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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Visualization of R410A Flow Boiling Inside Horizontal Smooth Tubes under Diabatic Conditions

This article presents a novel approach to visualize the flow boiling in round tubes under “diabatic conditions”. In the visualization test section, a 3D printed round tube is placed inside a glass tube with secondary fluid at a higher temperature flowing in the annulus between the two tubes thus providing diabatic conditions. Experimental work was conducted for evaporating R410A flow in a horizontal smooth round tube with the inner diameter of 6.3 mm. Compared to the traditional adiabatic visualization technique, the more realistic evaporative condition is simulated and the developing evaporation process is captured. New insights for the flow behavior at low vapor quality are brought by this diabatic method. The vapor plug occurs at very low vapor quality, and this is attributed to the coalescence of bubbles generated on the heated tube wall. For the intermittent flow, liquid slug triggered by Kelvin–Helmholtz instability affects the nucleation on the tube wall. It brings the fresh liquid to rewet the dry surface and activate the nucleation sites. Finally, heat flux condition affects the heat transfer mechanisms during the flow boiling, and the heat transfer through the nucleate boiling mechanism increases as the heat flux increases.

3D printed↗
DOE OSTI2018

Experimental investigation of subcooled flow boiling of a 50/50 ethylene glycol/water mixture in finned rectangular aluminum channels

Subcooled flow boiling heat transfer experiments were performed with a 50/50 ethylene glycol/water mixture in a finned aluminum channel. The channel represented a hybrid electric vehicle power electronic cold plate receiving a 50/50 mixture from the radiator at 105 degrees C and 2atmospheres. Experiments used a range of mixture flow rates and both top- and bottom-heating situations. Boiling curves were generated, and subcooled flow boiling heat transfer coefficients were determined including the test channel fin effects. Subcooled flow boiling heat transfer coefficients showed a 25-30% increase compared to single-phase convection.

boiling curve↗
NASA NTRS2024

Microgravity Flow Boiling Experiments With Liquid-Vapor Mixture Inlet Onboard the International Space Station

This article is part of a series of studies culminating from the multi-objective Flow Boiling and Condensation Experiment (FBCE) onboard the International Space Station, which utilized the Flow Boiling Module (FBM) for experiments between February and July 2022. This study investigates microgravity flow boiling of n-Perfluorohexane with liquid-vapor mixture (two-phase) inlet conditions to the FBM with either one or two opposite walls heated. The FBM’s channel has a rectangular cross-sectional area of 5.0 × 2.5 mm 2 and a heated length of 114.6 mm. Key parameters of interest include mass velocity (180 – 2400 kg/m 2 s), inlet quality (-0.01 – 0.87), inlet pressure (120 – 200 kPa), and heat flux (1.8 W/cm 2 to critical heat flux), and a large database is amassed. The flow is visualized via a high-speed video camera and photographs are recorded at each heating increment to assess the periodic flow patterns within the channel and the near-wall interfacial behavior. Flow patterns are complex and mainly characterized by high- and low-density fronts alternately traversing the channel to yield high- and low-density-dominant periods of boiling. At all operating conditions, high-density fronts are faster during high-density-dominant periods. At low inlet qualities, the flow is annular near the channel inlet with a central vapor core surrounded by an annular liquid layer. Each high-density front having a high liquid fraction leaves a thin liquid layer sheared onto the heated walls. Boiling occurs within the liquid layer and a vapor layer is formed next to the heated wall. Inlet quality and mass velocity most dictate the overall flow patterns followed by heating configuration, and to a much lesser extent, heat flux and inlet pressure. Heat transfer characteristics are assessed via averaged boiling curves, streamwise profiles of wall temperature and heat transfer coefficient, and parametric curves of local and averaged heat transfer coefficients. Inlet pressure has an insignificant effect on heat transfer. At similar operating conditions, both the heating configurations yield similar trends and values of heat transfer coefficient and critical heat flux (CHF, slightly higher for single-sided) even though double-sided heating adds twice the heat to the fluid and doubly raises local quality. The heat fluxes required for both onset of nucleate boiling degradation and CHF are larger at high mass velocities and low inlet qualities. For a fixed inlet quality, high mass velocities yield higher average heat transfer coefficients at both lower and higher heat fluxes, while the nucleate boiling regime at intermediate heat fluxes is unaffected. For a fixed mass velocity, higher inlet qualities yield higher and lower average heat transfer coefficients at lower and higher heat fluxes, respectively.

Microgravity↗
DOE OSTI2022

Effect of PVD-coated chromium on the subcooled flow boiling performance of nuclear reactor cladding materials

Here we elucidate the separate effect of a thin Cr coating deposited by physical vapor deposition (PVD) on the subcooled flow boiling performance of zircaloy-4. First, we run flow boiling experiments on prototypical zircaloy-4 surfaces mimicking the scratch pattern and surface roughness of nuclear reactor claddings. Then, we PVD-coat a 0.3 µm thick chromium layer on the same exact surface and repeat the same flow boiling investigations. All experiments are run using deionized water at atmospheric pressure, flowing on a 1 × 3 cm 2 rectangular cross section channel at a rate of 1000 kg/m 2 /s and a subcooling of 10 K. We measure the average temperature of the boiling surface at increasing surface heat fluxes, covering a wide range of heat transfer regimes, from single-phase forced convection to the boiling crisis. We also record high-speed videos of the boiling process, which we postprocess to measure bubble nucleation site density, growth time, departure diameter and frequency. The surface analysis reveals that, while the chromium coating does not seem change the surface roughness and morphology, it improves surface wettability. However, it decreases the critical heat flux. The chromium coating causes an increase of nucleation temperature, bubble departure diameter and growth time, and a reduction of the nucleation site density. The concurrence of these observations indicates that a size reduction of the nucleation sites, conformally covered by the chromium coating, may be the cause of the boiling performance deterioration. We confirm this hypothesis repeating the same analysis on a FeCrAl sample prepared and tested using the same protocol as the zircaloy-4 sample, but with a different initial surface texture.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Bubble departure and sliding in high-pressure flow boiling of water

Bubble growth, departure and sliding in low-pressure flow boiling has received considerable attention in the past. However, most applications of boiling heat transfer rely on high-pressure flow boiling, for which very little is known, as experimental data are scarce and very difficult to obtain. In this work, we conduct an experiment using high-resolution optical techniques. By combining backlit shadowgraphy and phase-detection imaging, we track bubble shape and physical footprint with high spatial ($6\,\mathrm {\mu }{\rm m}$) and temporal ($33\,\mathrm {\mu }{\rm s}$) resolutions, as well as bubble size and position as bubbles nucleate and slide on top of the heated surface. We show that at pressures above 1 MPa bubbles retain a spherical shape throughout the growth and sliding process. We analytically derive non-dimensional numbers to correlate bubble velocity and liquid velocity throughout the turbulent boundary layer and predict the sliding of bubbles on the surface, solely from physical properties and the bubble growth rate. We also show that these non-dimensional solutions can be leveraged to formulate elementary criteria that predict the effect of pressure and flow rate on bubble departure diameter and growth time.

Mechanics↗
NASA NTRS2016

Performance Evaluation of the International Space Station Flow Boiling and Condensation Experiment (FBCE) Test Facility

A ground-based experimental facility to perform flow boiling and condensation experiments is built in support of the development of the long duration Flow Boiling and Condensation Experiment (FBCE) destined for operation on board of the International Space Station (ISS) Fluid Integrated Rack (FIR). We performed tests with the condensation test module oriented horizontally and vertically. Using FC-72 as the test fluid and water as the cooling fluid, we evaluated the operational characteristics of the condensation module and generated ground based data encompassing the range of parameters of interest to the condensation experiment to be performed on the ISS. During this testing, we also evaluated the pressure drop profile across different components of the fluid subsystem, heater performance, on-orbit degassing subsystem, and the heat loss from different components. In this presentation, we discuss representative results of performance testing of the FBCE flow loop. These results will be used in the refinement of the flight system design and build-up of the FBCE which is scheduled for flight in 2019.

microgravity↗
DOE OSTI2014

New flow boiling heat transfer model for hydrocarbons evaporating inside horizontal tubes

Hydrocarbons have high thermodynamic performances, belong to the group of natural refrigerants, and they are the main components in mixture Joule-Thomson low temperature refrigerators (MJTR). New evaluations of nucleate boiling contribution and nucleate boiling suppression factor in flow boiling heat transfer have been proposed for hydrocarbons. A forced convection heat transfer enhancement factor correlation incorporating liquid velocity has also been proposed. In addition, the comparisons of the new model and other classic models were made to evaluate its accuracy in heat transfer prediction.

42 ENGINEERING↗
DOE OSTI2023

Development of experimental and computational frameworks to predict subcooled flow boiling in the LANL Isotope Production Facility

Cooling is crucial to maintain the integrity of target systems in isotope production facilities. At Los Alamos National Laboratory (LANL)’s Isotope Production Facility (IPF), multiple encapsulated targets are stacked and irradiated in tandem with a 100 MeV, ~250μA proton beam. To facilitate effective heat removal, these stacked targets are separated and cooled via a series of water channels. At these beam currents, this high-energy proton beam heats the target system, likely initiating subcooled flow boiling in the cooling channels. However, in-beam monitoring of the IPF target system is not possible due to the extreme radiation environment, and the necessarily significant shielding. To better understand high-power target performance, we developed ex-situ experimental and computational frameworks to predict the behavior of subcooled flow boiling at IPF. Subcooled flow boiling experiments on Inconel 625 samples under IPF conditions (2 bar pressure, 10 GPM flow rate (i.e., 2249 kg/m 2 /s), 85 K subcooling) revealed that IPF's average operating power is at the early stage of boiling with a heat transfer coefficient of 48,000 W/m 2 /s. The proposed modeling framework enables us to predict a complete boiling curve, i.e., single-phase heat transfer, onset of nucleate boiling, two-phase heat transfer, and critical heat flux (CHF), with specification of input boiling parameters up to intermediate heat flux levels. The estimated CHF under IPF conditions is 5.2 MW/m 2 . Experimental data under reduced conditions (2 bar pressure, 1.5 GPM flow rate (i.e., 337 kg/m 2 /s), 45 K subcooling) served as validation cases for the computational modeling. This computational model can be further extended to more complicated systems replicating the real IPF configuration, for instance, to study void distribution as a function of the incident proton beam profile and coolant velocity profile of multiple cooling channels. Finally, the proposed experimental and computational frameworks provide a means to better understand cooling systems in the isotope production facilities at different accelerators, where in-beam monitoring of the cooling process is not available.

07 ISOTOPE AND RADIATION SOURCES↗
NASA NTRS2005

Flow-Boiling Critical Heat Flux Experiments Performed in Reduced Gravity

Poor understanding of flow boiling in microgravity has recently emerged as a key obstacle to the development of many types of power generation and advanced life support systems intended for space exploration. The critical heat flux (CHF) is perhaps the most important thermal design parameter for boiling systems involving both heatflux-controlled devices and intense heat removal. Exceeding the CHF limit can lead to permanent damage, including physical burnout of the heat-dissipating device. The importance of the CHF limit creates an urgent need to develop predictive design tools to ensure both the safe and reliable operation of a two-phase thermal management system under the reduced-gravity (like that on the Moon and Mars) and microgravity environments of space. At present, very limited information is available on flow-boiling heat transfer and the CHF under these conditions.

Hasan, Mohammad M.↗
DOE OSTI2015

An experimental study on sub-cooled flow boiling CHF of R134a at low pressure condition with atmospheric pressure (AP) plasma assisted surface modification

In this study, sub-cooled flow boiling critical heat flux tests at low pressure were conducted in a rectangular flow channel with one uniformly heated surface, using simulant fluid R-134a as coolant. The experiments were conducted under the following conditions: (1) inlet pressure (P) of 400-800 kPa, (2) mass flux (G) of 124-248 kg/m 2 s, (3) inlet sub-cooling enthalpy (ΔH i ) of 12~ 26 kJ/kg. Parametric trends of macroscopic system parameters (G, P, H i ) were examined by changing inlet conditions. Those trends were found to be generally consistent with previous understandings of CHF behavior at low pressure condition (i.e. reduced pressure less than 0.2). A fluid-to-fluid scaling model was utilized to convert the test data obtained with the simulant fluid (R-134a) into the prototypical fluid (water). The comparison between the converted CHF of equivalent water and CHF look-up table with same operation conditions were conducted, which showed good agreement. Furthermore, the effect of surface wettability on CHF was also investigated by applying atmospheric pressure plasma (AP-Plasma) treatment to modify the surface characteristic. With AP-Plasma treatment, the change of microscopic surface characteristic was measured in terms of static contact angle. The static contact angle was reduced from 80° on original non-treated surface to 15° on treated surface. An enhancement of 18% on CHF values under flow boiling conditions were observed on AP-Plasma treated surfaces compared to those on non-treated heating surfaces.

42 ENGINEERING↗
NASA NTRS2021

Experimental Results and Interfacial Lift-off Model Predictions of Critical Heat Flux for Flow Boiling with Subcooled Inlet Conditions – In Preparation for Experiments Onboard the International Space Station

This study investigates critical heat flux (CHF) for subcooled flow boiling of n-Perfluorohexane based on results of pre-launch Earth-gravity Mission Sequence Tests (MSTs) of the Flow Boiling and Condensation Experiment (FBCE), which was launched to the International Space Station (ISS) in August 2021. CHF measurements were made in a rectangular channel having a 2.5 mm by 5 mm cross-section and a 114.6-mm long heated segment. Both single-sided and double-sided heating were tested in vertical upflow in Earth gravity for a variety of inlet conditions. The inlet subcooling was varied in the range of 0.4 – 32.0°C and encompassed both near-saturated and highly subcooled conditions. Experimental trends and high-speed video records were investigated to better understand the mechanism of CHF. Overall trends show CHF increases as flow rate and/or inlet subcooling are increased. Flow features from the events around CHF justify the applicability of the Interfacial Lift-off Model and the determination of limiting criteria for its application. The present experimental data are combined with prior databases for various flow orientations with respect to Earth gravity and microgravity data collected on parabolic flights. Predictions are made using the Interfacial Lift-off Model for this consolidated subcooled-inlet FBCE-CHF database. A heat utility ratio was included in the model to capture the effects of subcooling and corresponding thermodynamic non-equilibrium. An overall mean absolute error of 19.04% indicates good predictive capability of the model for both heating configurations, different gravity environments, and a wide range of inlet subcooling.

flow boiling↗
DOE OSTI2020

A new flow pattern map for flow boiling of R410A in horizontal micro-fin tubes considering the effect of the helix angle

This paper presents an improved flow pattern map for flow boiling in horizontal micro-fin tubes considering the effect of helix angle. The proposed map is modified from the one developed for horizontal smooth tubes by Wojtan et al. (2005) and takes the early transition to annular flow due to micro-fin geometry into account. Visualization of R410A flow boiling is carried out through the transparent smooth and micro-fin tubes with 0°, 10° and 18° helix angle and plotted on the proposed map for comparison. The result shows that the flow pattern map for micro-fin tube with 0° helix angle is generally similar to that for the smooth tube. For the tube with 10° and 18° helix angle, the annular flow occurs at lower vapor quality and lower mass flux. The proposed map shows good agreements when compared with the visualization and reflects the downward shift (to lower mass flux and vapor quality conditions) of the SW-WA transition with the increase of the helix angle. In order to further validate the proposed model, the flow pattern transitions calculated from the equations are also compared with the experimental data of the micro-fin tube in literature. The results show that the modified map increase the prediction accuracy of the flow patterns in the micro-fin tube.

42 ENGINEERING↗
NASA NTRS1991

Flow boiling with enhancement devices for cold plate coolant channel design

Future space exploration and commercialization will require more efficient heat rejection systems. For the required heat transfer rates, such systems must use advanced heat transfer techniques. Forced two phase flow boiling heat transfer with enhancements falls in this category. However, moderate to high quality two phase systems tend to require higher pressure losses. This report is divided into two major parts: (1) Multidimensional wall temperature measurement and heat transfer enhancement for top heated horizontal channels with flow boiling; and (2) Improved analytical heat transfer data reduction for a single side heated coolant channel. Part 1 summarizes over forty experiments which involve both single phase convection and flow boiling in a horizontal channel heated externally from the top side. Part 2 contains parametric dimensionless curves with parameters such as the coolant channel radius ratio, the Biot number, and the circumferential coordinate.

Boyd, Ronald D.↗
DOE OSTI2019

Comparison of steady and transient flow boiling critical heat flux for FeCrAl accident tolerant fuel cladding alloy, Zircaloy, and Inconel

Steady and transient (with a heating rate of 685?/s) internal-flow CHF (Critical Heat Flux) experiments were conducted under atmospheric pressure at a fixed inlet temperature (40? or 60?) and mass flow (300kg/m 2 s) on Fe-13Cr-6Al alloy, Inconel 600 and Zircaloy-4 tube samples. Multiple experiments were repeated on the same specimen to investigate the effect of surface characteristic changes (i.e., roughness, wettability, and oxide scale morphology) on the occurrence of CHF. Despite notable changes of wettability, roughness, and oxide layer characteristics on samples that had already been subjected to CHF, measured flow CHF remained unchanged throughout repeated experiments for tested materials. This demonstrates that the surface effects on flow CHF are limited in the test conditions. In the steady-state flow boiling condition, Fe-13Cr-6Al alloy demonstrated a 22% and 14% increase in CHF compared to Zircaloy-4 and Inconel 600, respectively. Compared to the 2006 Groeneveld CHF lookup table, Fe-13Cr-6Al alloy gives a 13% increase in the tested flow boiling condition. Material properties are considered primarily responsible for the observed CHF differences among the tested materials. The surface thermal economy parameter $\frac{(pc_p)^{3/2}}{\sqrt{k}}$ is proposed as an explanation for the observed CHF differences; this parameter is related to material’s ability to avoid an irreversible dry spot formation. The apparent disagreement of Zircaloy-4 CHF with both the look up table predictions and Inconel 600 shows the limitation of departure of nuclate boiling (DNB) evaluations that do not consider cladding materials. The transient Fe-13Cr-6Al CHF is 39% and 23% higher than the lookup table prediction and the steady-state condition experimental result, respectively.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRSDate not supplied

Flow Boiling and Condensation Experiment Overview

A brief overview of the Flow Boiling and Condensation Experiment will be presented at the Technical Interchange Meeting between NASA-GRC Scientists and Engineers and the Korea Aerospace Research Institute (KARI). The presentation describes the development of the FBCE, its constraints, and the on-going testing that had been and continues to be executed onboard of the International Space Station (ISS).

International Space Station↗
NASA NTRS2023

Validation of Universal Cryogenic Flow Boiling Correlations in Thermal Desktop for Liquid Helium

Understanding two-phase cryogenic propellant behavior is key to enabling technologies for future spaceflight missions. Developing accurate models of two-phase flow phenomena, particularly flow boiling in the heating configuration is relevant to the propellant transfer process both in microgravity and on other planetary surfaces. Currently there is a need for more accurate, direct cryogenic data anchored models for various boiling phenomena. Recently, universal correlations for cryogens flowing in heated tubes have been developed for a wide variety of fluids, thermodynamic conditions, and various regimes across the boiling curve, and have been patched to provide a smooth, continuous predictive curve. This paper demonstrates how these correlations have been ported into Thermal Desktop to improve predictive performance. To test the validity of the new correlations, Thermal Desktop is validated against a historical dataset of flow boiling experiments in the heating configuration using liquid helium. Based on results, the new correlations show a substantial improvement over the original built-in flow boiling correlations in Thermal Desktop in predicting the wall temperature as a function of preponderant parameters for this quantum fluid.

cryogenic propellant transfer↗
NASA NTRSDate not supplied

Validation of Universal Cryogenic Flow Boiling Correlations in Thermal Desktop for Liquid Helium

Understanding two-phase cryogenic propellant behavior is key to enabling technologies for future spaceflight missions. Developing accurate models of two-phase flow phenomena, particularly in the current work, flow boiling in the heating configuration, is relevant to the propellant transfer process both in 1-g and microgravity. Currently there is a need for more accurate, direct cryogenic data anchored models for various boiling phenomena. Recently, universal correlations for cryogens flowing in heated tubes have been developed for a wide variety of fluids, thermodynamic conditions, and various regimes across the boiling curve, and have been patched to provide a smooth, continuous predictive curve. This paper describes implementation and validation of these correlations into Thermal Desktop to improve predictive performance, with a focus on liquid helium. Results from Thermal Desktop using both the built-in and new correlations are validated against a historical dataset of flow boiling experiments in the heating configuration using liquid helium. Based on results, the new correlations show a substantial improvement over the original built-in flow boiling correlations in Thermal Desktop in predicting the wall temperature as a function of preponderant parameters for this quantum fluid at temperatures greater than the lambda temperature, T λ = 2.17K.

cryogenic propellant transfer↗
NASA NTRSDate not supplied

Modeling of Cryogenic Heated-Tube Flow Boiling Experiments of Nitrogen and Methane with the Generalized Fluid System Simulation Program

Accurate modeling of cryogenic boiling heat transfer is vital for the development of extended-duration space missions. Such missions may require the transfer of cryogenic propellants from in-space storage depots or the cooling of nuclear reactors. Purdue University in collaboration with NASA has assembled a database of cryogenic flow boiling data points from heated-tube experiments dating back to 1959, which has been used to develop new flow boiling correlations specifically for cryogens. Computational models of several of these experiments have been constructed in the Generalized Fluid System Simulation Program (GFSSP), a network flow code developed at NASA’s Marshall Space Flight Center. The new Purdue-developed correlations cover the full boiling curve: onset of nucleate boiling, nucleate boiling, critical heat flux, and film boiling. These correlations have been coded into GFSSP user subroutines. The fluids modeled are methane and nitrogen. Predictions of wall temperature and heat transfer coefficient are presented and compared to the test data.

Multi-Phase Flow↗