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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
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

A Review of Recent Advances in Heat Exchanger Technology and Future Applications

This talk describes current and historical efforts concerning the development of condensing heat exchangers for use in space systems. These devices are used for a wide range of applications, including humidity/environmental control and multiphase fluid systems in Earth and in space. Therefore, keeping these systems running consistently and with minimal downtime/repairs is a high priority for exploration life support. Recent advances in low gravity capillary fluidics can be applied to newer systems and offer continuous operation in the event of a system pump failure or blockage. Additionally, new methods in femtosecond laser processing have been used to create microbial resistant surfaces with unique wetting characteristics. This research builds on experiments at both Glenn Research Center and Johnson Space Center. Future applications of this work will also be discussed, including water processing and plant growth systems.

heat exchanger↗
DOE OSTI2022

Tube-in-tube ionic liquid heat exchanger employing a selectively permeable tube

A tube-in-tube heat exchanger utilizes a selectively permeable tube having a selective permeable layer to allow the refrigerant to transfer into an ionic liquid to generate heating or cooling. The ionic liquid then provides heating or cooling to a heat transfer fluid through a non-permeable layer or tube. The system may be configured as a shell and tube design, with the third fluid free to flow on the outside of the shell, or as a shell and tube-in-tube, with a central tube containing a first liquid, a second tube containing a second liquid, and an outer shell containing the third liquid. The selectively permeable tube may include an anion or cation selectively permeable layer and this layer may be supported by a support layer or tube.

Bahar, Bamdad↗
DOE OSTI2024

Tube-in-tube ionic liquid heat exchanger employing a selectively permeable tube

A tube-in-tube heat exchanger utilizes a selectively permeable tube having a selective permeable layer to allow the refrigerant to transfer into an ionic liquid to generate heating or cooling. The ionic liquid then provides heating or cooling to a heat transfer fluid through a non-permeable layer or tube. The system may be configured as a shell and tube design, with the third fluid free to flow on the outside of the shell, or as a shell and tube-in-tube, with a central tube containing a first liquid, a second tube containing a second liquid, and an outer shell containing the third liquid. The selectively permeable tube may include an anion or cation selectively permeable layer and this layer may be supported by a support layer or tube.

Bahar, Bamdad↗
NASA NTRS2009

Nano-Pervaporation Membrane with Heat Exchanger Generates Medical-Grade Water

A nanoporous membrane is used for the pervaporation process in which potable water is maintained, at atmospheric pressure, on the feed side of the membrane. The water enters the non-pervaporation (NPV) membrane device where it is separated into two streams -- retentate water and permeated water. The permeated pure water is removed by applying low vapor pressure on the permeate side to create water vapor before condensation. This permeated water vapor is subsequently condensed by coming in contact with the cool surface of a heat exchanger with heat being recovered through transfer to the feed water stream.

Tsai, Chung-Yi↗
DOE OSTI2026

Pumped Thermal Energy Storage Using Low-Cost Particles and a Fluid Bed Heat Exchanger for Maximum Power Efficiency

Robust, efficient, cost-effective long-duration electricity storage (LDES) solutions can enhance grid resiliency, support existing transmission and distribution infrastructure, and enable a greater share of low-cost, variable alternative energy sources to penetrate the market. To meet this need, the project team at the National Renewable Energy Laboratory developed a transformative LDES system based on pumped thermal energy storage (TES) using low-cost particles and a fluid bed heat exchanger for maximum power efficiency (PUMP). The PUMP system is composed of high-temperature, low-cost particle TES coupled with an advanced pressurized fluid bed heat exchanger (PFB HX) that supports a high-efficiency pumped thermal energy storage (PTES) system integrated with concentrating solar thermal power (CSP). The PUMP project developed and de-risked a PFB HX and particle CSP system intended to be integrated with reversible turbomachinery and a modeling tool to assess PTES cost and performance.

14 SOLAR ENERGY↗
NASA NTRS2005

Condensing Heat Exchanger Concept Developed for Space Systems

The current system for moisture removal and humidity control for the space shuttles and the International Space Station uses a two-stage process. Water first condenses onto fins and is pulled through "slurper bars." These bars take in a two-phase mixture of air and water that is then separated by the rotary separator. A more efficient design would remove the water directly from the air without the need of an additional water separator downstream. For the Condensing Heat Exchanger for Space Systems (CHESS) project, researchers at the NASA Glenn Research Center in collaboration with NASA Johnson Space Center are designing a condensing heat exchanger that utilizes capillary forces to collect and remove water and that can operate in varying gravitational conditions including microgravity, lunar gravity, and Martian gravity.

Hasan, Mohammad M.↗
DOE OSTI2021

Recent Developments in the Design of Vertical Borehole Ground Heat Exchangers for Cost Reduction and Thermal Energy Storage

Ground source (geothermal) heat pumps (GSHPs) can meet the thermal demands of buildings in an energy-efficient manner. The current high installation costs and long payback period limit the attractiveness of GSHP installation in the United States. Vertical borehole ground heat exchangers (VBGHEs), which are commonly used in GSHP systems, contribute most to the cost premium of GSHPs. Reducing the cost of VBGHEs could help increase market penetration of GSHP systems. This paper reviews recent developments for VBGHEs, including improvements in borehole heat transfer and borehole field layout, integration with thermal energy storage, and new design tools. Improvements in the borehole design and materials are more likely to be justified when the ground has high thermal conductivity. Integrating thermal energy storage can provide additional value to the GSHP system, especially when flexible electric demand at buildings becomes more valuable. Here, advanced design tools for VBGHEs that account for the thermal response of irregularly shaped borehole fields and that are more closely integrated with whole-building energy simulation programs may facilitate more innovations and optimization of GSHP system designs.

15 GEOTHERMAL ENERGY↗
DOE OSTI2025

REFRACTORY COMPACT HEAT EXCHANGERS WITH EMBEDDED SENSORS ENABLED BY HYBRID ADVANCED SINTERING AND ADDITIVE APPROACH

Structural health monitoring (SHM) of compact heat exchangers (CHXs) operating in extreme environments is essential for ensuring system reliability, safety, and longevity. This study presents the development of high-temperature sensors fabricated via aerosol jet printing (AJP) using platinum ink, selected for its exceptional thermal stability, oxidation resistance, and electrical conductivity. AJP enables precise deposition of fine-feature sensor patterns onto complex geometries, making it well-suited for integration within CHX architectures. To enhance sensor durability, an alumina-based ceramic protective layer was printed over the platinum sensing elements. The sensors demonstrated stable, repeatable performance up to 900?°C during extended thermal cycling. A custom test setup was developed to evaluate sensor accuracy and robustness under steady-state and transient conditions. Substrate screening identified HG-1 ceramic-coated stainless steel as the most effective platform, offering strong adhesion and low resistance. Furthermore, electric field-assisted sintering (EFAS) was employed to embed the sensors into stainless steel 316L matrices without degrading their functionality. Post-embedding electrical tests confirmed sensor integrity, and initial characterization suggests strong potential for in-situ monitoring. This work provides a scalable strategy for integrating high-performance temperature sensors directly into refractory components, advancing embedded SHM technologies for harsh operating environments.

36 - MATERIALS SCIENCE↗
NASA NTRS2011

Two-Phase Cryogenic Heat Exchanger for the Thermodynamic Vent System

A two-phase cryogenic heat exchanger for a thermodynamic vent system was designed and analyzed, and the predicted performance was compared with test results. A method for determining the required size of the Joule-Thomson device was also developed. Numerous sensitivity studies were performed to show that the design was robust and possessed a comfortable capacity margin. The comparison with the test results showed very similar heat extraction performance for similar inlet conditions. It was also shown that estimates for Joule- Thomson device flow rates and exit quality can vary significantly and these need to be accommodated for with a robust system design.

Christie, Robert J.↗
DOE OSTI2022

Toward extreme high-temperature supercritical CO 2 power cycles: Leakage characterization of ceramic 3D-printed heat exchangers

We report future supercritical carbon dioxide (sCO 2 ) Brayton power cycles demand high-performance gas-to-gas heat exchangers (HXs) operating under extreme temperature and pressure conditions at which most existing superalloy materials fail to function safely. Ceramic HXs are deemed excellent candidates for advanced sCO 2 power plants as they can withstand high-temperature working environments. Particularly, ceramic 3D printing enables compact HX topologies employing complex and efficient heat transfer features. However, ceramic 3D-printed walls separating hot and cold flow streams are susceptible to a through-plane leakage inherent to a powder-based manufacturing process, including ceramic 3D printing. A potential leakage through ceramic separating walls poses a significant challenge in developing reliable ceramic 3D-printed HXs and could deteriorate thermal performance. In this study, various parameters, including feedstock slurry, 3D-printing direction, and post-processing conditions, are considered, for the first time, to characterize the argon gas leakage rate associated with alumina 3D-printed parts. Three 3D-printed ceramic structures of flat plates, curved tubes, and small-scale plate-and-frame HXs with various thicknesses are systematically studied to determine powder and ceramic 3D-printing conditions to eliminate the through-plane leakage. The results showed that an alumina 3D-printed plate with a thickness of 0.75 mm demonstrates a permeability of 6 x 10 -4 milli-darcy. An alumina 3D-printed tube with a wall thickness of 0.9 mm revealed a permeability of 9.6 x 10 -7 milli-darcy. Furthermore, leakage test results of functional 3D-printed modules showed a dependency on the 3D-printing direction. Particularly, alumina cell-scale HXs employing 1.5-mm-thick horizontal and vertical 3D-printed separating walls demonstrated impermeability and gas permeability of 7.2 x 10 -5 millidarcy, respectively. Insights gained from the present study facilitate the development of complex ceramic 3D-printed HXs and other balance of plant components for next-generation high-temperature high-pressure sCO 2 power cycles.

36 MATERIALS SCIENCE↗
NASA NTRS2016

Thermal Propulsion Capture System Heat Exchanger Design

One of the biggest challenges of manned spaceflight beyond low earth orbit and the moon is harmful radiation that astronauts would be exposed to on their long journey to Mars and further destinations. Using nuclear energy has the potential to be a more effective means of propulsion compared to traditional chemical engines (higher specific impulse). An upper stage nuclear engine would allow astronauts to reach their destination faster and more fuel efficiently. Testing these engines poses engineering challenges due to the need to totally capture the engine exhaust. The Thermal Propulsion Capture System is a concept for cost effectively and safely testing Nuclear Thermal Engines. Nominally, hydrogen exhausted from the engine is not radioactive, but is treated as such in case of fuel element failure. The Thermal Propulsion Capture System involves injecting liquid oxygen to convert the hydrogen exhaust into steam. The steam is then cooled and condensed into liquid water to allow for storage. The Thermal Propulsion Capture System concept for ground testing of a nuclear powered engine involves capturing the engine exhaust to be cooled and condensed before being stored. The hydrogen exhaust is injected with liquid oxygen and burned to form steam. That steam must be cooled to saturation temperatures before being condensed into liquid water. A crossflow heat exchanger using water as a working fluid will be designed to accomplish this goal. Design a cross flow heat exchanger for the Thermal Propulsion Capture System testing which: Eliminates the need for water injection cooling, Cools steam from 5800 F to saturation temperature, and Is efficient and minimizes water requirement.

Richard, Evan M.↗
DOE OSTI2025

Comparative evaluation and selection of heat exchangers using multicriteria decision-making

Here, this study presents a well-structured method for comparing and selecting Heat Exchanger (HE) technologies for Integrated Energy Systems (IES). The decision to select a HE for a particular IES configuration can vary greatly depending not only on engineering requirements but also on customer’s specific demand. In other words, the HE selection for IES requires a multicriteria decision-making approach, taking into account diverse technical, economic, and safety aspects, as well as the relative priorities considered by energy users. This study employs a HE evaluation approach combining multicriteria decision-making techniques widely used in various industries: quality function deployment (QFD) and analytic hierarchy process (AHP) techniques. Of particular interest is the use of the proposed method to select a high-temperature HEs that couples advanced nuclear reactors and industrial processes. To build a practical basis for comparing HEs within the proposed framework, efforts were made to identify the various HEs requirements for IES purposes. In addition, leveraging the insights obtained from the literature review and the market survey of commercial HE suppliers, a knowledge base was built to facilitate the comparison of each requirement across various HE designs. Also, evaluation metrics were identified for HE requirements with robust rational to enhance the quality of decisions made throughout the proposed evaluation process. The evaluation procedure and knowledge base described in this study can provide a useful basis for those interested in screening the appropriate HE designs for various IES scenarios.

Analytic Hierarchy Process (AHP)↗
DOE OSTI2025

Low-cost and high-performance heat exchangers for CSP

This project aimed to design and manufacture a low-cost and high-performance, particle–to–sCO 2 heat exchanger (HX) for Concentrated Solar Power (CSP) using additive manufacturing (AM). Three enabling technologies will be integrated to achieve the targeted cost and performance. The first technology is the extreme high‐speed laser materials deposition (LMD) AM process known by its German acronym EHLA that was invented at the Fraunhofer Institute for Laser Technology. The EHLA process utilizes a specially designed powder-feeding nozzle that enables a laser to melt the powder particles above the melt pool, in contrast to the conventional LMD process where the powders are melted inside the melt pool. EHLA enables much faster deposition rate than conventional LMD without the need to wait for the powders to melt. The second technology is an innovative double-helical HX geometry that can be easily fabricated using the EHLA process by rotating a rod at a high-speed to take advantage of the high EHLA deposition rate. The double-helical fins separate the hot region (the hot particle side) and the cold region (the sCO 2 side) and provide large heat transfer surface area without a large pressure drop on the sCO 2 side. The particle side will have a larger gap to facilitate the particle flow. The outer rims of the double helixes can be sealed off using the same AM process. After sealing-off, additional double helixes can be built radially on top of the first set to improve HX performance. The HX can be installed vertically for gravity-driven flow of the hot particles if necessary. The third technology is a low-cost high-temperature alumina-forming austenitic (AFA) steel TMA-6350 that has creep and oxidation resistance up to 1100 °C. These technologies together will enable high-performance and low-cost HXs for particle–to–sCO 2 for CSP.

14 SOLAR ENERGY↗
NASA NTRS1979

Low-cost, high-efficiency silicon by heat exchanger method and fixed abrasive slicing technique

The paper describes the heat exchanger method (HEM) for growing silicon crystals. The problem of ingot cracking was solved by using a graded structure silica crucible, and vacuum processing eliminated expensive high-purity argon. Solar cells fabricated from HEM silicon demonstrated conversion efficiencies up to 15% (AM1) at low cost, using square cross-section, single crystal silicon. A modified multiblade slurry machine was adapted for multiwire fixed abrasive slicing of silicon which uses a diamond attached to wires; this method provides a conversion ratio of 1.08 sq m of wafer per kg of silicon ingot, and produces wafers free of edge chipping with a surface damage of 3-5 microns.

Khattak, C. P.↗
DOE OSTI2023

Additively featured plates for heat exchangers

Hybrid additive featured plates used to form an overall microchannel heat exchanger and corresponding method of manufacture are disclosed. Various additive manufacturing (AM) techniques may be used to form walls defining microchannel features on a plate substrate. The manufacturing method is a hybrid process in that leverages both additive and conventional manufacturing techniques to minimize both cost and fabrication time.

Carlson, Matthew David↗