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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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NASA NTRS2011

Overview of NASA's Thermal Control System Development for Exploration Project

The now-cancelled Constellation Program included the Orion, Altair, and Lunar Surface Systems project offices. The first two elements, Orion and Altair, were planned to be manned space vehicles while the third element was much more diverse and included several sub-elements. Among other things, these sub-elements were Rovers and a Lunar Habitat. The planned missions involving these systems and vehicles included several risks and design challenges. Due to the unique thermal operating environment, many of these risks and challenges were associated with the vehicles thermal control system. NASA s Exploration Technology Development Program (ETDP) consisted of various technology development projects. The project chartered with mitigating the aforementioned thermal risks and design challenges was the Thermal Control System Development for Exploration Project. These risks and design challenges were being addressed through a rigorous technology development process that was planned to culminate with an integrated thermal control system test. Although the technologies being developed were originally aimed towards mitigating specific Constellation risks, the technology development process is being continued within a new program. This continued effort is justified by the fact that many of the technologies are generically applicable to future spacecraft thermal control systems. The current paper summarizes the development efforts being performed by the technology development project. The development efforts involve heat acquisition and heat rejection hardware including radiators, heat exchangers, and evaporators. The project has also been developing advanced phase change material heat sinks and performing a material compatibility assessment for a promising thermal control system working fluid. The to-date progress and lessons-learned from these development efforts will be discussed throughout the paper.

Stephan, Ryan A.↗

NASA NTRS1973

Cyclic arc plasma tests of RSI materials using a preheater

The results of a test program are reported in which a preheater was used with an arc plasma stream to study the thermal response of samples of candidate reusable surface insulation materials for the space shuttle. The preheater simulated the shuttle temperature history during the first and last portions of the test cycle, which could not be simulated by the air arc plasma flow. Pre- and post-test data taken for each of the materials included magnified views, optical properties, and chemical analyses. The test results indicate that the mullite base samples experience higher surface temperatures than the other materials at heating rates greater than 225 kw/sq m. The ceramic fibrous mullite and silica coatings show noncatalytic wall behavior. Internal temperature response data for the materials are compared and correlated with analytical predictions.

Stewart, D. A.↗

NASA NTRS2008

10.2 Thermal-Structural Testing

Objective: Test a C/SiC Ruddervator Subcomponent under relevant thermal, mechanical & dynamic loading a) Thermal-structural mission cycling for re-entry and hypersonic cruise conditions; b) High-temperature modal survey to study the effect of heating on mode shapes, natural frequencies and damping. Supports NASA ARMD Hypersonics Material & Structures Program. Partners: NASA Dryden / Langley / Glenn, Lockheed-Martin, Materials Research & Design, GE CCP Test Phases - Phase 1: Acoustic-Vibration Testing (LaRC) completed - Phase 2: Thermal-Mechanical Testing (DFRC) in assembly - Phase 3: Mechanical Testing (DFRC) in assembly

Hudson, Larry D.↗

NASA NTRS2000

2nd & 3rd Generation Vehicle Subsystems

This paper contains viewgraph presentation on the "2nd & 3rd Generation Vehicle Subsystems" project. The objective behind this project is to design, develop and test advanced avionics, power systems, power control and distribution components and subsystems for insertion into a highly reliable and low-cost system for a Reusable Launch Vehicles (RLV). The project is divided into two sections: 3rd Generation Vehicle Subsystems and 2nd Generation Vehicle Subsystems. The following topics are discussed under the first section, 3rd Generation Vehicle Subsystems: supporting the NASA RLV program; high-performance guidance & control adaptation for future RLVs; Evolvable Hardware (EHW) for 3rd generation avionics description; Scaleable, Fault-tolerant Intelligent Network or X(trans)ducers (SFINIX); advance electric actuation devices and subsystem technology; hybrid power sources and regeneration technology for electric actuators; and intelligent internal thermal control. Topics discussed in the 2nd Generation Vehicle Subsystems program include: design, development and test of a robust, low-maintenance avionics with no active cooling requirements and autonomous rendezvous and docking systems; design and development of a low maintenance, high reliability, intelligent power systems (fuel cells and battery); and design of a low cost, low maintenance high horsepower actuation systems (actuators).

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NASA NTRS1990

Structures technology development for hypersonic vehicles

This paper summarizes some of the efforts to advance hypersonic structures technology through the National Aero-Space Plane (NASP) Structures Technology Maturation Program. The ranges of expected structural loads and results from analysis and test activities are described. Topics briefly covered include shock impingement effects on aerothermal loads, actively-cooled structures concepts and test results to date for leading edges and panels, design and fabrication of a carbon-carbon control surface, a program for predicting performance of metal matrix composites, an analysis and sizing procedure for thermal structures, and some recently-developed test fixtures for seals, thermal insulation, and actively-cooled panels.

Camarda, Charles J.↗

NASA NTRS1976

Report to the NASA Administrator by the Aerospace Safety Advisory Panel on the Space Shuttle Program. Part 1: Observations and Conclusions

Each system was chosen on the basis of its importance with respect to crew safety and mission success. An overview of the systems management is presented. The space shuttle main engine, orbiter thermal protection system, avionics, external tanks and solid rocket boosters were examined. The ground test and ground support equipment programs were studied. Program management was found to have an adequate understanding of the significant ground and flight risks involved.

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NASA NTRS1983

Proceedings: Fourth Parabolic Dish Solar Thermal Power Program Review

The results of activities within the parabolic dish technology and applications development program are presented. Stirling, organic Rankine and Brayton module technologies, associated hardware and test results to date; concentrator development and progress; economic analyses; and international dish development activities are covered. Two panel discussions, concerning industry issues affecting solar thermal dish development and dish technology from a utility/user perspective, are also included.

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NASA NTRS1990

Thermal balance testing of the Anik-E spacecraft

Spar Aerospace, Ltd. of Canada has recently completed the first of two infrared thermal balance/thermal vacuum tests on Canada's next generation of telecommunication satellites: Anik-E. Anik-E is a two spacecraft program using a three axis stabilized GE 5000 series bus as the vehicle for its payload. The infrared test setup consists of the mechanical hardware required to support the spacecraft within the thermal vacuum chamber and the infrared rig which supports the spacecraft. Spar developed a software package which calculated the lamp positions to provide the necessary uniform heat flux, based on the required heat inputs on the various isothermal zones of the spacecraft for the different phases of the tests. Infrared heat sensors, radiometers, were installed on the spacecraft surfaces. These were connected to the facility data processing system and continually monitored the flux absorbed by the various spacecraft surfaces. The test set up had distinct advantages. It enabled testing to progress directly from the thermal balance to thermal vacuum. Waveguide runs were installed for the communications portion of the testing prior to pumpdown. This precluded the requirement to return to ambient to reconfigure the setup.

Golob, Alex↗

NASA NTRS2005

STS-114: Discovery Day 5 Post MMT Briefing

Wayne Hill, Space Shuttle Deputy Program Manager, and Chair of the Mission Management Team, reports the following: the testing of the thermal protection system in space, on orbit was successful; the MMT meeting formally approved the mission extension for one day; image analysis from the launch phase has been completed; tile and blankets had been formally cleared by the Engineering team; additional inspection of the reinforced carbon-carbon (RCC); gap filler, heat shield and small black spot phenomenon are carefully inspected and evaluated to prepare the safe return of the Discovery. Bill Gerstenmaier, ISS Program Manager reports on the extra vehicular activities (EVA): replaced the GPS antenna; prepared the airlock to attach the ESP2; re-powered CMG2; transfer of CWCs; and the MISSE packages were wrapped around thru at the end of the air lock. He mentioned the high currents problem seen on CMG3, which they will have to take off line to check and understand the problem. Consumables, engineering performance of the three sensors (LCS, LDRI, ITVC), CMG removal and replacement, EVA2 and EVA3, gap fillers, RCC, hydrogen tank pre-press cycles, thermal protection system, inspection, ISS supply maintenance, and projection of next flight are topics covered with the News Media.

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NASA NTRS2020

Passive Thermal Control of the Primordial Inflation Polarization Explorer (PIPER) Flight Electronics

The scientific balloon program at NASA offers an exciting and open area of opportunity for testing new technologies and for conducting meaningful experimentation at a fraction of the cost of a space mission. This paper outlines a simple thermal model developed and employed for the Primordial Inflation Polarization ExplorER (PIPER). The sub-orbital environment that PIPER operates in hosts an interesting mix of atmospheric and space thermal challenges. The work done was to mitigate thermal loads and passively cool the payload's exterior mounted electronics at an altitude of 36.6 km. This was done by characterizing the thermal environment and then designing solutions for the heat loads through a combined radiation and conduction passive cooling radiator system thermal model. Despite the simplicity and subsequent limitations of the model, as well as some unexpected payload operational events, the model produced results between 0.31% and 11.8% difference between the predicted values and measured average temperatures. From these results, the model was able to successfully provide estimates for the electronics temperatures. Additional flights will be needed to eliminate unknowns encountered in this flight in order to further refine the model for higher accuracy.

Walts, Alexander R.↗

NASA NTRS1985

Thermal barrier coating life-prediction model development

Life predictions are made for two types of strain-tolerant and oxidation-resistant Thermal Barrier Coating (TBC) systems produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system, composed of a low-pressure plasma spray (LPPS) applied oxidation-resistant NiCrAlY bond coating and an air-plasma-sprayed yttria (8 percent) partially stabilized zirconia insulative layer, is applied by both Chromalloy and Klock. The second type of TBC is applied by the electron-beam/physical vapor deposition process by Temescal. Thermomechanical and thermochemical testing of the program TBCs is in progress. A number of the former tests has been completed. Fracture mechanics data for the Chromalloy plasma-sprayed TBC system indicate that the cohesive toughness of the zirconia layer is increased by thermal cycling and reduced by high temperature exposure at 1150 C. Eddy current technology feasibility has been established with respect to nondestructively measuring zirconia layer thickness of a TBC system. High pressure turbine blades have been coated with program TBC systems for a piggyback test in a TFE731-5 turbofan factory engine test. Data from this test will be used to validate the TBC life models.

Strangman, T. E.↗

NASA NTRS2013

Accuracy Analysis and Validation of the Mars Science Laboratory (MSL) Robotic Arm

The Mars Science Laboratory (MSL) Curiosity Rover is currently exploring the surface of Mars with a suite of tools and instruments mounted to the end of a five degree-of-freedom robotic arm. To verify and meet a set of end-to-end system level accuracy requirements, a detailed positioning uncertainty model of the arm was developed and exercised over the arm operational workspace. Error sources at each link in the arm kinematic chain were estimated and their effects propagated to the tool frames.A rigorous test and measurement program was developed and implemented to collect data to characterize and calibrate the kinematic and stiffness parameters of the arm. Numerous absolute and relative accuracy and repeatability requirements were validated with a combination of analysis and test data extrapolated to the Mars gravity and thermal environment. Initial results of arm accuracy and repeatability on Mars demonstrate the effectiveness of the modeling and test program as the rover continues to explore the foothills of Mount Sharp.

rovers↗

NASA NTRS1973

Space shuttle thermal scale modeling application study

The critical thermal control problems and verification of thermal mathematical model results for the space shuttle concept are discussed. The use of a small scale thermal model of the space shuttle is proposed. It was determined that a one-third scale model of the space shuttle would serve as a useful tool throughout the entire thermal design and verification program. The major considerations in modeling the conduction-radiation-convection fields, the level of detail for modeling various systems, preliminary test requirements, and potential applications of the thermal scale model are summarized.

Marshall, K. N.↗

NASA NTRS2015

Simplified Abrasion Test Methodology for Candidate EVA Glove Lay-Ups

During the Apollo Program, space suit outer‐layer fabrics were badly abraded after performing just a few extravehicular activities (EVAs). For example, the Apollo 12 commander reported abrasive wear on the boots that penetrated the outer‐layer fabric into the thermal protection layers after less than 8 hrs of surface operations. Current plans for the exploration planetary space suits require the space suits to support hundreds of hours of EVA on a lunar or Martian surface, creating a challenge for space suit designers to utilize materials advances made over the last 40 years and improve on the space suit fabrics used in the Apollo Program. Over the past 25 years the NASA Johnson Space Center Crew and Thermal Systems Division has focused on tumble testing as means of simulating wear on the outer layer of the space suit fabric. Most recently, in 2009, testing was performed on 4 different candidate outer layers to gather baseline data for future use in design of planetary space suit outer layers. In support of the High Performance EVA Glove Element of the Next Generation Life Support Project, testing a new configuration was recently attempted in which require 10% of the fabric per replicate of that need in 2009. The smaller fabric samples allowed for reduced per sample cost and flexibility to test small samples from manufacturers without the overhead to have a production run completed. Data collected from this iteration was compared to that taken in 2009 to validate the new test method. In addition the method also evaluated the fabrics and fabric layups used in a prototype thermal micrometeoroid garment (TMG) developed for EVA gloves under the NASA High Performance EVA Glove Project. This paper provides a review of previous abrasion studies on space suit fabrics, details methodologies used for abrasion testing in this particular study, results of the validation study, and results of the TMG testing.

Rabel, Emily↗

NASA NTRSDate not supplied

Artemis II Mission Performance of the Orion Active Thermal Control System

The Orion spacecraft has recently completed Artemis II, the first crewed mission around the moon in 54 years. This test flight demonstrated vehicle capability as the foundation for all future missions under the Artemis program. As a major system of Orion, the Active Thermal Control System (ATCS) successfully managed crew and vehicle heat loads to provide adequate cooling and thermal comfort for the duration of the Artemis II mission. Thermal control on the Orion vehicle is managed through two redundant cooling loops in the Crew Module (CM) that absorb heat loads from the cabin and Air Revitalization System (ARS) heat exchangers, the Liquid Cooling Garment (LCG) heat exchanger, and the avionics cold plates, and then transfer those heat loads to the Service Module (SM) radiator loops and/or the Phase Change Material (PCM) and ammonia boilers when required through thermal configuration or mission phase. During Artemis II, Orion did not necessitate any supplemental cooling from ammonia boilers until service module separation, allowing the maximum availability of ammonia cooling prior to entry. This presentation will provide an overview of the Orion ATCS major subsystems, highlight the performance during key mission phases, and comment on the applicability of the observed thermal response to future Artemis missions.

Ellie Thurston↗

NASA NTRS1972

Thermal Skin fabrication technology

Advanced fabrication techniques applicable to Thermal Skin structures were investigated, including: (1) chemical machining; (2) braze bonding; (3) diffusion bonding; and (4) electron beam welding. Materials investigated were nickel and nickel alloys. Sample Thermal Skin panels were manufactured using the advanced fabrication techniques studied and were structurally tested. Results of the program included: (1) development of improved chemical machining processes for nickel and several nickel alloys; (2) identification of design geometry limits; (3) identification of diffusion bonding requirements; (4) development of a unique diffusion bonding tool; (5) identification of electron beam welding limits; and (6) identification of structural properties of Thermal Skin material.

Milam, T. B.↗

NASA NTRS1982

Solar array Shuttle flight experiment - Hardware development and testing

This paper reports on the fabrication and ground testing of (a) a large area, light-weight, flexible substrate developmental solar array wing that has been built for NASA-MSFC and of (b) the supporting structure and data acquisition system (DAS) which, with the wing, will be flown in the Shuttle as an experiment in 1984. The experiment will verify the dynamics, thermodynamic, and electrical performance predictions of the array wing and will demonstrate the structural capability of the array wing for Orbiter launch and re-entry environments. The experiment hardware verification program was designed to minimize costs and risk of experiment performance degradation while maintaining Shuttle and crew safety. The previous full-scale wing hardware tests included an extension mast water table test and wing testing for random vibration, thermal vacuum, and acoustic environments. The results of these tests were used to define wing design modifications and to scope the test program for the experiment hardware.

Elms, R. V.↗

NASA NTRS2011

Thermal Properties of Microstrain Gauges Used for Protection of Lithium-Ion Cells of Different Designs

The purpose of this innovation is to use microstrain gauges to monitor minute changes in temperature along with material properties of the metal cans and pouches used in the construction of lithium-ion cells. The sensitivity of the microstrain gauges to extremely small changes in temperatures internal to the cells makes them a valuable asset in controlling the hazards in lithium-ion cells. The test program on lithium-ion cells included various cell configurations, including the pouch type configurations. The thermal properties of microstrain gauges have been found to contribute significantly as safety monitors in lithium-ion cells that are designed even with hard metal cases. Although the metal cans do not undergo changes in material property, even under worst-case unsafe conditions, the small changes in thermal properties observed during charge and discharge of the cell provide an observable change in resistance of the strain gauge. Under abusive or unsafe conditions, the change in the resistance is large. This large change is observed as a significant change in slope, and this can be used to prevent cells from going into a thermal runaway condition. For flexible metal cans or pouch-type lithium-ion cells, combinations of changes in material properties along with thermal changes can be used as an indication for the initiation of an unsafe condition. Lithium-ion cells have a very high energy density, no memory effect, and almost 100-percent efficiency of charge and discharge. However, due to the presence of a flammable electrolyte, along with the very high energy density and the capability of releasing oxygen from the cathode, these cells can go into a hazardous condition of venting, fire, and thermal runaway. Commercial lithium-ion cells have current and voltage monitoring devices that are used to control the charge and discharge of the batteries. Some lithium-ion cells have internal protective devices, but when used in multi-cell configurations, these protective devices either do not protect or are themselves a hazard to the cell due to their limitations. These devices do not help in cases where the cells develop high impedance that suddenly causes them to go into a thermal runaway condition. Temperature monitoring typically helps with tracking the performance of a battery. But normal thermistors or thermal sensors do not provide the accuracy needed for this and cannot track a change in internal cell temperatures until it is too late to stop a thermal runaway.

Jeevarajan, Judith↗