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NASA NTRS2023

Developing a Hybrid Space Suit Simulator as a Research Tool for Assessing Extravehicular Activity Relevant Workload

Suited testing time is limited and hard to come by, expensive, and requires a whole team to operate and monitor the suit; however, pressurized spacesuits are not always necessary for initial developmental efforts or assessment of informatics. The Human Physiology, Performance, Protection & Operations Laboratory (H-3PO) at NASA Johnson Space Center (JSC) is developing a Hybrid Space Suit Simulator (HS3) to support characterization of human performance during planetary surface exploration analogs. The primary goal of HS3 is to create a low cost, modular, and unpressurized suit simulator for use as a research tool which provides relevant physical and cognitive workload approximations with EVA-like immersion during planetary extravehicular activity (EVA) simulations. HS3 consists of a soft suit, communication, thermal control, gloves, boots, helmet, and integrated bioinformatics/sensors. The modular design of HS3 allows it to be modified to support test objectives as needed. HS3 enables H-3PO and NASA to complete critical human health and performance testing to address open risks and knowledge gaps in a timely, repeatable, and controlled manner. Four engineering runs were completed with HS3 as a baseline for capability. General workload was assessed while traversing on a passive treadmill and conducting geology tasks. Liquid cooling temperature, suit temperature, and metabolic rates were collected during one extended three-hour engineering run. For the duration of the engineering run the suit temperature was 26.6 ± 1.58 °C while suit humidity was 53.7 ± 5.11 %. Helmet temperature was higher than suit temperature at 27.8 ± 1.58 °C. Helmet humidity was lower than average suit humidity at 50.12 ± 11.3 °C. The liquid cooling temperature remained stable at 22.4 ± 1.62 °C. Resting metabolic rate was 597 ± 88 BTU/hr while metabolic rate increased during traverse tasks at 1500 ± 319 BTU/hr and geology tasks at 921 ± 129 BTU/hr. Following the engineering runs, a characterization study will be conducted. The subjects will perform EVA-like scenarios in both a shirtsleeve only and donned HS3, consisting of EVA task circuit focused on traversing, geological rock sampling, and task board manipulation. The characterization study will provide data capability for implementing HS3 in analog EVA testing environments.

Monica Hew↗

NASA NTRS1973

Space shuttle orbit maneuvering engine reusable thrust chamber program

Tests were conducted on the regenerative cooled thrust chamber of the space shuttle orbit maneuvering engine. The conditions for the tests and the durations obtained are presented. The tests demonstrated thrust chamber operation over the nominal ranges of chamber pressure mixture ratio. Variations in auxiliary film coolant flowrate were also demonstrated. High pressure tests were conducted to demonstrate the thrust chamber operation at conditions approaching the design chamber pressure for the derivative space tug application.

Pauckert, R. P.↗

NASA NTRS1975

Internal convective cooling systems for hypersonic aircraft

Parametric studies were conducted to investigate the relative merits of construction materials, coolants, and cooled panel concepts for internal convective cooling systems applied to airframe structures of hydrogen-fueled hypersonic aircraft. These parametric studies were then used as a means of comparing various cooled structural arrangements for a hypersonic transport and a hypersonic research airplane. The cooled airplane studies emphasized weight aspects as related to the choice of materials, structural arrangements, structural temperatures, and matching of the cooling system heat load to the available hydrogen fuel-flow heat sink. Consideration was given to reliability and to fatigue and fracture aspects, as well. Even when auxiliary thermal protection system items such as heat shielding, insulation, and excess hydrogen for cooling are considered the more attractive actively cooled airframe concepts indicated potential payload increases of from 40 percent to over 100 percent for the hypersonic transport as compared to the results of previous studies of the same vehicle configuration with an uncooled airframe.

Anthony, F. M.↗

NASA NTRS2013

Feasibility Study of Venus Surface Cooling Using Chemical Reactions with the Atmosphere

A literature search and theoretical analysis were conducted to investigate the feasibility of cooling a craft on Venus through chemical reformation of materials from the atmosphere. The core concept was to take carbon dioxide (CO2) from the Venus atmosphere and chemically reform it into simpler compounds such as carbon, oxygen, and carbon monoxide. This process is endothermic, taking energy from the surroundings to produce a cooling effect. A literature search was performed to document possible routes for achieving the desired reactions. Analyses indicated that on Venus, this concept could theoretically be used to produce cooling, but would not perform as well as a conventional heat pump. For environments other than Venus, the low theoretical performance limits general applicability of this concept, however this approach to cooling may be useful in niche applications. Analysis indicated that environments with particular atmospheric compositions and temperatures could allow a similar cooling system to operate with very good performance. This approach to cooling may also be useful where the products of reaction are also desirable, or for missions where design simplicity is valued. Conceptual designs for Venus cooling systems were developed using a modified concept, in which an expendable reactant supply would be used to promote more energetically favorable reactions with the ambient CO2, providing cooling for a more limited duration. This approach does not have the same performance issues, but the use of expendable supplies increases the mass requirements and limits the operating lifetime. This paper summarizes the findings of the literature search and corresponding analyses of the various cooling options.

Evans, Christopher↗

NASA NTRS2013

Feasibility Study of Venus Surfuce Cooling Using Chemical Reactions with the Atmosphere

Evans, Christopher↗

NASA NTRS1997

Advanced Film Cooling Rig: Development and Test Results

The Advanced Film Cooling Rig (AFCR) test was a program to develop a thermal imaging camera system to measure the effectiveness of multihole film cooling. This system was used to evaluate low-thermal conductivity ceramic test panels incorporating a wide range of multihole cooling geometries. Tests were conducted with a mainstream flow of 600 F at Mach numbers of 0.37 and 1.57. Coolant flow was controlled to give a blowing parameter variation of up to 2.9. Data reduction techniques are given for camera calibration, rig temperature reflection correction, and deriving surface temperatures from video images. Results are presented in terms of overall and film cooling effectiveness distributions. A one-dimensional analysis of a unit film cooling hole was performed to generate film temperature.

Reilly, R. S.↗

NASA NTRS1975

Experimental transient turbine blade temperatures in a research engine for gas stream temperatures cycling between 1067 and 1567 k

Experimental transient turbine blade temperatures were obtained from tests conducted on air-cooled blades in a research turbojet engine, cycling between cruise and idle conditions. Transient data were recorded by a high speed data acquisition system. Temperatures at the same phase of each transient cycle were repeatable between cycles to within 3.9 K (7 F). Turbine inlet pressures were repeatable between cycles to within 0.32 N/sq cm (0.47 psia). The tests were conducted at a gas stream temperature of 1567 K (2360 F) at cruise, and 1067 K (1460 F) at idle conditions. The corresponding gas stream pressures were about 26.2 and 22.4 N/sq cm (38 and 32.5 psia) respectively. The nominal coolant inlet temperature was about 811 K (1000 F).

Gauntner, D. J.↗

NASA NTRS1977

Experimental flow coefficients of a full-coverage film-cooled-vane chamber

Ambient- and elevated-temperature flow tests were performed on a four-times-actual-size model of an impingement- and film-cooled segment of a core engine turbine vane. Tests were conducted with the impingement and film cooling plates combined to form a chamber and also with each of the individual separated plates. For the combined tests, the proximity of the film cooling plate affected the flow of coolant through the impingement plate, but not conversely. Impingement flow is presented in terms of a discharge coefficient, and the film cooling flow discharging into still air with no main stream gas flow is presented in terms of a total pressure-loss coefficient. The effects of main stream gas flow on discharge from the film cooling holes are evaluated as a function of coolant to main-stream gas momentum flux ratio. A smoothing technique is developed that identifies and helps reduce flow measurement data scatter.

Meitner, P. L.↗

NASA NTRS1994

Experimental studies of shock-wave/wall-jet interaction in hypersonic flow

Experimental studies have been conducted to examine slot film cooling effectiveness and the interaction between the cooling film and an incident planar shock wave in turbulent hypersonic flow. The experimental studies were conducted in the 48-inch shock tunnel at Calspan at a freestream Mach number of close to 6.4 and at a Reynolds number of 35 x 10(exp 6) based on the length of the model at the injection point. The Mach 2.3 planar wall jet was generated from 40 transverse nozzles (with heights of both 0.080 inch and 0.120 inch), producing a film that extended the full width of the model. The nozzles were operated at pressures and velocities close to matching the freestream, as well as at conditions where the nozzle flows were over- and under-expanded. A two-dimensional shock generator was used to generate oblique shocks that deflected the flow through total turnings of 11, 16, and 21 degrees; the flows impinged downstream of the nozzle exits. Detailed measurements of heat transfer and pressure were made both ahead and downstream of the injection station, with the greatest concentration of measurements in the regions of shock-wave/boundary layer interaction. The major objectives of these experimental studies were to explore the effectiveness of film cooling in the presence of regions of shock-wave/boundary layer interaction and, more specifically, to determine how boundary layer separation and the large recompression heating rates were modified by film cooling. Detailed distributions of heat transfer and pressure were obtained in the incident shock/wall-jet interaction region for a series of shock strengths and impingement positions for each of the two nozzle heights. Measurements were also made to examine the effects of nozzle lip thickness on cooling effectiveness. The major conclusion from these studies was that the effect of the cooling film could be readily dispersed by relatively weak incident shocks, so the peak heating in the recompression region was not significantly reduced by even the largest levels of film cooling. For the case studies in the absence of film cooling, the interaction regions were unseparated. However, adding film cooling resulted in regions of boundary layer separation induced in the film cooling layer -- the size of which regions first increased and then decreased with increased film cooling. Surprisingly, the size of the separated regions and the magnitude of the recompression heating were not strongly influenced by the thickness of the cooling film, nor by the point of shock impingement relative to the exit plane of the nozzles. The lip thickness was found to have little effect on cooling effectiveness. Measurements with and in the absence of shock interaction were compared with the results of earlier experimental studies and correlated in terms of the major parameters controlling these flows.

Holden, Michael S.↗

NASA NTRS1994

Experimental studies of shock-wave/wall-jet interaction in hypersonic flow, part A

Experimental studies have been conducted to examine slot film cooling effectiveness and the interaction between the cooling film and an incident planar shock wave in turbulent hypersonic flow. The experimental studies were conducted in the 48-inch shock tunnel at Calspan at a freestream Mach number of close to 6.4 and at a Reynolds number of 35 x 10(exp 6) based on the length of the model at the injection point. The Mach 2.3 planar wall jet was generated from 40 transverse nozzles (with heights of both 0.080 inch and 0.120 inch), producing a film that extended the full width of the model. The nozzles were operated at pressures and velocities close to matching the freestream, as well as at conditions where the nozzle flows were over- and under-expanded. A two-dimensional shock generator was used to generate oblique shocks that deflected the flow through total turnings of 11, 16, and 21 degrees; the flows impinged downstream of the nozzle exits. Detailed measurements of heat transfer and pressure were made both ahead and downstream of the injection station, with the greatest concentration of measurements in the regions of shock-wave/boundary layer interaction. The major objectives of these experimental studies were to explore the effectiveness of film cooling in the presence of regions of shock-wave/boundary layer interaction and, more specifically, to determine how boundary layer separation and the large recompression heating rates were modified by film cooling. Detailed distributions of heat transfer and pressure were obtained in the incident-shock/wall-jet interaction region for a series of shock strengths and impingement positions for each of the two nozzle heights. Measurements were also made to examine the effects of nozzle lip thickness on cooling effectiveness. The major conclusion from these studies was that the effect of the cooling film could be readily dispersed by relatively weak incident shocks, so the peak heating in the recompression region was not significantly reduced by even the largest levels of film cooling. For the case studies in the absence of film cooling, the interaction regions were unseparated. However, adding film cooling resulted in regions of boundary layer separation induced in the film cooling layer, the size of which regions first increased and then decreased with increased film cooling. Surprisingly, the size of the separated regions and the magnitude of the recompression heating were not strongly influenced by the thickness of the cooling film, nor by the point of shock impingement relative to the exit plane of the nozzles. The lip thickness was found to have little effect on cooling effectiveness. Measurements with and in the absence of shock interaction were compared with the results of earlier experimental studies and correlated in terms of the major parameters controlling these flows.

Holden, Michael S.↗

NASA NTRS1978

Liquid-cooling technology for gas turbines review and status

A review of research related to liquid cooling of gas turbines was conducted and an assessment of the state of the art was made. Various methods of liquid cooling turbines were reviewed. Examples and results with test and demonstrator turbines utilizing these methods along with the advantages and disadvantages of the various methods are discussed.

Vanfossen, G. J., Jr.↗

DOE OSTI2022

Design, Deployment, and Characterization of the World’s First Flexible Large Power Transformer

GE Research and its partner Prolec GE have designed, built and deployed in the field the world’s first flexible power transformer. The flexible power transformer is a transmission class 3-phase autotransformer configurable in impedance and in voltage which allows it to serve as a universal spare for multiple units in a given fleet. However, the key innovation in this new concept is the online adjustable leakage impedance which allows the transformer to change its impedance without interrupting the transmission line operation. The flexible power transformer can be designed with up to three low voltage transmission class ratings and up to 12 impedance values changeable both online and offline. This report provides an overview of the design, manufacturing, testing, and commissioning of the 165kV, 60MVA prototype built including the results of the field performance validation tests. The prototype was specified in collaboration with Cooperative Energy, the utility host. It was designed and tested in the factory according to IEEE standard C57.12.00 and followed all protocols for transportation, installation, and commissioning of a power transformer. In addition to the prototype, a flexible protection system capable of automatically adjusting its settings upon the transformer impedance was also developed and deployed in the for testing and validation. On September 3, 2021 the prototype was energized in Cooperative Energy’s substation in Columbia, Mississippi to become the world’s first flexible power transformer in operation. Its performances and impact on the grid operation were demonstrated through different field tests. Results obtained confirm that the impedance of the flexible transformer can be varied under load through its full range, from 4.3% to 9.3%, without adverse impacts on the line operation, the protection system, the transformer stability and health condition. Results also proved that the flexible transformer is very effective in controlling power transfer through the line or load sharing between units operating in parallel. Indeed, it was proven that higher impedances decrease the thruput power of the transformer while lower impedances increase it. Up to 26MW was controllable on a line loading of 45MVA. It was also possible to demonstrate that the variation of the transformer impedance has no effect on the circulating current between units in parallel, except a minor transient during the impedance change. It was also proven that the flexible protection relay can update its protection settings automatically when the impedance change was detected. The prototype has operated continuously for more than 12 months now with a peak load exceeding 50MVA corresponding to >80% of its ONAN power rating. No alarm, trip or sign of failure has been reported by the utility. In addition to the development and deployment of the flexible transformer prototype, investigations were carried out on new nanodielectric fluids to replace the mineral oil used in power transformers with the goal of reducing their footprint and weight. The key parameters that were targeted for improvement included the breakdown voltage to reduce clearances between windings and tank hence the footprint; viscosity and thermal conductivity to increase the cooling efficiency and therefore to reduce the winding material. Several nanodielectric mixtures with mineral oil including with alumina (Al2O3), titania (TiO2) and Borum Nitrate (BN) with different surfactants have been analyzed and tested. Unfortunately, despite encouraging results no nanofluid candidate has been found viable to replace mineral oil. With the formulations tested, breakdown voltages are generally similar to mineral oil at lower particle contents and worse at higher particle contents. Viscosity appreciably increased at particles concertation over 2 wt% and thermal conductivity increased slightly at 5wt% and appears to be 10-15% higher at 10 wt% particle content. It is recommended to continue investigations to find solutions that can help increase the power density of future flexible power transformers. Flexible power transformers can significantly help the future power grid by providing more flexibility and resiliency. Indeed, by providing voltage and impedance flexibility, flexible power transformers reduce the need for multiple spares, hence inventory costs for utilities. With their online controllable impedance, they can provide support to the grid and help manage short-circuit currents, power flow, line congestion, and grid stability which will become more important with higher penetrations of intermittent renewable resources. During the field validation tests, it was demonstrated that up to 26MW was controllable on a line loading of 45MVA when the transformer impedance was varied from its minimum to its maximum range. Also, with the impedance range, the short-circuit currents could be reduced by up to 38% at the load side of the transformer. With its controllable impedance, flexible transformers can be used in future strategies of grid resilience to help better prepare the grid to face forecasted severe events including storms, heat waves and contingencies. The flexible power transformers can also find role in other applications including high voltage transmission cables such as offshore wind farms where solutions for energizing the cables and managing the reactive power are of critical importance. The designed flexible power transformer is now fully validated and ready for commercialization. Further analysis on the benefits of flexible power transformers for grid stability and short-circuit management including current limiting capability, reclosure and line restoration, control of inrush current, sizing of flexible AC components (FACTS) would help its rapid adoption by the industry.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS1979

Review of the metallographic cooling rates of meteorites and a new model for the planetesimals in which they formed

The cooling rates of meteorites through approximately 900 -650 K, as read from their metal alloy compositions, are reviewed. Metallographic cooling rates are compared with the cooling rates that appear to be required by the K/Ar and Ar-40/Ar-39 ages of five meteorite classes, and discrepancies are found in all cases. Either (1) the metallographic cooling rates (and also Pu-244 fission cooling rates) are systematically in error, being too slow by a factor of approximately 6; or (2) the traditional thermal model for parent meteorite planets (having constant dimension and uniform physical properties) is oversimplified and the Ar closure temperatures for chondrites derived by Turner et al. (1978) are too low. An alternative parent planet model is proposed and numerically modeled, in which accretion of thermally insulating particulate matter, heat generation by Al-26 decay, melting or sintering of the particulate matter into conductive rock, and establishment of the properties of the meteorites occurred concurrently. Meteorite chronologies are somewhat easier to understand in this context, since the initially small, hot (thus sintered and conductive) bodies would have cooled rapidly to isotopic closure, but later cooling might have been much slower as a result of the continued accretion of insulating particulate matter.

Wood, J. A.↗

NASA NTRS1972

Structural active cooling applications for the Space Shuttle.

Analytic and experimental studies have been conducted to evaluate a number of active cooling approaches to structural thermal protection for the Space Shuttle. The primary emphasis was directed toward the thermal protection system. Trade study results are presented for various heat shield material and TPS arrangements. Both metallic and reusable surface insulation (RSI) concepts were considered. Active systems heat sinks consisted of hydrogen, phase change materials, and expendable water. If consideration is given only to controlling the surface temperature, passive TPS was found to provide the most efficient system. Use of active cooling which incorporates some interior temperature control made the thermally less efficient RSI system more attractive.

Masek, R. V.↗

NASA NTRS1974

Experimental transient vane temperatures in a cascade for gas stream temperature cycling between 922 and 1644 K (1200 and 2500 F)

Experimental transient turbine vane metal temperatures were obtained from tests conducted on air-cooled vanes installed in a four-vane cascade for a gas temperature cycled between 922 and 1644 K (1200 and 2500 F). Transient data were recorded by a high-speed data acquisition system. Temperatures at the same phase of each transient cycle were repeatable between cycles to within 11 kelvins (20 F), simulated cruise and idle steady-state readings were repeated by the cruise and idle readings taken from the ends of a transient half-cycle at low pressure to within 17 kelvins (30 F). The tests were conducted at pressure levels of 31 and 83 N-sq cm (45 and 120 psia) with coolant temperatures of 811 and 589 K (1000 and 600 F), respectively.

Gauntner, D. J.↗

NASA NTRS2003

Selection And Evaluation Of An Alloy For Nozzle Application

The present work includes results on material characterization conducted under COBRA Hydrogen Cooled Nozzle Program and was funded by NASA MSFC. The nozzle requires a material that has high strength at ambient and high (up to l200 F) temperatures in air and hydrogen. Presently, a precipitation hardened steel; A-286 is used in nozzles for Space Shuttle Engines. The A-286 alloy has limited hydrogen compatibility and weldability. The present work focused on selection and characterization of JBK-75 alloy that has significantly higher capability in hydrogen and weldability in addition to other attributes. The alloy was evaluated at different temperatures and environments. Tungsten Inert Gas (TIG) and Electron Beam welding techniques were used to evaluate the weldability of material. Brazing was also conducted on the alloy and evaluated. The characterization of base JBK-75 alloy, welded and brazed alloy included tensile properties, low cycle fatigue and crack growth resistance at different temperatures in air and hydrogen environments. The results indicated that JBK-75 has excellent tensile and fatigue properties in air and hydrogen. The welded and brazed alloy also showed very good properties.

Pandey, A. B.↗

DOE OSTI2026

Effect of a transparent water-cooled cathode on the neutron production rate in the glow discharge-type fusion neutron source

In glow discharge-type deuterium–deuterium fusion neutron sources, fusion reactions occurring on the cathode surface contribute significantly to the neutron production rate (NPR); therefore, cathode design plays a crucial role in enhancing NPR. Although the NPR generally increases with discharge current, deuterium desorption caused by cathode heating tends to stagnate it in the high-current regime. Water cooling has been shown to mitigate this stagnation for nontransparent cathodes, but its effectiveness for transparent cathodes has not been experimentally clarified. Here, in this study, a transparent cathode with active water cooling and a spherical geometry was designed and fabricated using stainless steel tubing. Neutron production experiments were conducted with and without water cooling: with water cooling, applied voltages of 20–40 kV were investigated, while without water cooling, the applied voltage was limited to 25 kV. The results showed that the NPR increased continuously with discharge current without stagnation when water cooling was applied. A maximum NPR of (1.8 ± 0.02) × 10 6 n/s was achieved at 40 kV and 50 mA. Compared with our previously reported disk cathode and nontransparent water-cooled cathode of the same diameter, the transparent water-cooled cathode exhibited a significantly enhanced NPR. These findings indicate that combining cathode transparency with active cooling is an effective strategy for improving neutron production in glow discharge-type fusion neutron sources.

43 PARTICLE ACCELERATORS↗

NASA NTRS1980

Low-pressure performance of annular, high-pressure (40 atm) high-temperature (2480 K) combustion system

Experimental tests were conducted to develop a combustion system for a 40 atmosphere pressure, 2480 K exhaust gas temperature, turbine cooling facility. The tests were conducted in an existing facility with a maximum pressure capability of 10 atmospheres and where inlet air temperatures as high as 894 K could be attained. Exhaust gas temperatures were as high as 2365 K. Combustion efficiences were about 100 percent over a fuel air ratio range of 0.016 to 0.056. Combustion efficiency decreased at leaner and richer ratios when the inlet air temperature was 589 K. Data are presented that show the effect of fuel air ratio and inlet air temperature on liner metal temperature. Isothermal system pressure loss as a function of diffuser inlet Mach number is also presented. Data included exhaust gas pattern factors; unburned hydrocarbon, carbon monoxide, and oxides of nitrogen emission index values; and smoke numbers.

Wear, J. D.↗