anode. Since the wedge-and-strip principle requires only three anode signals, flight electronics can be reduced to three charge amplifiers and three analog-to-digital converters.

Lampton, M.

Imaging by time-tagging photons with the multi-anode microchannel array detector system

The capability and initial use of the Multi-Anode Microchannel Array (MAMA) detector in the time-tag mode is reported. The detector hardware currently in use consists of a visible-light detector tube with a semitransparent photocathode proximity-focused to a high-gain curved-channel microchannel plate MCP. The photoevents are detected by a (256 x 1024)-pixel coincidence-anode array with pixel dimensions of 25 x 25 microns connected to charge-sensitive amplifiers and event-detection circuitry. In the time-lag mode, the detector delivers the pixel address and the time of arrival for each detected photon to an accuracy of 10 microns. The maximum count rate is limited by the speed of data-acquisition hardware. The MAMA detector in the time-lag mode is currently being evaluated in programs of astrometry and speckle imaging.

Timothy, J. G.

Hex-square moire patterns in imagers using microchannel plates

In electronic imaging detectors using microchannel plates, the mismatch between the pixels on a square mesh and the microchannels on a hexagonal mesh produces moire image defects. Theoretical statistical estimates of the sizes of the microposition offsets and the flat field intensity errors are calculated, showing the trade-off between resolution and position accuracy. A distinction is made between moments of spot images and moments of the single-pixel-response functions. As the resolution between the hex and square meshes is improved, the detector resolution is improved, but at the expense of an about 10 percent moire pattern. These moire patterns will not be properly corrected by dividing by the flat field image.

Lawrence, George M.

Performance characteristics of a curved-channel microchannel plate with a curved input face and a plane output face

The presently performance-evaluated format, in which a high-gain curved-channel microchannel plate (M2MCP) has a spherical concave input face and a plane output face, allows the input face of the MCP (1) to match such curved focal surfaces as that of a Rowland-circle spectrometer mounting, while (2) having a high-resolution plane readout array in proximity focus with the output face. This MCP has been evaluated in a discrete-anode multicathode microchannel array detector system. The saturated modal gain was found to be inversely proportional to the length/diameter ratio of the channels and directly proportional to the applied MCP voltage.

Slater, David C.

High resolution decoding techniques and single-chip decoders for multi-anode microchannel arrays

While the pixel size in a standard multianode microchannel array (MAMA) photon-counting detector is determined by the spacing of the anode array, the factor most fundamentally limiting pixel resolution is the spacing of the channels in the microchannel plate. Detector resolution can be improved by means of digitization followed by a centroiding procedure. The decoding hardware and the techniques for enhanced pixel resolution are presently discussed with a view to the factors of speed and complexity. A single-chip CMOS gate-array implementation of the decoder is devised and compared with existing multichip decoders' performance.

Kasle, David B.

Flat field response of the microchannel plate detectors used on the Extreme Ultraviolet Explorer

The results of the extreme ultraviolet (EUV) flat field calibrations of two of the flight detectors to be flown on the Extreme Ultraviolet Explorer Satellite (EUVE) are presented. Images of about 40 million detected events binned 512 by 512 are sufficient to show microchannel plate fixed pattern noise such as hexagonal microchannel multifiber bundle interfaces, 'dead' spots, edge distortion, and differential nonlinearity. Differences due to photocathode material and dependencies on EUV wavelength are also described. Over large spatial scales, the detector response is flat to better than 10 percent of the mean response, but, at spatial scales less than 1 mm, the variations from the mean can be as large as 20 percent.

Vallerga, J. V.

High resolution decoding of Multi-Anode Microchannel Array detectors

The Multi-Anode Microchannel Array (MAMA) is a photon counting detector which utilizes a photocathode for photon to electron conversion, a microchannel plate (MCP) for signal amplification and a proximity focused anode array for position sensitivity. The detector electronics decode the position of an event through coincidence discrimination. The decoding algorithm which associates a given event with the appropriate pixel is determined by the geometry of the array. A new algorithm incorporated into a CMOS Application Specific Integrated Circuit (ASIC) decoder which improves the pixel spatial resolution is described. The new algorithm does not degrade the detector throughput and does not require any modifications to the detector tube. The standard MAMA detector has a pixel size of 25 x 25 square microns, but with the new decoder circuit the pixel size is reduced to 12.5 x 12.5 square microns. We have built the first set of decode electronics utilizing the new ASIC chips and report here on the first imaging tests of this system.

Kasle, David B.