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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2009

Treating Fibrous Insulation to Reduce Thermal Conductivity

A chemical treatment reduces the convective and radiative contributions to the effective thermal conductivity of porous fibrous thermal-insulation tile. The net effect of the treatment is to coat the surfaces of fibers with a mixture of transition-metal oxides (TMOs) without filling the pores. The TMO coats reduce the cross-sectional areas available for convection while absorbing and scattering thermal radiation in the pores, thereby rendering the tile largely opaque to thermal radiation. The treatment involves a sol-gel process: A solution containing a mixture of transition-metal-oxide-precursor salts plus a gelling agent (e.g., tetraethylorthosilicate) is partially cured, then, before it visibly gels, is used to impregnate the tile. The solution in the tile is gelled, then dried, and then the tile is fired to convert the precursor salts to the desired mixed TMO phases. The amounts of the various TMOs ultimately incorporated into the tile can be tailored via the concentrations of salts in the solution, and the impregnation depth can be tailored via the viscosity of the solution and/or the volume of the solution relative to that of the tile. The amounts of the TMOs determine the absorption and scattering spectra.

Zinn, Alfred↗
NASA NTRSDate not supplied

Thermal Conductivity of 3D Woven Composite Thermal Protection System Materials via Multiscale Recursive Micromechanics

Multiscale micromechanics predictions have been made for the effective thermal conductivities and local thermal fields for a novel 3D woven composite thermal protection system material. The Multiscale Recursive Micromechanics approach, which enables micromechanics models to call other micromechanics models (or themselves recursively) to consider finer and finer length scales, has been employed. The multiscale model uses a recently developed version of the High-Fidelity Generalized Method of Cells micromechanics theory at each of three length scales. Results focus on the impact of the microstructural geometry representation at each length scale on the material’s effective thermal conductivity, along with the local thermal flux and temperature fields induced in the microstructures.

Composites↗
NASA NTRS2021

Thermal Conductivity of 3D Woven Composite Thermal Protection System Materials via Multiscale Recursive Micromechanics

Multiscale micromechanics predictions have been made for the effective thermal conductivities and local thermal fields for a novel 3D woven composite thermal protection system material. The Multiscale Recursive Micromechanics approach, which enables micromechanics models to call other micromechanics models (or themselves recursively) to consider finer and finer length scales, has been employed. The multiscale model uses a recently developed version of the High-Fidelity Generalized Method of Cells micromechanics theory at each of three length scales. Results focus on the impact of the microstructural geometry representation at each length scale on the material’s effective thermal conductivity, along with the local thermal flux and temperature fields induced in the microstructures.

composite↗
NASA NTRS1973

The infrared properties of reusable surface insulations.

The total infrared scattering and absorption cross sections of both flexible and rigidized high temperature fibrous insulations have been measured. The methods for accomplishing these measurements are described. Infrared reflection and transmission spectra were obtained to study the dependence of the total cross sections on the spectral characteristics of the transported radiation. These results are applied to steady-state effective thermal conductivity measurements via a four-flux model of radiative heat transfer to separate the radiative component and to calculate the effective thermal conductivity under transient heating conditions. Data for both silica and mullite fibers are presented.

Schmitt, R. J.↗
NASA NTRS2006

Preliminary Results of an Experimental Investigation of the Qu Superconducting Heat Pipe

This note on preliminary results of our evaluation of the so-called Qu Tube is prompted in part by recent concerns expressed to the authors by some researchers regarding the performance characteristics of the superconducting, solid-state heat pipe as described in the patents, or on the company's websites. Briefly, the company's claims include: a new type of heat transfer mechanism that is a form of solid state thermal superconductivity, which results in an effective thermal conductivity of the order of tens of thousands of times that of an equivalent solid silver bar, or, tens to hundreds of times that of liquid - vapor heat pipes. The company's website also refers to tests conducted by Stanford Research Institute that substantiate these claims, but the report is apparently not publicly available. We are conducting an investigation of the Qu Tube under a NASA Grant, and in general find that these claims have merit, but our study is not yet complete. We present some of our preliminary results in part to show that it would not be imprudent to conduct such studies, especially for possible future applications requiring exceptional thermal management performance capabilities. Working with HiTek Services, we originally acquired several Qu Tubes, including 17" long, 5/16" diameter copper tubes, one that is 7 7/8" long, 3/16" diameter, and one that is 4" long, 1" diameter. We subjected the smaller tubes to various exploratory tests, including a transient test with electrical band heaters, boiling water tests, and a series of steady state tests with electrical band heaters heating one end with free convective cooling along the remainder of the length. All results indicate a very high thermal conductivity, but the length of these tubes limited our ability to obtain accurate data on temperature gradients, necessary to determine the effective thermal conductivity. We then acquired nine Qu Tubes that are 10' long, 5/16" diameter, and we have recently conducted initial tests, which further support the claims of exceptional thermal conductivity.

Blackmon, James B.↗
NASA NTRSDate not supplied

Multiscale Thermal Conductivity Modeling of 3D Woven Composite Thermal Protection System Materials

Novel thermal protection systems (TPS) for re-entry and hypersonic vehicles utilize 3D woven composite materials with blended carbon filament tows (yarns) and a phenolic resin matrix. The presence of continuous carbon fibers provides superior stiffness and strength compared to legacy TPS, while the 3D weave pattern provides a great deal of design flexibility for both in-plane and through thickness thermomechanical behavior. However, modeling of 3D woven composites is notoriously complex and numerically intensive. The present investigation utilizes a unique ultra-efficient approach, known as Multiscale Recursive Micromechanics (MsRM), wherein recursive semi-analytical micromechanics methods are employed at various length scales within the composite. The MsRM approach has recently been extended to solve for the effective thermal conductivity as well as the local temperature and thermal flux fields throughout the composite. Presented model results focus on the impact of the microstructural geometry representation at each length scale on the material’s effective thermal conductivity, along with the local thermal flux and temperature fields induced in the microstructures, for a novel 3D woven TPS.

Composite↗
NASA NTRS2006

Heat Transfer In High-Temperature Multilayer Insulation

The combined radiation/conduction heat transfer in high-temperature multilayer insulations for typical reentry of reusable launch vehicles from low Earth orbit was investigated experimentally and numerically. The high-temperature multilayer insulation investigated consisted of gold-coated reflective foils separated by alumina fibrous insulation spacers. The steady-state heat transfer through four multilayer insulation configurations was investigated experimentally over the temperature range of 300-1300 K and environmental pressure range of 1.33 10(exp -5)-101.32 kPa. It was shown that including the reflective foils reduced the effective thermal conductivity compared to fibrous insulation sample at 1.5 times the density of the multilayer sample. A finite volume numerical model was developed to solve the governing combined radiation/conduction heat transfer equations. The radiation heat transfer in the fibrous insulation spacers was modeled using the modified two-flux approximation assuming anisotropic scattering and gray medium. The numerical model was validated by comparison with steady-state experimental data. The root mean square deviation between the predicted and measured effective thermal conductivity of the samples was 9.5%.

Daryabeigi, Kamran↗
NASA NTRS1990

Global effects of thermal conduction on two-phase media

The evolution of two-phase systems of astrophysical gases which change mass between the phases is studied to see whether a steady state is ever reached. The criterion for thermal instability in a cloudy medium is derived. The evolution of the pressure and density of the intercloud medium under the combined effects of heating and radiative cooling of the intercloud gas on the one hand and evaporation and condensation of the clouds on the other is determined. The equilibrium density to which the system evolves is determined for the case when the pressure is fixed. The theory is illustrated by the case in which the intercloud gas is heated by Compton scattering in a hard radiation field and cooled by bremsstrahlung and inverse Compton scattering.

Begelman, Mitchell C.↗
NASA NTRSDate not supplied

Recent Developments to the Porous Microstructure Analysis (PuMA) Software

Introduction The Porous Microstructure Analysis (PuMA) software is an open source framework for image-based simulation, primarily used to determine effective properties based on material microstructure. PuMA was originally developed for the study of NASA thermal protection materials; however, many of the solvers in PuMA have applicability to a broad range of materials science applications. PuMA version 3.2 computes material surface area, pore diameters, effective thermal conductivity, continuum and rarefied tortuosity, and permeability. For anisotropic materials, PuMA can estimate material orientation and compute anisotropic thermal conductivity and elasticity. In this talk, a brief overview of the PuMA software and underlying methods will be presented, as well as some recent and ongoing developments, including the use of immersed boundary methods for image-based simulation and the development of a new weave segmentation tool, called TomoSAM. Cut-Cell method for heat and mass transfer For simulations on complex microstructures, traditional unstructured meshing techniques often prove to be difficult and time-intensive. Voxel-based solvers, which represent the surface as a staircase structure, are relatively simple to implement but can lose accuracy when feature resolution is poor. In this work, we present a novel 3D cut-cell method for solving the variable coefficient Poisson equation on complex microstructures, suitable for the determination of effective thermal conductivity or tortuosity of a material. The method uses a Marching Cubes/Marching Squares surface reconstruction to create cut-cells and determine geometric quantities. A flux-correction method is extended to 3D, with least squares gradient reconstruction, to solve for the boundary fluxes in the cut-cells. Verification cases show the solver achieves globally 2nd order accuracy on complex microstructures. TomoSAM TomoSAM, a module of the PuMA software, has been developed as a plugin for 3D Slicer, a software platform used for 3D image processing and visualization. It utilizes the Segment Anything Model (SAM), a deep learning model capable of identifying objects and generating image masks based on minimal user input. This feature enables efficient segmentation of complex 3D datasets, particularly of woven materials, from tomography or similar imaging methods, reducing the need for manual segmentation.

Tomography↗
NASA NTRSDate not supplied

Recent Developments to the Porous Microstructure Analysis (PuMA) Software

The Porous Microstructure Analysis (PuMA) software is an open source framework for image-based simulation, primarily used to determine effective properties based on material microstructure. PuMA was originally developed for the study of NASA thermal protection materials; however, many of the solvers in PuMA have applicability to a broad range of materials science applications. PuMA version 3.2 computes material surface area, pore diameters, effective thermal conductivity, continuum and rarefied tortuosity, and permeability. For anisotropic materials, PuMA can estimate material orientation and compute anisotropic thermal conductivity and elasticity. In this talk, a brief overview of the PuMA software and underlying methods will be presented, as well as some recent and ongoing developments, including the use of immersed boundary methods for image-based simulation and the development of a new weave segmentation tool, called TomoSAM. Cut-Cell method for heat and mass transfer For simulations on complex microstructures, traditional unstructured meshing techniques often prove to be difficult and time-intensive. Voxel-based solvers, which represent the surface as a staircase structure, are relatively simple to implement but can lose accuracy when feature resolution is poor. In this work, we present a novel 3D cut-cell method for solving the variable coefficient Poisson equation on complex microstructures, suitable for the determination of effective thermal conductivity or tortuosity of a material. The method uses a Marching Cubes/Marching Squares surface reconstruction to create cut-cells and determine geometric quantities. A flux-correction method is extended to 3D, with least squares gradient reconstruction, to solve for the boundary fluxes in the cut-cells. Verification cases show the solver achieves globally 2nd order accuracy on complex microstructures. TomoSAM TomoSAM, a module of the PuMA software, has been developed as a plugin for 3D Slicer, a software platform used for 3D image processing and visualization. It utilizes the Segment Anything Model (SAM), a deep learning model capable of identifying objects and generating image masks based on minimal user input. This feature enables efficient segmentation of complex 3D datasets, particularly of woven materials, from tomography or similar imaging methods, reducing the need for manual segmentation.

Tomography↗
NASA NTRS1973

Thermal conductivity of heterogeneous mixtures and lunar soils

The theoretical evaluation of the effective thermal conductivity of granular materials is discussed with emphasis upon the heat transport properties of lunar soil. The following types of models are compared: probabilistic, parallel isotherm, stochastic, lunar, and a model based on nonlinear heat flow system synthesis.

Vachon, R. I.↗
NASA NTRS1987

Thermal diffusive conductivity of dilute superfluid (He-3)-(He-4) mixtures

A new technique is described for measuring the effective thermal conductivity of superfluid (He-3)-(He-4) mixtures. The results confirm the large departures from hydrodynamic theory reported previously. The analysis suggests that the measured conductivity is the finite thermal diffusive conductivity of superfluid helium in the absence of counterflow. This conductivity need not diverge in the limit of small He-3 concentration.

Chui, T. C. P.↗
NASA NTRS2006

Aerogels for Thermal Insulation of Thermoelectric Devices

Silica aerogels have been shown to be attractive for use as thermal-insulation materials for thermoelectric devices. It is desirable to thermally insulate the legs of thermoelectric devices to suppress lateral heat leaks that degrade thermal efficiency. Aerogels offer not only high thermal- insulation effectiveness, but also a combination of other properties that are especially advantageous in thermoelectric- device applications. Aerogels are synthesized by means of sol-gel chemistry, which is ideal for casting insulation into place. As the scale of the devices to be insulated decreases, the castability from liquid solutions becomes increasingly advantageous: By virtue of castability, aerogel insulation can be made to encapsulate devices having any size from macroscopic down to nanoscopic and possibly having complex, three-dimensional shapes. Castable aerogels can permeate voids having characteristic dimensions as small as nanometers. Hence, practically all the void space surrounding the legs of thermoelectric devices could be filled with aerogel insulation, making the insulation highly effective. Because aerogels have the lowest densities of any known solid materials, they would add very little mass to the encapsulated devices. The thermal-conductivity values of aerogels are among the lowest reported for any material, even after taking account of the contributions of convection and radiation (in addition to true thermal conduction) to overall effective thermal conductivities. Even in ambient air, the contribution of convection to effective overall thermal conductivity of an aerogel is extremely low because of the highly tortuous nature of the flow paths through the porous aerogel structure. For applications that involve operating temperatures high enough to give rise to significant amounts of infrared radiation, opacifiers could be added to aerogels to reduce the radiative contributions to overall effective thermal conductivities. One example of an opacifier is carbon black, which absorbs infrared radiation. Another example of an opacifier is micron- sized metal flakes, which reflect infrared radiation. Encapsulation in cast aerogel insulation also can help prolong the operational lifetimes of thermoelectric devices that must operate in vacuum and that contain SiGe or such advanced skutterudite thermoelectric materials as CoSb3 and CeFe3.5Co0.5Sb12. The primary cause of deterioration of most thermoelectric materials is thermal decomposition or sublimation (e.g., sublimation of Sb from CoSb3) at typical high operating temperatures. Aerogel present near the surface of CoSb3 can impede the outward transport of Sb vapor by establishing a highly localized, equilibrium Sb vapor atmosphere at the surface of the CoSb3.

Sakamoto, Jeffrey↗
NASA NTRS2026

Development and Validation of a High-Vacuum Thermal Conductivity Testbed for Aerospace Interface Materials

Thermal Interface Materials (TIMs) are critical components in spacecraft thermal management systems, where thermal performance is strongly influenced by vacuum conditions, interface contact resistance, and layered metallic joint behavior. However, manufacturer-reported thermal conductivity values are often derived under idealized conditions and may not accurately represent performance within operational aerospace applications. To address this limitation, the Testbed for Advanced Interface Materials in Vacuum (TAIMV) was developed as a modular vacuum-compatible thermal conductivity characterization platform capable of evaluating aerospace-relevant TIM configurations under both ambient and high-vacuum environments. The testbed was derived from the ASTM C1044-16 guarded hot plate methodology and incorporates interchangeable layers of stainless steel coupon geometries, independently controlled main and guard heaters, embedded resistance temperature detectors (RTDs), thermocouples, multi-layer insulation (MLI), and a temperature-controlled cold plate to characterize through-thickness thermal gradients across layered interfaces. In the current configuration, interface compression is limited to the nominal contact pressure generated by the experimental stack assembly. Initial experimental campaigns were conducted at ambient pressure and below 1×10-5 torr for vacuum cases using multiple interface materials including Braycote 601EF and Krytox-based greases across a range of thermal operating conditions. In parallel, a coupled numerical Python thermal model was developed to predict temperature distribution throughout the stack while accounting for conduction, radiation, and parasitic heat transfer pathways and effective interface resistance effects. Experimental measurements and numerical predictions showed consistent thermal trends across multiple operating conditions and environmental states. Results also revealed measurable differences between ambient and vacuum thermal behavior, demonstrating the importance of interface resistance, parasitic heat transfer mechanisms, and stack geometry in determining effective thermal performance within layered thermal interfaces. The presented work establishes a foundation for future thermal model correlation efforts and expanded characterization of aerospace thermal interface materials under representative environmental conditions. Future work will focus on the integration of a load cell system to enable controlled pressure-dependent characterization of thermal interface materials under compressive loading. This capability will allow investigation of the influence of contact pressure on effective thermal conductivity, interface resistance, and thermal performance within layered aerospace thermal interfaces under representative operational conditions.

Thermal Development Testing↗
NASA NTRS2015

Cryogenic Insulation Standard Data and Methodologies Project

Extending some recent developments in the area of technical consensus standards for cryogenic thermal insulation systems, a preliminary Inter-Laboratory Study of foam insulation materials was performed by NASA Kennedy Space Center and LeTourneau University. The initial focus was ambient pressure cryogenic boil off testing using the Cryostat-400 flat-plate instrument. Completion of a test facility at LETU has enabled direct, comparative testing, using identical cryostat instruments and methods, and the production of standard thermal data sets for a number of materials under sub-ambient conditions. The two sets of measurements were analyzed and indicate there is reasonable agreement between the two laboratories. Based on cryogenic boiloff calorimetry, new equipment and methods for testing thermal insulation systems have been successfully developed. These boiloff instruments (or cryostats) include both flat plate and cylindrical models and are applicable to a wide range of different materials under a wide range of test conditions. Test measurements are generally made at large temperature difference (boundary temperatures of 293 K and 78 K are typical) and include the full vacuum pressure range. Results are generally reported in effective thermal conductivity (ke) and mean heat flux (q) through the insulation system. The new cryostat instruments provide an effective and reliable way to characterize the thermal performance of materials under subambient conditions. Proven in through thousands of tests of hundreds of material systems, they have supported a wide range of aerospace, industry, and research projects. Boiloff testing technology is not just for cryogenic testing but is a cost effective, field-representative methodology to test any material or system for applications at sub-ambient temperatures. This technology, when adequately coupled with a technical standards basis, can provide a cost-effective, field-representative methodology to test any material or system for applications at sub-ambient to cryogenic temperatures. A growing need for energy efficiency and cryogenic applications is creating a worldwide demand for improved thermal insulation systems for low temperatures. The need for thermal characterization of these systems and materials raises a corresponding need for insulation test standards and thermal data targeted for cryogenic-vacuum applications. Such standards have a strong correlation to energy, transportation, and environment and the advancement of new materials technologies in these areas. In conjunction with this project, two new standards on cryogenic insulation were recently published by ASTM International: C1774 and C740. Following the requirements of NPR 7120.10, Technical Standards for NASA Programs and Projects, the appropriate information in this report can be provided to the NASA Chief Engineer as input for NASA's annual report to NIST, as required by OMB Circular No. A-119, describing NASA's use of voluntary consensus standards and participation in the development of voluntary consensus standards and bodies.

Technology Portfolio System↗
NASA NTRSDate not supplied

Ice Growth Model for Polar Water Capture Systems

In-situ resource utilization (ISRU) is essential to NASA’s goal of sustainable and cost-effective missions to the Moon and beyond. Water has become a particular source of interest since its discovery in the permanently shadowed regions (PSRs) of the Moon. This water exists as ice bound within the regolith, so one mode of capture is heating to sublimation temperatures and capturing at very low pressure. It then can be stored in ice form and transported out of the PSR and to a sunlit ridge, where processes such as electrolysis can be performed[2]. An understanding of frost growth dynamics under rarefied conditions is necessary for successful water capture and storage due to transient thermal properties of frost. A Diffusion-Limited Aggregation (DLA) approach was taken to analytically model bulk thermal conductivity changes of the growing frost layer under varying wall temperatures and frost layer porosities. The model utilizes well-known correlations for effective thermal conductivity and records the values as the frost layer thickness increases. This thermal conductivity can be applied to a known temperature change and be used to evaluate heat flux through the combined frost layer and tank wall for either a flat plate or cylindrical geometry. An experiment is described that will evaluate this model using one-dimensional frost growth on a horizontal, flat plate under low-pressure. The ice growth will be measured using a millimeter-scale photogrammetry camera system and a load cell measured transient mass growth.

In situ Resource Utilization↗