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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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At least 505 records · Page 28

Heating and Thermal Control of Brazing Technique to Break Contamination Path for Potential Mars Sample Return

The potential return of Mars sample material is of great interest to the planetary science community, as it would enable extensive analysis of samples with highly sensitive laboratory instruments. It is important to make sure such a mission concept would not bring any living microbes, which may possibly exist on Mars, back to Earth’s environment. In order to ensure the isolation of Mars microbes from Earth’s Atmosphere, a brazing sealing and sterilizing technique was proposed to break the Mars-to-Earth contamination path. Effectively, heating the brazing zone in high vacuum space and controlling the sample temperature for integrity are key challenges to the implementation of this technique. The break-the-chain procedures for container configurations, which are being considered, were simulated by multi-physics finite element models. Different heating methods including induction and resistive/radiation were evaluated. The temperature profiles of Martian samples in a proposed container structure were predicted. The results show that the sealing and sterilizing process can be controlled such that the samples temperature is maintained below the level that may cause damage, and that the brazing technique is a feasible approach to breaking the contamination path.

Bao, Xiaoqi↗

Heating of coronal plasma by anomalous current dissipation

It is shown that there exist heating mechanisms which connect the observed radiative properties of the inner corona in a simple way to the underlying solar magnetic field. The mechanisms considered involve the generation and consequent dissipation of coronal currents. It is argued that the spatially and temporally inhomogeneous nature of the erupting solar magnetic field is an essential element of coronal heating. Unlike heating theories conceived in the context of the 'homogeneous' corona, this class of current heating models incorporates the observed stochastic coronal structuring at the onset, and does not view it as a complication of an otherwise straightforward model. Attention is given to the generation of coronal currents, the flux-tube emergence, the gradual growth and decay of active regions, the energetics of current dissipation, current sheath geometry and heat transport, and anomalous current dissipation.

Rosner, R.↗

Design Considerations for Lightweight Space Radiators Based on Fabrication and Test Experience With a Carbon-Carbon Composite Prototype Heat Pipe

This report discusses the design implications for spacecraft radiators made possible by the successful fabrication and proof-of-concept testing of a graphite-fiber-carbon-matrix composite (i.e., carbon-carbon (C-C)) heat pipe. The prototype heat pipe, or space radiator element, consists of a C-C composite shell with integrally woven fins. It has a thin-walled furnace-brazed metallic (Nb-1%Zr) liner with end caps for containment of the potassium working fluid. A short extension of this liner, at increased wall thickness beyond the C-C shell, forms the heat pipe evaporator section which is in thermal contact with the radiator fluid that needs to be cooled. From geometric and thermal transport properties of the C-C composite heat pipe tested, a specific radiator mass of 1.45 kg/sq m can be derived. This is less than one-fourth the specific mass of present day satellite radiators. The report also discusses the advantage of segmented space radiator designs utilizing heat pipe elements, or segments, in their survivability to micrometeoroid damage. This survivability is further raised by the use of condenser sections with attached fins, which also improve the radiation heat transfer rate. Since the problem of heat radiation from a fin does not lend itself to a closed analytical solution, a derivation of the governing differential equation and boundary conditions is given in appendix A, along with solutions for rectangular and parabolic fin profile geometries obtained by use of a finite difference computer code written by the author.

Juhasz, Albert J.↗

Design Considerations for Lightweight Space Radiators Based on Fabrication and Test Experience with a Carbon-Carbon Composite Prototype Heat Pipe

This report discusses the design implications for spacecraft radiators made possible by the successful fabrication and Proof-of-concept testing of a graphite-fiber-carbon-matrix composite (i.e., carbon-carbon (C-C)) heat pipe. The proto-type heat pipe, or space radiator element, consists of a C-C composite shell with integrally woven fins. It has a thin-walled furnace-brazed metallic (Nb-1%Zr) liner with end caps for containment of the potassium working fluid. A short extension of this liner, at increased wall thickness beyond the C-C shell, forms the heat pipe evaporator section which is in thermal contact with the radiator fluid that needs to be cooled. From geometric and thermal transport properties of the C-C composite heat pipe tested, a specific radiator mass of 1.45 kg/m2 can be derived. This is less than one-fourth the specific mass of present day satellite radiators. The report also discusses the advantage of segmented space radiator designs utilizing heat pipe elements, or segments, in their survivability to micro-meteoroid damage. This survivability is further raised by the use of condenser sections with attached fins, which also improve the radiation heat transfer rate. Since the problem of heat radiation from a fin does not lend itself to a closed analytical solution, a derivation of the governing differential equation and boundary conditions is given in appendix A, along with solutions for rectangular and parabolic fin profile geometries obtained by use of a finite difference computer code written by the author.

Juhasz, Albert J.↗

Implementation of a self-controlling heater

Temperature control of radiation sensors, targets, and other critical components is a common requirement in modern scientific instruments. Conventional control systems use a heater and a temperature sensor mounted on the body to be controlled. For proportional control, the sensor provides feedback to circuitry which drives the heater with an amount of power proportional to the temperature error. It is impractical or undesirable to mount both a heater and a sensor on certain components such as ultra-small parts or thin filaments. In principle, a variable current through the element is used for heating, and the change in voltage drop due to the element's temperature coefficient is separated and used to monitor or control its own temperature. Since there are no thermal propagation delays between heater and sensor, such control systems are exceptionally stable.

Strange, M. G.↗

Simplified cyclic structural analyses of SSME turbine blades

Anisotropic high-temperature alloys are used to meet the safety and durability requirements of turbine blades for high-pressure turbopumps in reusable space propulsion systems. The applicability to anisotropic components of a simplified inelastic structural analysis procedure developed at the NASA Lewis Research Center is assessed. The procedure uses as input the history of the total strain at the critical crack initiation location computed from elastic finite-element analyses. Cyclic heat transfer and structural analyses are performed for the first stage high-pressure fuel turbopump blade of the space shuttle main engine. The blade alloy is directionally solidified MAR-M 246 (nickel base). The analyses are based on a typical test stand engine cycle. Stress-strain histories for the airfoil critical location are computed using both the MARC nonlinear finite-element computer code and the simplified procedure. Additional cases are analyzed in which the material yield strength is arbitrarily reduced to increase the plastic strains and, therefore, the severity of the problem. Good agreement is shown between the predicted stress-strain solutions from the two methods. The simplified analysis uses about 0.02 percent (5 percent with the required elastic finite-element analyses) of the CPU time used by the nonlinear finite element analysis.

Kaufman, A.↗

Innovative Thermal Strategies: Electrification's Best Friend

Because transportation and heat are the most significant contributors to greenhouse gas (GHG) emissions in the northern U.S., electrification of transport and heat are prominent elements of many decarbonization plans, such as that of New York State (NYS). A key challenge is then to decarbonize the electric supply and distribution system ("the grid") that supplies electricity, a process colloquially known as "greening the grid", so that the saved direct carbon emissions are not offset by additional indirect emissions from electrical generation on the grid. Applying this "simple" decarbonization plan to locations with high winter heating loads and modest renewable resources is challenging. Understanding the impact of thermal system design to grid demands in these locations and the related marginal power source for electrification options is critical to allocating proper resources to solve decarbonization challenges and quantifying the resultant carbon emissions impact.

battery storage↗

Thermal stir welding apparatus

A welding method and apparatus are provided for forming a weld joint between first and second elements of a workpiece. The method includes heating 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 process, to remove any dendritic-type weld microstructures introduced into the interface material during the heating process.

Ding, R. Jeffrey↗

Thermal stir welding process

A welding method is provided for forming a weld joint between first and second elements of a workpiece. The method includes heating 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 process, to remove any dendritic-type weld microstructures introduced into the interface material during the heating process.

Ding, R. Jeffrey↗

NASTRAN solutions of problems described by simultaneous parabolic differential equations

NASTRAN solution techniques are shown for a numerical analysis of a class of coupled vector flow processes described by simultaneous parabolic differential equations. To define one physical problem type where equations of this form arise, the differential equations describing the coupled transfers of heat and mass in mechanical equilibrium with negligible mass average velocity are presented and discussed. Also shown are the equations describing seepage when both electrokinetic and hydrodynamic forces occur. Based on a variational statement of the general problem type, the concepts of scalar transfer elements and parallel element systems are introduced. It is shown that adoptation of these concepts allows the direct use of NASTRAN's existing Laplace type elements for uncoupled flow (the heat transfer elements) for treating multicomponent coupled transfer. Sample problems are included which demonstrate the application of these techniques for both steady-state and transient problems.

Mason, J. B.↗

Fully Solid State Thermomagnetoelectric Generator: Cycle Model and Proof-of-Concept Results

Electricity generation from heat in small-scale systems is currently limited to internal and external combustion heat engine generators or thermoelectric elements. This study introduces a new concept for a solid state thermomagnetoelectric power generator and presents a theoretical study of the cycle. While magnetocaloric materials (MCMs) are common in cryogenic cooling applications, in this work the magnetocaloric thermodynamic heat pump cycle is reversed to generate electricity from low-grade heat. A critical distinguishing feature of the approach is that there are no moving parts: the system directly converts heat into electricity with no moving magnet or regenerators (similar to thermoelectric elements). By periodic heating and cooling of the MCM, the magnetic field inside the copper coil changes in time, generating alternating current electricity. This fully solid state system can directly convert heat into electricity and is modeled at 54% of Carnot efficiency. Compared with state-of-the-art thermoelectric elements, the proposed technology has 3-4 times higher heat-to-electricity conversion efficiency at the same driving temperature difference.

Zhang, Mingkan↗

Local Heat Flux Measurements with Single and Small Multi-element Coaxial Element-Injectors

To support NASA's Vision for Space Exploration mission, the NASA Marshall Space Flight Center conducted a program in 2005 to improve the capability to predict local thermal compatibility and heat transfer in liquid propellant rocket engine combustion devices. The ultimate objective was to predict and hence reduce the local peak heat flux due to injector design, resulting in a significant improvement in overall engine reliability and durability. Such analyses are applicable to combustion devices in booster, upper stage, and in-space engines with regeneratively cooled chamber walls, as well as in small thrust chambers with few elements in the injector. In this program, single and three-element injectors were hot-fire tested with liquid oxygen and gaseous hydrogen propellants at The Pennsylvania State University Cryogenic Combustor Laboratory from May to August 2005. Local heat fluxes were measured in a 1-inch internal diameter heat sink combustion chamber using Medtherm coaxial thermocouples and Gardon heat flux gauges, Injector configurations were tested with both shear coaxial elements and swirl coaxial elements. Both a straight and a scarfed single element swirl injector were tested. This paper includes general descriptions of the experimental hardware, instrumentation, and results of the hot-fire testing for three coaxial shear and swirl elements. Detailed geometry and test results the for shear coax elements has already been published. Detailed test result for the remaining 6 swirl coax element for the will be published in a future JANNAF presentation to provide well-defined data sets for development and model validation.

Jones, Gregg↗

Custom Controls for Improved Demand Response from Heat Pump Water Heaters

As part of a Grid Modernization Laboratory Consortium (GMLC) project looking at defining grid services for a range of devices, NREL used a custom controller to investigate the ability of a HPWH to provide load add and load shed in hybrid and electric resistance mode using standard set point control. Based on those results, changes were made to the controls to increase the amount of grid services delivered, especially in the load-add case, and speed up the recovery from those events. The custom controls also include less common methods, such as duty cycling of the heat pump or elements. The improved controls led to an increase the amount of demand response that could be provided and enabled faster recovery. Results from the laboratory experiments will be presented, along with details about the custom controls that were implemented.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Autoignition Chamber for Remote Testing of Pyrotechnic Devices

The autoignition chamber (AIC) performs by remotely heating pyrotechnic devices that can fit the inner diameter of the tube furnace. Two methods, a cold start or a hot start, can be used with this device in autoignition testing of pyrotechnics. A cold start means extending a pyrotechnic device into the cold autoignition chamber and then heating the device until autoignition occurs. A hot start means heating the autoignition chamber to a specified temperature, and then extending the device into a hot autoignition chamber until autoignition occurs. Personnel are remote from the chamber during the extension into the hot chamber. The autoignition chamber, a commercially produced tubular furnace, has a 230-V, single-phase, 60-Hz electrical supply, with a total power output of 2,400 W. It has a 6-in. (15.2-cm) inner diameter, a 12-in. (30.4-cm) outer diameter and a 12-in.- long (30.4-cm), single-zone, solid tubular furnace (element) capable of heating to temperatures up to 2,012 F (1,100 C) in air.

Harrington, Maureen L.↗

Single and Multi-Node Modeling of Direct, Submerged, and Self-Pressurization of A Cryogenic Propellant Tank Using Nodal Tools

The pressurization of cryogenic propellant tanks will always be an important process so long as cryogenic liquids are being considered as fuel sources or used for other in-space applications. Pressure control of the tank ullage is necessary for managing propellant flowrates to an engine or a receiver tank, and modeling of the process is used to predict the pressurant requirements and the amount of propellant boiloff. Direct ullage pressurization is the more traditional approach to tank pressurization, as the physics are straight-forward, and ample test (flight) data have been collected and analyzed over the past several decades. Submerged injection pressurization is an alternate method for tank pressurization and has been shown to reduce pressurant requirements, subcool the propellant, and reduce the risk of ullage collapse. Additionally, the pressurant gas entering the ullage is usually much colder when using the submerged pressurization approach, resulting in reduced propellant boiloff. These benefits are at the expense of vaporizing a small percentage of the propellent. Both tank pressurization methods are viable options for current and future space missions, and it is important to have the capability of analyzing the tank ullage conditions for both approaches. Our previous work has demonstrated the development of a Generalized Fluid System Simulation Program (GFSSP) model, which contains a thermodynamic equilibrium heat and mass transfer subroutine capable of effectively analyzing both direct and submerged pressurization systems [1-2]. This subroutine has most recently been enhanced to include the non-equilibrium effect of pressurant dissolution into the propellant. To date the ullage has always been represented as a single node, and although the simulated single-node temperatures have good comparison with the volume-averaged ullage temperatures computed from test data, the physics of the thermal stratification in the ullage were never captured, and adjustment factors in the model were required. The purpose of this paper is to introduce the development of a multi-node ullage model using GFSSP and to discuss the improvements of the simulated ullage temperature distribution and its resulting effects on ullage heat transfer processes. Test data from the Cryogenic Propellant Storage and Transfer Engineering Developmental Unit (CPST EDU) was used for model validation. For additional comparison, a Thermal Desktop (TD) model was also developed to analyze the CPST EDU direct ullage pressurization tests using both a single node and multi-node approach. The model includes the direct pressurant line, vent line, fill/drain line, and a TD FloCAD Compartment. The TD FloCAD Compartment is employed to represent the liquid and ullage as single volumes inside the tank, to include a liquid/vapor interface, and to generate network level objects such as lumps (analogous to nodes in GFSSP), paths, and ties between the fluid and thermal elements. An established heat load on the model tank was leveraged from a pre-existing higher-fidelity model correlated to CPST EDU test data.

pressurization↗

Experimental solar heating-cooling system model tests of a full-scale building system

An experimental solar heating and cooling system model has been built and operated, combining elements that are programmable - heating and/or cooling load of a building, collected solar energy - with experimental equipment. The system model was based on the loads and components used in the Solar Building Test Facility (SBTF) which includes a 1394 square meter solar collector field, at NASA-Langley. Operations covered 5 continuous days under summer conditions. For the system model, up to 55% of the simulated collected solar energy was used for the building load. This amount constituted 35% of the building cooling load. Heat loss was significant. If tank heat loss were eliminated, 75% of the collected solar energy would be used. This amount would supply approximately 50% of the building cooling load.

Namkoong, D.↗

Comparison of evolving photovoltaic and nuclear power systems for earth orbital applications

Photovoltaic and fission reactor orbital power systems are compared in terms of the end-to-end system power-to-mass ratios. Three PV systems are examined, i.e., a solid substrate with a cell array and a NiCd battery, a modified SEP array and an NiH2 battery, and a 62-micron Si cell array and a fuel cell. All arrays were modeled to be 13.5% efficient and to produce 25 kW dc. The SP-100 reactor consists of the heat source, radiation shield, heat pipes to transfer thermal energy from the reactor to thermoelectric elements, and a waste heat radiator. Consideration is given to system applications in orbits ranging from LEO to GEO, and to mission durations of 1, 5, and 10 yr. PV systems are concluded to be flight-proven, useful out of radiation belts, and best for low to moderate power levels. Limitations exist for operations where atmospheric drag may become a factor and due to the size of a large PV power supply. Space nuclear reactors will continue under development and uses at high power levels and in low altitude orbits are foreseen.

Rockey, D. E.↗

Development of prototype air/liquid solar collector subsystem

Testing of the evacuated tubular air collector in conjunction with air/liquid heat exchange and liquid storage elements was completed. Test results emphasize matching of heat exchanger and collector characteristics with specific attention to the dynamic response of each of the elements.

Source record↗