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NASA NTRS2012

Overview of Heat Addition and Efficiency Predictions for an Advanced Stirling Convertor

The U.S. Department of Energy (DOE) and Lockheed Martin Space Systems Company (LMSSC) have been developing the Advanced Stirling Radioisotope Generator (ASRG) for use as a power system for space science missions. This generator would use two high-efficiency Advanced Stirling Convertors (ASCs), developed by Sunpower Inc. and NASA Glenn Research Center (GRC). The ASCs convert thermal energy from a radioisotope heat source into electricity. As part of ground testing of these ASCs, different operating conditions are used to simulate expected mission conditions. These conditions require achieving a particular operating frequency, hot end and cold end temperatures, and specified electrical power output for a given net heat input. Microporous bulk insulation is used in the ground support test hardware to minimize the loss of thermal energy from the electric heat source to the environment. The insulation package is characterized before operation to predict how much heat will be absorbed by the convertor and how much will be lost to the environment during operation. In an effort to validate these predictions, numerous tasks have been performed, which provided a more accurate value for net heat input into the ASCs. This test and modeling effort included: (a) making thermophysical property measurements of test setup materials to provide inputs to the numerical models, (b) acquiring additional test data that was collected during convertor tests to provide numerical models with temperature profiles of the test setup via thermocouple and infrared measurements, (c) using multidimensional numerical models (computational fluid dynamics code) to predict net heat input of an operating convertor, and (d) using validation test hardware to provide direct comparison of numerical results and validate the multidimensional numerical models used to predict convertor net heat input. This effort produced high fidelity ASC net heat input predictions, which were successfully validated using specially designed test hardware enabling measurement of heat transferred through a simulated Stirling cycle. The overall effort and results are discussed.

Wilson, Scott D.↗

NASA NTRS1988

Capillary heat transport and fluid management device

A passive heat transporting and fluid management apparatus including a housing in the form of an extruded body member having flat upper and lower surfaces is disclosed. A main liquid channel and at least two vapor channels extend longitudinally through the housing from a heat input end to a heat output end. The vapor channels have sintered powdered metal fused about the peripheries to form a porous capillary wick structure. A substantial number of liquid arteries extend transversely through the wicks adjacent the respective upper and lower surfaces of the housing, the arteries extending through the wall of the housing between the vapor channels and the main liquid channel and open into the main liquid channel. Liquid from the main channel enters the artery at the heat input end, wets the wick and is vaporized. When the vapor is cooled at the heat output end, the condensed vapor refills the wick and the liquid reenters the main liquid channel.

James W Owen↗

NASA NTRS1982

An Io thermal model with intermittent volcanism

Observations have indicated that heat flow out of Io at present may be several times greater than the heat input from enhanced tidal heating; this may indicate that the observed heat flow is intermittent, rather than continuous. A two-dimensional time-dependent thermal model of Io was constructed to examine the relationship between enhanced tidal heating, heat flow within the body, and surface volcanism. From the models one can conclude that (1) a simple homogeneous body cannot maintain enhanced tidal heating in a thin crust, but such heating is possible if the crust contains an insulating layer, as of sulfur; (2) this sulfur layer will be subject to melting by heat from the interior, resulting in hotspots which can expel heat much more rapidly than tidal heating inputs it; and (3) the location of these hotspots will vary in time and space; they can appear anywhere on the surface, even if tidal heating is concentrated at the poles, and they seem to occur roughly 10% of the time.

Consolmagno, G. J.↗

NASA NTRS1991

Free-piston Stirling component test power converter

The National Aeronautics and Space Administration (NASA) has been evaluating free-piston Stirling power converters (FPSPCs) for use on a wide variety of space missions. They provide high reliability, long life, and efficient operation and can be coupled with all potential heat sources, various heat input and heat rejection systems, and various power management and distribution systems. FPSPCs can compete favorably with alternative power conversion systems over a range of hundreds of watts to megawatts. Mechanical Technology Incorporated (MTI) is developing FPSPC technology under contract to NASA Lewis Research Center and will demonstrate this technology in two full-scale power converters operating at space temperature conditions. The testing of the first of these, the component test power converter (CTPC), was initiated in Spring 1991 to evaluate mechanical operation at space operating temperatures. The CTPC design, hardware fabrication, and initial test results are reviewed.

Dochat, George↗

NASA NTRS2008

5-kWe Free-piston Stirling Engine Convertor

The high reliability, long life, and efficient operation of Free-Piston Stirling Engines (FPSEs) make them an attractive power system to meet future space power requirements with less mass, better efficiency, and less total heat exchanger area than other power convertor options. FPSEs are also flexible in configuration as they can be coupled with many potential heat sources and various heat input systems, heat rejection systems, and power management and distribution systems. Development of a 5-kWe Stirling Convertor Assembly (SCA) is underway to demonstrate the viability of an FPSE for space power. The design is a scaled-down version of the successful 12.5-kWe Component Test Power Converter (CTPC) developed under NAS3-25463. The ultimate efficiency target is 25% overall convertor efficiency (electrical power out over heat in). For the single cylinder prototype now in development, cost and time constraints required use of economical and readily available materials (steel versus beryllium) and components (a commercially available linear alternator) and thus lower efficiency. The working gas is helium at 150 bar mean pressure. The design consists of a displacer suspended on internally pumped gas bearings and a power piston/alternator supported on flexures. Non-contacting clearance seals are used between internal volumes. Heat to and from the prototype convertor is done via pumped liquid loops passing through shell and tube heat exchangers. The preliminary and detail designs of the convertor, controller, and support systems (heating loop, cooling loop, and helium supply system) are complete and all hardware is on order. Assembly and test of the prototype at Foster- Miller is planned for early 2008, when work will focus on characterizing convertor dynamics and steady-state operation to determine maximum power output and system efficiency. The device will then be delivered to Auburn University where assessments will include start-up and shutdown characterization and transient response to temperature and load variations. Future activities may include testing at NASA GRC.

Chapman, Peter A.↗

NASA NTRS2004

Calibration, Data Acquisition, and Post Analysis of Turbulent Fluid Flow in a Calibration Jet Using Hot-wire Anemometry

The Turbine Branch concentrates on the following areas: Computational Fluid Dynamics (CFD), and implementing experimental procedures to obtain physical modeling data. Hot-wire Anemometry is a valuable tool for obtaining physical modeling data. Hot-wire Anemometry is likely to remain the principal research tool for most turbulent air/gas flow studies. The Hot-wire anemometer consists of a fine wire heated by electric current. When placed in a fluid stream, the hot-wire loses heat to the fluid by forced convection. In forced convection, energy transfer is due to molecular motion imposed by an extraneous force moving fluid parcels. When the hot-wire is in "equilibrium", the rate of heat input to the wire is equal to the rate of heat loss at the wire ends. The equality between heat input and heat loss is the basis for King s equation, which relates the electrical parameters of the hot-wire to the flow parameters of the fluid. Hot-wire anemometry is based on convective heat transfer from a heated wire element placed in a fluid flow. Any change in the fluid flow condition that affects the heat transfer from the heated element will be detected virtually instantaneously by a constant-temperature Hot-wire anemometry system. The system implemented for this research is the IFA 300. The system is a fully-integrated, thermal anemometer-based system that measures mean and fluctuating velocity components in air, water, and other fluids. It also measures turbulence and makes localized temperature measurements. A constant-temperature anemometer is a bridge and amplifier circuit that controls a tiny wire at constant temperature. As a fluid flow passes over the heated sensor, the amplifier senses the bridge off-balance and adjusts the voltage to the top of the bridge, keeping the bridge in balance. The voltage on top of the bridge can then be related to the velocity of the flow. The bridge voltage is sensitive to temperature as well as velocity and so the built-in thermocouple circuit can be attached to a thermocouple that can measure the fluid temperature. Additional information is included in the original extended abstract.

Moreno, Michelle↗

NASA NTRS1990

Heat Pipe Vapor Dynamics

The dynamic behavior of the vapor flow in heat pipes is investigated at startup and during operational transients. The vapor is modeled as two-dimensional, compressible viscous flow in an enclosure with inflow and outflow boundary conditions. For steady-state and operating transients, the SIMPLER method is used. In this method a control volume approach is employed on a staggered grid which makes the scheme very stable. It is shown that for relatively low input heat fluxes the compressibility of the vapor flow is low and the SIMPLER scheme is suitable for the study of transient vapor dynamics. When the input heat flux is high or the process under a startup operation starts at very low pressures and temperatures, the vapor is highly compressible and a shock wave is created in the evaporator. It is shown that for a wide range of input heat fluxes, the standard methods, including the SIMPLER scheme, are not suitable. A nonlinear filtering technique, along with the centered difference scheme, are then used for shock capturing as well as for the solution of the cell Reynolds-number problem. For high heat flux, the startup transient phase involves multiple shock reflections in the evaporator region. Each shock reflection causes a significant increase in the local pressure and a large pressure drop along the heat pipe. Furthermore, shock reflections cause flow reversal in the evaporation region and flow circulations in the adiabatic region. The maximum and maximum-averaged pressure drops in different sections of the heat pipe oscillate periodically with time because of multiple shock reflections. The pressure drop converges to a constant value at steady state. However, it is significantly higher than its steady-state value at the initiation of the startup transient. The time for the vapor core to reach steady-state condition depends on the input heat flux, the heat pipe geometry, the working fluid, and the condenser conditions. However, the vapor transient time, for an Na-filled heat pipe is on the order of seconds. Depending on the time constant for the overall system, the vapor transient time may be very short. Therefore, the vapor core may be assumed to be quasi-steady in the transient analysis of a heat pipe operation.

Issacci, Farrokh↗

NASA NTRS1994

Computing Temperatures And Pressures Along Heat Pipes

NASA Lewis Research Center Heat Pipe, LERCHP, computer code developed to predict performances of heat pipes in steady state. Used as design software tool on personal computer or, with suitable calling routine, as subroutine for mainframe-computer radiator code. For accurate mathematical modeling of heat pipes, LERCHP makes variety of wick structures available to user. User chooses among several working fluids, for which monomer/dimer equilibrium considered. Vapor-flow algorithm treats compressibility and axially varying heat input. Facilitates determination of heat-pipe operating temperatures and heat-pipe limits encountered at specified heat input and environmental temperature. Written in FORTRAN 77.

Faker, K. W.↗

NASA NTRS2011

Overview of Heat Addition and Efficiency Predictions for an Advanced Stirling Convertor

Past methods of predicting net heat input needed to be validated. Validation effort pursued with several paths including improving model inputs, using test hardware to provide validation data, and validating high fidelity models. Validation test hardware provided direct measurement of net heat input for comparison to predicted values. Predicted value of net heat input was 1.7 percent less than measured value and initial calculations of measurement uncertainty were 2.1 percent (under review). Lessons learned during validation effort were incorporated into convertor modeling approach which improved predictions of convertor efficiency.

Wilson, Scott D.↗

NASA NTRS2012

Environmental Loss Characterization of an Advanced Stirling Convertor (ASC-E2) Insulation Package Using a Mock Heater Head

Schifer, Nicholas A.↗

NASA NTRS1961

Flight-Path Characteristics for Decelerating From Supercircular Speed

Characteristics of the following six flight paths for decelerating from a supercircular speed are developed in closed form: constant angle of attack, constant net acceleration, constant altitude" constant free-stream Reynolds number, and "modulated roll." The vehicles were required to remain in or near the atmosphere, and to stay within the aerodynamic capabilities of a vehicle with a maximum lift-drag ratio of 1.0 and within a maximum net acceleration G of 10 g's. The local Reynolds number for all the flight paths for a vehicle with a gross weight of 10,000 pounds and a 600 swept wing was found to be about 0.7 x 10(exp 6). With the assumption of a laminar boundary layer, the heating of the vehicle is studied as a function of type of flight path, initial G load, and initial velocity. The following heating parameters were considered: the distribution of the heating rate over the vehicle, the distribution of the heat per square foot over the vehicle, and the total heat input to the vehicle. The constant G load path at limiting G was found to give the lowest total heat input for a given initial velocity. For a vehicle with a maximum lift-drag ratio of 1.0 and a flight path with a maximum G of 10 g's, entry velocities of twice circular appear thermo- dynamically feasible, and entries at velocities of 2.8 times circular are aerodynamically possible. The predominant heating (about 85 percent) occurs at the leading edge of the vehicle. The total ablated weight for a 10,000-pound-gross-weight vehicle decelerating from an initial velocity of twice circular velocity is estimated to be 5 percent of gross weight. Modifying the constant G load flight path by a constant-angle-of-attack segment through a flight- to circular-velocity ratio of 1.0 gives essentially a "point landing" capability but also results in an increased total heat input to the vehicle.

Luidens, Roger W.↗

NASA NTRS1958

Structural design considerations for boost-glide and orbital reentry vehicles

The preceding papers have discussed the aerodynamics and heating of several vehicles designed for atmospheric reentry from satellite orbits. Because of large heating inputs, some fundamental questions about the structure of these vehicles are also raised. Although there are many factors which influence structural design, only a brief examination of the relationship between heating input and structural weight is discussed here. For this purpose the heating inputs associated with the four vehicles shown in figure 1 are employed.

William A. Brooks, Jr.↗

NASA NTRS2011

A Computational Methodology for Simulating Thermal Loss Testing of the Advanced Stirling Convertor

Convertor and generator testing is carried out in tests designed to characterize convertor performance when subjected to environments intended to simulate launch and space conditions. The value of net heat input must be known in order to calculate convertor efficiency and to validate convertor performance. Specially designed test hardware was used to verify and validate a two step methodology for the prediction of net heat input. This lessons learned from these simulations have been applied to previous convertor simulations. As heat is supplied to the convertors, electric power is produced and measured. Net heat input to the convertor is one parameter that will contribute to the calculation of efficiency. This parameter is not measured directly. Insulation Loss. Determine the current status of the thermal conductivity of the micro-porous insulation. - Match heat source and hot end temperatures. - Match temperature difference across Kaowool insulation

Reid, Terry V.↗

NASA NTRS2019

Electron Beam Welding of Pure Tungsten Hex Cans for Nuclear Thermal Propulsion Engines

Nuclear thermal propulsion (NTP) is an in-space propulsion method currently being developed at the NASA Marshall Space Flight Center (MSFC). NTP systems are a high specific impulse (750–1,100 s), high thrust (15,000–250,000 lbf ) method of propulsion which have the potential to allow for faster transit times when optimizing for high ΔV. In the nuclear rocket engine, the heat from the nuclear fission reaction is transferred to a low molecular mass propellant (such as hydrogen). Hot propellant is expanded through a nozzle to generate thrust. Development of ceramic metal (cermet) fuel systems for NTP applications is currently ongoing at MSFC. In cermet fuel systems, ceramic fissile fuel particles such as uranium nitride or uranium dioxide are dispersed within a net-shaped, high-density structural matrix. The composite material is cladded by a protective metal structure to make up an NTP fuel element. Cladding materials must be able to withstand the demanding operating conditions required of the engine as well as retain a hermetic seal to allow for retention of fuel element structural integrity, prevent hydrogen attack or migration of the ceramic fuel, and limit release of fission products during operation. For NTP applications, tungsten is a prime material for both the metal matrix and cladding in cermet fuel systems because of its high melting point, high temperature strength, and compatibility with hot hydrogen. If a weld in tungsten with the capability of holding a hermetic seal is achievable, tungsten becomes a strong candidate for NTP applications. This Technical Memorandum focuses on determining the weldability of pure tungsten using electron beam welding (EBW). Tungsten appears well suited for NTP applications, but it has a high ductile to brittle transition temperature (DBTT) dependent upon chemical composition, structure/stress distribution, and mechanical conditions. Therefore, it is highly subject to brittle fracture. Because of its high susceptibility to brittle fracture, it is very difficult to weld. EBW was chosen for joining pure tungsten because of its low heat input compared to gas tungsten arc welding. Reduced heat input can be directly correlated with an increase in ductility of a tungsten weld. EBW is a high energy density welding process in which a stream of electrons penetrates a weld joint in a deep, narrow spike in contrast to a broad gas tungsten arc weld pool. The investigation initially focused on EBW of tungsten plates of both 0.01 in and 0.03 in thickness to determine if EBW could weld pure tungsten without the presence of visual defects—particularly cracking—in the welds. Variation in the weld procedure and post-weld heat treatment (PWHT) was used to improve the surface appearance of flat EBWs on a pure tungsten sheet. The investigation moved on to weld 0.05-in-thick hexagonal tungsten cans with a weld joint thickness of 0.025 in. The goal for welding the pure tungsten hex cans was to avoid any visual surface defects and generate a weld capable of a hermetic seal. This proved difficult. Cold welds commonly exhibited porosity that leaked air. Hot welds exhibited cracks, typically observed immediately after welding. Later welds were preheated to increase ductility and decrease the likelihood of through-thickness cracking. PWHT was used to arrest microcrack growth both in the flat weld samples and hexagonal weld samples.

Courtright, Z. S.↗

NASA NTRS1993

Insoluble coatings for Stirling engine heat pipe condenser surfaces

The work done by Thermacore, Inc., Lancaster, Pennsylvania, for the Phase 1, 1992 SBIR National Aeronautics and Space Administration Contract, 'Insoluble Coatings for Stirling Engine Heat Pipe Condenser Surfaces' is described. The work was performed between January 1992 and July 1992. Stirling heat engines are being developed for electrical power generation use on manned and unmanned earth orbital and planetary missions. Dish Stirling solar systems and nuclear reactor Stirling systems are two of the most promising applications of the Stirling engine electrical power generation technology. The sources of thermal energy used to drive the Stirling engine typically are non-uniform in temperature and heat flux. Liquid metal heat pipe receivers are used as thermal transformers and isothermalizers to deliver the thermal energy at a uniform high temperature to the heat input section of the Stirling engine. The use of a heat pipe receiver greatly enhances system efficiency and potential life span. One issue that is raised during the design phase of heat pipe receivers is the potential solubility corrosion of the Stirling engine heat input section by the liquid metal working fluid. This Phase 1 effort initiated a program to evaluate and demonstrate coatings, applied to nickel based Stirling engine heater head materials, that are practically 'insoluble' in sodium, potassium, and NaK. This program initiated a study of nickel aluminide as a coating and developed and demonstrated a heat pipe test vehicle that can be used to test candidate materials and coatings. Nickel 200 and nickel aluminide coated Nickel 200 were tested for 1000 hours at 800 C at a condensation heat flux of 25 W/sq cm. Subsequent analyses of the samples showed no visible sign of solubility corrosion of either coated or uncoated samples. The analysis technique, photomicrographs at 200X, has a resolution of better than 2.5 microns (.0001 in). The results indicate that the heat pipe environment is not directly comparable to liquid metal pumped loop data, that nickel aluminide is still a leading candidate for solubility corrosion protection, and that longer duration tests are required to reach a definitive conclusion whether coatings are required at all. Should further testing be required, the test vehicle and analytical tools were developed.

Dussinger, Peter M.↗

NASA NTRS2007

Antenna for Measuring Electric Fields Within the Inner Heliosphere

A document discusses concepts for the design of an antenna to be deployed from a spacecraft for measuring the ambient electric field associated with plasma waves at a location within 3 solar radii from the solar photosphere. The antenna must be long enough to extend beyond the photoelectron and plasma sheaths of the spacecraft (expected to be of the order of meters thick) and to enable measurements at frequencies from 20 Hz to 10 MHz without contamination by spacecraft electric-field noise. The antenna must, therefore, extend beyond the thermal protection system (TPS) of the main body of the spacecraft and must withstand solar heating to a temperature as high as 2,000 C while not conducting excessive heat to the interior of the spacecraft. The TPS would be conical and its axis would be pointed toward the Sun. The antenna would include monopole halves of dipoles that would be deployed from within the shadow of the TPS. The outer potion of each monopole would be composed of a carbon-carbon (C-C) composite surface exposed to direct sunlight (hot side) and a C-C side in shadow (cold side) with yttria-stabilized zirconia spacers in-between. The hot side cannot view the spacecraft bus, while the cold side can. The booms also can be tilted to minimize heat input to spacecraft bus. This design allows one to reduce heat input to the spacecraft bus to acceptable levels.

Sittler, Edward Charles↗

NASA NTRS2016

The Flux-Anomaly-Forced Model Intercomparison Project (FAFMIP) Contribution to CMIP6: Investigation of Sea-Level and Ocean Climate Change in Response to CO2 Forcing

The Flux-Anomaly-Forced Model Intercomparison Project (FAFMIP) aims to investigate the spread in simulations of sea-level and ocean climate change in response to CO2 forcing by atmosphere-ocean general circulation models (AOGCMs). It is particularly motivated by the uncertainties in projections of ocean heat uptake, global-mean sealevel rise due to thermal expansion and the geographical patterns of sea-level change due to ocean density and circulation change. FAFMIP has three tier-1 experiments, in which prescribed surface flux perturbations of momentum, heat and freshwater respectively are applied to the ocean in separate AOGCM simulations. All other conditions are as in the pre-industrial control. The prescribed fields are typical of pattern and magnitude of changes in these fluxes projected by AOGCMs for doubled CO2 concentration. Five groups have tested the experimental design with existing AOGCMs. Their results show diversity in the pattern and magnitude of changes, with some common qualitative features. Heat and water flux perturbation cause the dipole in sea-level change in the North Atlantic, while momentum and heat flux perturbation cause the gradient across the Antarctic Circumpolar Current. The Atlantic meridional overturning circulation (AMOC) declines in response to the heat flux perturbation, and there is a strong positive feedback on this effect due to the consequent cooling of sea-surface temperature in the North Atlantic, which enhances the local heat input to the ocean. The momentum and water flux perturbations do not substantially affect the AMOC. Heat is taken up largely as a passive tracer in the Southern Ocean, which is the region of greatest heat input, while the weakening of the AMOC causes redistribution of heat towards lower latitudes. Future analysis of these and other phenomena with the wider range of CMIP6 FAFMIP AOGCMs will benefit from new diagnostics of temperature and salinity tendencies, which will enable investigation of the model spread in behaviour in terms of physical processes as formulated in the models.

thermosteric sea-level change↗

NASA NTRS1971

Multichamber controllable heat pipe

Valve throttles transfer of vapor between heat input surface and heat rejection surface of heat pipe to control rate of transfer of energy. Valve is operated by control signals which sense temperatures or pressures.

Shlosinger, A. P.↗