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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).
This study is the culmination of a long-term collaborative effort between researchers from the Purdue University Boiling and Two-Phase Flow Laboratory (PU-BTPFL) and the NASA Glenn Research Center to investigate gravitational effects on flow boiling and flow condensation. The science and design concepts for this large-scale effort were initiated in 2011 and included several studies detailing various aspects of two-phase fluid physics in both Earth gravity and microgravity, culminating in construction of the large-scale experimental facility named “Flow Boiling and Condensation Experiment (FBCE)”. The experiment was launched to the International Space Station (ISS) in August 2021. Following the successful installation of FBCE, equipped with the Flow Boiling Module (FBM), onboard the ISS and completion of several safety checks, flow boiling experiments were performed for five months from February 2022 until July 2022. This resulted in a large flow boiling database covering broad ranges of operating parameters and heating configurations spanning several research objectives. This study investigates microgravity flow boiling of n-perfluorohexane with subcooled inlet in a single-side-heated rectangular channel of dimensions 114.6-mm heated length, 2.5-mm heated width, and 5.0-mm height. Key operating parameters investigated are mass velocity (199.90 – 3200.13 kg/m 2 s), inlet subcooling (0.10 – 45.76°C), and inlet pressure (113.30 – 164.29 kPa). Images and image sequences acquired via high-speed-video are presented to elucidate the interfacial flow physics. To analyze and explain the effects of various parameters in microgravity, heat transfer results are presented as flow boiling curves, streamwise profiles of wall temperature and heat transfer coefficient, and parametric trends of local and averaged heat transfer coefficient. Mass velocity and inlet subcooling significantly influenced most of the aforementioned aspects of flow boiling, whereas effects of inlet pressure were comparatively insignificant. Although the data and observed flow physics might be different, the parametric effects and trends in microgravity are similar to vertical upflow in Earth gravity. Some cases, especially low mass velocities, high heat fluxes, and large degrees of inlet subcooling, experienced temporally anomalous flow behaviors caused by two-phase flow instabilities manifesting as flow reversals and resulted in deviations in overall trends. Severe thermodynamic non-equilibrium is observed throughout the channel. Overall, FBCE’s ISS experiments were successful for subcooled inlet with single-sided heating of rectangular channel, and the collected data well established the various effects on flow boiling physics in highly controlled long-term microgravity conditions.
Deadband condenser inlet pressure control method for SNAP 8 startup
A cermet fueled potassium rankine power system concept has been developed for various power ranges and operating lifetimes. This concept utilizes a single primary lithium loop to transport thermal energy from the reactor to the boiler. Multiple, independent potassium loops are employed to achieve the required reliability of 99 percent. The potassium loops are two phase systems which expand heated potassium vapor through multistage turboalternators to produce a 10-kV dc electrical output. Condensation occurs by-way-of a shear-flow condenser, producing a 100 percent liquid potassium stream which is pumped back to the boiler. Waste heat is rejected by an advanced carbon-carbon radiator at approximately 1000 K. Overall system efficiencies of 19.3 percent to 20.5 percent were calculated depending on mission life and power level.
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.
Basic equations of momentum and energy are presented and discussed with respect to heat transfer and pressure drop for forced flow condensation in horizontal tubes under 1-g and 0-g conditions. Some experimental results are presented for condensing refrigerant-12 in a system of three parallel-connected quartz tubes (3-mm inside diameter, G = 1.037 to 3.456 x 105 lbm/hr-sq. ft). From high speed photographs, measurements were obtained of film thickness, phase velocities, disturbance wavelengths, and flow regimes and their transitions. Based upon these measurements various dimensionless force ratios (flow and instability parameters) were calculated. Under 0-g conditions a uniformly thick redistribution of liquid condensate about the tube walls was found to result in a lowered heat transfer coefficient as compared with 1-g conditions, based upon fundamental heat transfer theory. A model is proposed that takes into account the difference in heat transfer due to condensate distribution under 1-g and 0-g conditions.
Two phase thermal management systems that capitalize on both latent and sensible heats of the working fluid can yield orders of magnitude enhancements in flow boiling and condensation heat transfer coefficients and reduce size and weight of future space systems. Because the understanding of microgravity influences on two-phase flow and heat transfer is quite limited, there is presently an urgent need for a new experimental microgravity facility to enable investigators to perform long-duration flow boiling and condensation experiments in pursuit of reliable databases. This presentation will discuss evolution of the Flow Boiling and Condensation Experiment (FBCE), a collaborative effort between Purdue University and NASA Glenn Research Center, from initial concept with clearly defined objectives to full implementation on the International Space Station (ISS). It will be shown how this facility will serve as a primary platform for obtaining two-phase flow and heat transfer data in microgravity. By comparing the microgravity data against those obtained in Earth gravity, it will be possible to ascertain the influence of body force on two-phase transport phenomena in pursuit of mechanistic models as well as correlations, and to help determine the minimum flow criteria to ensure gravity independent flow boiling and condensation.
The application of capillary screen liquid acquisition devices to space-based cryogenic propulsion systems is expected to necessitate thermodynamic conditioning in order to stabilize surface tension retention characteristics. The present results have been obtained in the framework of the research of low gravity condensation-flow processes for conditioning cryogenic liquid acquisition devices. The following system is studied: On the top of a subcooled horizontal disk, a liquid film condenses from the ambient saturated vapor. The liquid is forcedly removed at the disk edge, and there is an outward radial flow of the film. Stationary regimes of the flow are uncovered such that (i) the gravity is negligible, being eclipsed by the capillary forces; (ii) the film thickness is everywhere much smaller than the disk radius; and (iii) the slow-flow lubrication approximation is valid. A nonlinear differential equation for the film thickness as a function of the radial coordinate is obtained. The (two-dimensional) fields of velocities, temperature and pressure in the film are explicitly determined by the radial profile of its thickness. The equilibrium is controlled by two parameters: (i) the vapor-disk difference of temperatures and (ii) the liquid exhaust rate. For the flow regimes with a nearly uniform film thickness, the governing equation linearizes, and the film interface is analytically predicted to have a concave-up quartic parabola profile. Thus, perhaps counter-intuitively, the liquid film is thicker at the edge and thinner at the center of the disk.
A high-level description of the Flow Boiling and Condensation Experiment (FBCE) system capabilities, design and interface characteristics is presented. Each of the eight FBCE modules are discussed as well as the mechanical, electrical, and software interfaces with the Fluid Combustion Facility’s (FCF) Fluid Integration Rack (FIR), where the experiment will be installed for International Space Station (ISS) operations.
An effective means to reducing the size and weight of future space vehicles is to replace present mostly single-phase thermal management systems with two-phase counterparts. By capitalizing upon both latent and sensible heat of the coolant rather than sensible heat alone, two-phase thermal management systems can yield orders of magnitude enhancement in flow boiling and condensation heat transfer coefficients. Because the understanding of the influence of microgravity on two-phase flow and heat transfer is quite limited, there is an urgent need for a new experimental microgravity facility to enable investigators to perform long-duration flow boiling and condensation experiments in pursuit of reliable databases, correlations and models. This presentation will discuss recent progress in the development of the Flow Boiling and Condensation Experiment (FBCE) for the International Space Station (ISS) in collaboration between Purdue University and NASA Glenn Research Center. Emphasis will be placed on the design of the flow boiling module and on new flow boiling data that were measured in parabolic flight, along with extensive flow visualization of interfacial features at heat fluxes up to critical heat flux (CHF). Also discussed a theoretical model that will be shown to predict CHF with high accuracy.
Pressure drop of nonwetting condensing flow of mercury vapor in 1-g and zero gravity environments
Variable polarity plasma arc (VPPA) welding has been used with considerable success by NASA for the welds on the Space Shuttle External Tank as well as by others concerned with high quality welded structures. The effects of gaseous contaminants on the appearance of VPPA welds on 2219 aluminum are examined so that a welder can recognize that such contamination is present and take corrective measures. There are many possible sources of such contamination including, contaminated gas bottles, leaks in the gas plumbing, inadequate shield gas flow, condensed moisture in the gas lines or torch body, or excessive contaminants on the workpiece. The gasses chosen for study in the program were nitrogen, oxygen, methane, and hydrogen. Welds were made in a carefully controlled environment and comparisons were made between welds with various levels of these contaminants and welds made with research purity (99.9999 percent) gasses. Photographs of the weld front and backside as well as polished and etched cross sections are presented.
Experimental techniques for studying the processes which occur during the life cycle of a refractory grain are reviewed. Consideration is given to the construction of a differentially-pumped beam-mass spectrometer which is expected to determine the relative stability of small clusters in the Fe-Mg-Si-O and Ca-Ti-Al-O systems as a function of temperature and pressure. Also, a smoke generator has been constructed to produce gram quantities of amorphous grains for use in thermal annealing and hydrous alteration studies of smokes containing Fe-Mg-Al-Ti-Ca-Si-O and Cl. Topics of the studies include the properties of grains produced in a flow condensation apparatus, the sorption efficiency of Si2O3 smokes for AR gas, the processing of ices containing refractory precursors such as SiH4 or Fe(CO)5 plus water, and the residue from 1 MeV bombardment and warming of an amorphous Fe-SiO smoke.
Grains produced in porous Fe-SiO smoke are analyzed by means of electron microscopy to determine their crystallographical, morphological, and chemical properties. The nucleation of metal oxide condensates takes place as the vapor evolves in a condensation-flow apparatus, initially producing simple crystalline phases. Fe nucleation follows, and the subsequent heterogeneous nucleation of quenched mixed high-Fe silica grains exhibits associated Fe-depletion, eventually producing pure silica grains. The coalescence exhibited by the pure silica grains is compatible with the higher surface energy found in the pure silica phase. During coagulation the grains melt and anneal to a chemically pure mixture of alpha- and beta-tridymite, and the precipitation of amorphous silica material is observed. The settling of grains in evolving solar nebula is theorized to be related to the stickiness of this material, and maghemite is suggested to contribute to the Fe/Si fractionation in solar nebula.
NASA LeRC is currently developing a FORTRAN based computer model of a complete nuclear electric propulsion (NEP) vehicle that can be used for piloted and cargo missions to the Moon or Mars. Proposed designs feature either a Brayton or a K-Rankine power conversion cycle to drive a turbine coupled with rotary alternators. Both ion and magnetoplasmodynamic (MPD) thrusters will be considered in the model. In support of the NEP model, Rocketdyne is developing power conversion, heat rejection, and power management and distribution (PMAD) subroutines. The subroutines will be incorporated into the NEP vehicle model which will be written by NASA LeRC. The purpose is to document the heat pipe cooled heat rejection subsystem model and its supporting subroutines. The heat pipe cooled heat rejection subsystem model is designed to provide estimate of the mass and performance of the equipment used to reject heat from Brayton and Rankine cycle power conversion systems. The subroutine models the ductwork and heat pipe cooled manifold for a gas cooled Brayton; the heat sink heat exchanger, liquid loop piping, expansion compensator, pump and manifold for a liquid loop cooled Brayton; and a shear flow condenser for a K-Rankine system. In each case, the final heat rejection is made by way of a heat pipe radiator. The radiator is sized to reject the amount of heat necessary.
Dust in suspension within the martian atmosphere is an important driver of the atmospheric thermal and, ultimately, dynamical states. By virtue of its presence in the atmosphere, this suspended dust is susceptible to transport by the winds and thus the location from which dust is lifted from the surface is not necessarily the location at which it will return to the surface. Such surface dust lifting and subsequent transport, when accumulated over daily, seasonal and annual time intervals define the martian dust cycle. The atmospheric transport element (and equally surface lifting and redeposition) of this cycle is strongly dependent upon season and the quantity of dust in suspension. The seasonal dependence arises due to the dominance of particular components of the atmospheric circulation at particular locations (latitudes) at various times through the year. The dependence on dust abundance is due to the amount of dust available for transport, but it is also due to the influence that the dust has on the intensity of the circulation. As dust abundance and therefore its radiative influence increases, some components of the circulation intensity (Hadley circulation, thermal tides), while some components may decline in intensity (baroclinic waves, condensation flow). For these reasons, our ability to understand the martian dust cycle is dependent on our ability to define the contributions that various circulation components, under varying seasonal and dust-radiative forcings, play in the transport of dust around the planet.
The interstellar grain population in the giant molecular cloud from which the sun formed contained little or no iron metal. However, thermal processing of individual interstellar silicates in the solar nebula is likely to result in the formation of a population of very small iron metal grains. If such grains are exposed to even transient magnetic fields, each will become a tiny dipole magnet capable of interacting with other such dipoles over spatial scale orders of magnitude larger than the radii of individual grains. Such interactions will greatly increase the coagulation cross-section for this grain population. Furthermore, the magnetic attraction between two iron dipoles will significantly increase both the collisional sticking coefficient and the strength of the interparticle binding energy for iron aggregates. Formation of iron metal may therefore be a key step in the aggregation of planetesimals in a protoplanetary nebula. Such aggregates may have already been observed in protoplanetary systems. The enhancement in the effective interaction distance between two magnetic dipoles is directly proportional to the strength of the magnetic dipoles and inversely proportional to the relative velocity. It is less sensitive to the reduced mass of the interacting particles (alpha M(exp -1/2)) and almost insensitive to the initial number density of magnetic dipoles (alpha n(sub o)(exp 1/6)). We are in the process of measuring the degree of coagulation in our condensation flow apparatus as a function of applied magnetic field and correlating these results by means of magnetic remanance acquisition measurements on our iron grains with the strength of the magnetic field to which the grains are exposed. Results of our magnetic remanance acquisition measurements and the magnetic-induced coagulation study will be presented as well as an estimate of the importance of such processes near the nebular midplane.
Two improvements in heat-transfer design have been investigated with a view toward increasing the efficiency of refrigerators used to liquefy gases. The improvements could contribute to the development of relatively inexpensive, portable oxygen liquefiers for medical use. A description of the heat-transfer problem in a pulse-tube refrigerator is prerequisite to a meaningful description of the first improvement. In a pulse-tube refrigerator in particular, one of in-line configuration heat must be rejected from two locations: an aftercooler (where most of the heat is rejected) and a warm heat exchanger (where a small fraction of the total input power must be rejected as heat). Rejection of heat from the warm heat exchanger can be problematic because this heat exchanger is usually inside a vacuum vessel. When an acoustic-inertance tube is used to provide a phase shift needed in the pulse-tube cooling cycle, another problem arises: Inasmuch as the acoustic power in the acoustic-inertance tube is dissipated over the entire length of the tube, the gas in the tube must be warmer than the warm heat exchanger in order to reject heat at the warm heat exchanger. This is disadvantageous because the increase in viscosity with temperature causes an undesired increase in dissipation of acoustic energy and an undesired decrease in the achievable phase shift. Consequently, the overall performance of the pulse-tube refrigerator decreases with increasing temperature in the acoustic-inertance tube. In the first improvement, the acoustic-inertance tube is made to serve as the warm heat exchanger and to operate in an approximately isothermal condition at a lower temperature, thereby increasing the achievable phase shift and the overall performance of the refrigerator. This is accomplished by placing the acoustic-inertance tube inside another tube and pumping a cooling fluid (e.g., water) in the annular space between the tubes. Another benefit of this improvement is added flexibility of design to locate the warm heat-rejection components outside the vacuum vessel. The second improvement is the development of a compact radial-flow condenser characterized by a very high heat transfer coefficient and a small pressure drop.