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The purpose of this paper is to provide an error analysis for the p-version of the discontinuous Galerkin finite element method for heat transfer in built-up structures. As a special case of the results in this paper, a theoretical error estimate for the numerical experiments recently conducted by James Tomey is obtained.
Gas-gap heat switches can serve as an effective means of thermally disconnecting a standby cryocooler when the primary (operating) cooler is connected and vice versa. The final phase of the development and test of a cryogenic heat switch designed for loads ranging from 2 watts at 8 K, to 100 watts at 80 K are described. Achieved heat-switch on/off conductance ratio ranged from 11,000 at 8 K to 2200 at 80 K. A particularly challenging element of heat-switch design is achieving satisfactory operation when large temperatures differentials exist across the switch. A special series of tests and analyses was conducted and used in this Phase-2 activity to evaluate the developed switches for temperature differentials ranging up to 200 K. Problems encountered at the maximum levels are described and analyzed, and means of avoiding the problems in the future are presented. A comprehensive summary of the overall heat-switch design methodology is also presented with special emphasis on lessons learned over the course of the 4-year development effort.
The invention is a method and apparatus for joining structures, an active structure and a passive structure, and imposing a tensile pre-load on the joint by a remotely operable mechanism comprising a heat contractible joining element. The method and apparatus include mounting on the structure, a probe shaft of material which is transformable from an expanded length to a contracted length when heated to a specific temperature range. The shaft is provided with a probe head which is receivable in a receptacle opening formed in the passive structure, when the active structure is moved into engagement therewith by an appropriate manipulator mechanism. A latching system mounted on the structure adjacent to the receptacle opening captures the probe head, when the probe head is inserted a predetermined amount. A heating coil on the shaft is energizable by remote control for heating the shaft to a temperature range which transforms the shaft to its contracted length, whereby a latching shoulder thereof engages latching elements of the latching system and imposes a tensile preload on the structural joint. Provision is also made for manually adjusting the probe head on the shaft to allow for manual detachment of the structures or manual preloading of the structural joint.
The invention is a method and apparatus for joining structures, an active structure and a passive structure, and imposing a tensile pre-load on the joint by a remotely operable mechanism comprising a heat contractible joining element. The method and apparatus include mounting on the structure, a probe shaft of material which is transformable from an expanded length to a contracted length when heated to a specific temperature range. The shaft is provided with a probe head which is receivable in a receptacle opening formed in the passive structure, when the active structure is moved into engagement therewith by an appropriate manipulator mechanism. A latching system mounted on the structure adjacent to the receptacle opening captures the probe head, when the probe head is inserted a predetermined amount. A heating coil on the shaft is energizable by remote control for heating the shaft to a temperature range which transforms the shaft to its contracted length, whereby a latching shoulder thereof engages latching elements of the latching system and imposes a tensile preload on the structural joint. Provision is also made for manually adjusting the probe head on the shaft to allow for manual detachment of the structures or manual preloading of the structural joint.
Space heating represents approximately one-tenth of the United States’ energy use and has a breadth of potential for emission reduction. An element of space heating, hydronic heat distribution methods, use water supply temperatures up to 82.2 °C (180 °F). However, this operating temperature can be incompatible with high-efficiency heat generation systems, which typically provide heating temperatures of up to 60 °C (140 °F). In this work, a low-cost retrofit solution is developed using experimentally validated computational tools by incorporating an airflow distributor that preferentially directs the airflow from a fan to enhance heat transfer over the finned-tube heat exchanger found in conventional baseboards. The same heat output of traditional baseboard heat distribution systems operating at higher water supply temperatures (71.1 – 82.2 °C) can also be achieved at lower temperatures (≤60 °C). Specifically, results indicate that the technology can produce more than a 46.7% improvement in the heat transfer output at temperatures as low as 60 °C (140 °F), effectively matching the same output range achieved by 71.1 – 82.2 °C (160–180 °F) water supply temperatures. An important benefit of this solution is that it utilizes the existing infrastructure as opposed to requiring the replacement of the entire distribution system. Additionally, this technology enables existing building infrastructure to be coupled with newer, high-efficiency heating systems such as condensing boilers, solar-thermal systems, and geothermal/air-to-water heat pumps that may produce lower water supply temperatures (60 °C). A geospatially resolved techno-economic and environmental analysis is completed and presented to further understand the equivalent carbon footprint of enabling higher efficiency heat generation systems with the improved efficiency heat distribution system disclosed. Using 2021 grid-average emission factors, an emission reduction of up to a 67.5% decrease (2658 kgCO 2 /yr) for a single-family home, depending on state and climate region, could be realized by replacing a traditional natural gas-fired boiler with an air-to-water heat pump coupled to the same high-temperature heat distribution system along with the low-cost retrofit solution. A complete CO 2 emission reduction of 6688 kgCO 2 /yr, depending on state and climate region, could be realized if all electricity is further renewably sourced. Thus, this study provides a possible pathway towards enabling the reduction of operational emissions in space heating.
The Delivery Environments Testbeds to Reduce Uncertainty in Simulations and Tests (TRUST) project is a broad project intended to analyze simplified problems experimentally and with modeling and simulation. The purpose of analyzing these simplified problems is to extend solution methods to more complex problems, as well as understand deficiencies and gaps in knowledge of methods currently used in more complex analyses. The TRUST project encompasses several smaller testbeds intended to isolate individual phenomena. The testbed under consideration in this report is the Sensors in Environments: Thermocouples testbed. In previous years, the purpose of this testbed was to quantify uncertainty of thermocouple sensors. To accomplish this, an aluminum plate was placed in a thermal chamber and subject to various types of thermal loading. Thermocouples were placed in various locations on the aluminum plate in various configurations (e.g., embedded in the plate, placed under Kapton tape), and an effort was made to quantify uncertainty in these measurements. Finite element simulations were performed to investigate how sensitive these measurements were to parameters such as the boundary conditions on the plate and material properties. However, a fundamental source of uncertainty in this analysis was the convective heat transfer from the plate. Convective heat transfer is a complex physical phenomenon comprised of a number of interacting sub-processes and is difficult to predict accurately a priori. As such, the main purpose of this testbed in FY25 was to better understand, both experimentally and numerically, the convective heat transfer from the plate. This is a highly applicable problem to several more complex problems, as convective heat transfer occurs in nearly all problems where a body is moving through air. Numerically, this required a two-step approach. First, the air flow in the thermal chamber was in vestigated using computational fluid dynamics. The commercial solver Fluent was used to perform these simulations. From these simulations, a heat transfer coefficient over the surface of the plate was calculated. This heat transfer was then used as boundary conditions for finite element heat transfer simulations within the plate, which were performed using Abaqus. Significant effort was devoted to automating the handoff between these two solvers. Experimentally, previous thermocouple results in the plate were used to validate the time-dependent thermal profiles produced from Abaqus. Further experimental efforts were performed both to help validate the Fluent simulations and to inform its boundary conditions. For example, hot-wire anemometers were used to measure the velocity in the chamber, which would be particularly useful in understanding the chamber inlet velocity. Thermocouple measurements were also taken in the chamber, instead of only on the plate, to serve as validation evidence for the Fluent simulations. Numerical results showed that the Fluent to Abaqus workflow matched previous plate thermocouple measurements well. This type of handoff is useful for more complex experiments, or those that are not able to be examined in as great of detail as this testbed, as it was performed without any experimental input. Experimental results, however, were more mixed. The anemometers proved unreliable, with inconsistent measurements across all anemometers, even at locations that were nearly identical. On the other hand, the thermocouples provided a relatively rich view of the temperature field in the chamber.
Here, this paper presents the phase stability and elemental partitioning in a Co-40Ni-10Al-7.5W-10Cr-3Nb-0.06B-0.6C (at.%) superalloy (referred to as 3Nb) after a two-step heat treatment. The resulting microstructure consisted of γ, γ', MC carbides and µ-Co 7 W 6 phase decorating the regions near and at the grain boundaries. Nb preferentially partitioned to the γ'-phase and other elements such as Ni, Cr and W were responsible for the μ-phase formation.
Design of the nuclear thermionic space power system, 40 50 70 Kw(e) power range, are given. The design configuration (1) meets the constraints of readily available launch vehicles; (2) allows for off-design operation including startup, shutdown, and possible emergency conditions; (3) provides tolerance of failure by extensive use of modular, redundant elements; (4) incorporates and uses heat pipes in a fashion that reduces the need for extensive in-pile testing of system components; and (5) uses thermionic converters, nuclear fuel elements, and heat transfer devices in a geometrical form adapted from existing incore thermionic system designs. Designs and in some cases performance data for elements and groups of the elements of the system are included. Benefits of the highly modular system approach to reliability, safety, economy of development, and flexibility are discussed.
Highlights: • Atom probe is used to investigate the element concentration changes in γ and γ' phase during creep. • Mo, W and Re diffuse from γ' to γ phase and enrich in γ/γ' interface during high temperature creep. • Super-dislocations in γ' phase may cross-slip from {111} to {100} plane due to the elements diffusions. • Dislocations shearing into γ' phase may decompose into K-W locks plus APB due to the refractory elements enrichment. - Abstract: By means of creep property measurement, microstructure observation and atom probe tomography, the elements distribution and deformation features of a 4.5% Re nickel-based single crystal superalloy during creep are investigated. Results show that after fully heat treated, the elements Al and Ta are mainly distributed in γ′ phase of alloy. After the alloy is crept up to fracture at 1100 °C/137 MPa, the change of the elements distributing in γ and γ′ phases occurs, wherein, the concentration decrement of the elements Al and Cr in γ′ and γ phases is attributed to their oxidation which may consume the ones. Moreover, some of the atoms Re, W and Mo dissolving in γ′ phase are repelled into γ matrix to reduce its internal energy. And the peak concentration of the atoms Re and W appears in the γ phase near the transition region, the atoms Re, W in the peak region cause the lattice distortion to increase the resistance of dislocations motion, which may improve the creep resistance of alloy. In the later stage of creep, dislocations shearing into the rafted γ′ phase may cross-slip from {111} to {100} plane to form the configuration of K-W locks, which may restrain the slipping of dislocations to improve the creep resistance of alloy. Wherein, the atom Re with lower diffusion coefficient may delay the dislocations in K-W locks for slipping and cross-slipping, which is thought to be the main reason of the K-W locks keeping in 4.5%Re alloy during creep at 1100 °C.
The investigation of heat transfer in supercritical CO2 (sCO2) has garnered considerable attention in recent decades, given sCO2's potential as a promising working fluid for advanced power conversion cycles. Despite previous research efforts, there are still gaps in our understanding of sCO2 heat transfer, particularly in conditions associated with heat transfer deterioration. To delve into sCO2 heat transfer more comprehensively, we propose employing the high-fidelity computational fluid dynamics code NekRS to simulate sCO2 flow using the large eddy simulation technique. Through graphics processing unit acceleration, NekRS achieves a higher computational speed than traditional CPU-based systems. However, before using NekRS in practical applications involving sCO2, it is imperative to perform verification and validation. Here, this paper presents our efforts to verify and validate the NekRS code's capability for simulating sCO2 using heated vertical tubes, where heat transfer deterioration usually happens. To accommodate the unique properties of sCO2, we have modified the NekRS code by integrating third-party property modules, such as REFPROP and PROPATH. Our simulations are compared with experimental and numerical data from the literature, instilling confidence in leveraging NekRS for future engineering applications. Our simulations also reveal that the accuracy of the property module significantly impacts the results, with REFPROP outperforming PROPATH for sCO2 properties. Additionally, we observed that, depending on the flow direction, buoyancy can either enhance or suppress turbulence in sCO2 flow. In upward flow, under certain conditions, the suppressed turbulence leads to heat transfer deterioration, resulting in elevated wall temperatures.
Based on the integration of classical differential equations of motion of bearing elements, a real-time dynamic simulation of ball bearing performance is coupled with simultaneous modeling of thermal interactions between the bearing elements. The transient heat generations are time averaged over a significantly larger time step before they are used to compute the changes in bearing temperature fields. Such an averaging algorithm eliminates the numerical difficulties associated with simultaneous integration of mechanical thermal differential equations with vastly different time scales. Under stable operation, the step change in temperatures at each thermal time step converges to a steady-state solution. Following is a list of accomplishments in the present investigation: (1) A real-time dynamic performance of both 440C and hybrid ball bearings in a LOX environment is modeled in both transient and steady-state time domains, as the inner race accelerates to a prescribed operating speed. (2) The frictional interactions at the ball to race contacts are modeled by experimentally measured traction coefficients as a function of slide-to-roll ratios. (3) Bearing heat generation, as defined by the heat transferred to circulating LOX, is validated against experimental values determined by measured LOX temperatures under prescribed pressures and flow rates. The predicted heat generation is in good agreement with the experimental values. (4) The steady-state solutions are shown to be independent of initial conditions. This establishes convergence of the numerical integration of a differential equation of motion of the bearing elements. (5) Churning and drag losses in the circulating LOX constitutes the majority of bearing heat generation under the experimental test conditions. (6) The heat dissipated in frictional interactions in hybrid bearings is significantly lower in hybrid bearings in comparison to that simulated in all-steel bearings, while the churning and drag losses are relatively unchanged.
The Mars Sample Return Earth Entry System is a mission concept which would be the first NASA entry vehicle to utilize a woven thermal protection system as well as a 52.5 degree sphere-cone forebody geometry. Due to its novel design, historic experimental data sets were insufficient to validate the models used to characterize the expected aerothermal environment. A wind tunnel test campaign was funded by the Mars Sample Return Earth Entry System project in the NASA Langley 20-Inch Mach 6 Air Tunnel in order to obtain validation data. The December 2023 test entry of this campaign sought to obtain thermographic data to capture the impact of supersonic flow near woven surface roughness elements on convective heating augmentation, which was the largest remaining uncertainty in aerothermal design of the Earth Entry System. Data obtained were in family with prior results obtained on identical woven patterns without supersonic flow present at roughness elements, and it was found that this presence of supersonic flow did not have a noticeable effect on surface convective heating augmentation. Data were directly leveraged to support the NASA Mars Sample Return flight program and this data set is valuable for validating computational solutions on roughness-resolved grids.
The Mars Sample Return Earth Entry System is a mission concept which would be the first NASA entry vehicle to utilize a woven thermal protection system as well as a 52.5 degree sphere-cone forebody geometry. Due to its novel design, historic experimental data sets were insufficient to validate the models used to characterize the expected aerothermal environment. A wind tunnel test campaign was funded by the Mars Sample Return Earth Entry System project in the NASA Langley 20-Inch Mach 6 Air Tunnel in order to obtain validation data. The December 2023 test entry of this campaign sought to obtain thermographic data to capture the impact of supersonic flow near woven surface roughness elements on convective heating augmentation, which was the largest remaining uncertainty in aerothermal design of the Earth Entry System. Data obtained were in family with prior results obtained on identical woven patterns without supersonic flow present at roughness elements, and it was found that this presence of supersonic flow did not have a noticeable effect on surface convective heating augmentation. Data were directly leveraged to support the NASA Mars Sample Return flight program and this data set is valuable for validating computational solutions on roughness-resolved grids.
A NASTRAN model of the Bearing Tester was developed to determine the fit of its components while in use. The model was executed for three loading conditions involving appropriate thermal and pressure loading throughout: rotation (30,000 rpm), rotation with 5000 lb axial shaft loading, and rotation with 2000 lb lateral shaft loading. A 30 deg slice of the Bearing Tester was modeled with solid isoparametric elements (CIHEX). Five more slices were generated to form a 180 deg symmetrical half. Each component was modeled separately for two reasons: (1) in the heat transfer version each component required covering with appropriate heat transfer coefficient elements, and (2) for the displacement version each component required independent radial expansion with respect to adjacent components. The components are connected at fastener and bearing locations axially and/or tangentially. Differences in radial displacements of adjacent cylindrical surfaces were calculated and added to those differences calculated for 180 deg opposite locations to determine the diametric change.
The results of thermal volatilization studies on lunar basalts, breccias, and soils, carried out to measure the depletion of selected elemental abundances during heating under vacuum, are evaluated. The kinetics of K, Rb, and Pb loss are found to be sufficiently fast to permit vaporization and loss of these elements during the production of impact glasses. There is little probability that lunar basalt flows have lost a significant percentage of K, Rb, and Na by volatilization, unless the flow is extensively stirred. The uniformly low Na concentrations of mare basalts cannot be attributed to post eruption vaporization and loss on Na.
A welding apparatus is provided for forming a weld joint between first and second elements of a workpiece. The apparatus heats the first and second elements to form an interface of material in a plasticized or melted state interface between the elements. The interface material is then allowed to cool to a plasticized state if previously in a melted state. The interface material, while in the plasticized state, is then mixed, for example, using a grinding/extruding mixer, to remove any dendritic-type weld microstructures introduced into the interface material during heating.
Composite consisting of commercially available elements has been developed to measure heat transfer. Composite provides a simple, convenient, low-cost device for use in heat-transfer work for rapid evaluation of thermal performance of both flat and simply curved objects. Device utilizes available off-the-shelf materials and provides a convenient method, with good resolution of local temperatures and heat transfer, with measurement accuracy at near-normal room conditions.
A number of candidate thermal energy storage system elements were identified as having the potential for the successful application of solar industrial process heat. These elements which include storage media, containment and heat exchange are shown.