Development of Thermal Testing Techniques at High Solar Intensities Final Report, 13 Aug. 1965 - 13 May 1967
Solar energy simulation techniques for testing spacecraft thermal performance
THERMAL PROTECTION↗
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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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Numerical and Experimental Study of a Novel Additively Manufactured Metal-Polymer Composite Heat-Exchanger for Liquid Cooling Electronics
In order to meet increasing power-dissipation requirements of the electronics industry, compact, low-cost, and lightweight heat exchangers (HXs) are desired. With proper design, materials, and manufacture, polymer composite heat exchangers could meet these requirements. This paper presents a novel crossflow air-to-water, low-cost, and lightweight metal-polymer composite HX. This HX, which is entirely additively manufactured, utilizes a novel cross-media approach that provides direct heat exchange between air and liquid sides by using connecting fins. A robust numerical model was developed, which includes the dimensional effects of additive manufacturing. The study consists of a simplified 3D CFD model based on ellipsoidal-shaped staggered tube banks for the laminar range. It then uses an analytical approach to compute entire HX performance. The model is validated experimentally within 8% for thermal performance, 12% for air-side impedance, and 18% for water-side impedance. Finally, HX is compared with a conventional CPU radiator and performs within 10% of the conventional unit for reasonable flow rates and pressure-drop ranges. Moreover, HX also provides added design and cost advantages over the conventional unit, which makes the HX a potential candidate for electronic cooling applications.
30 DIRECT ENERGY CONVERSION↗
Solar energy system performance evaluation: Seasonal report for Decade 80 House, Tucson, Arizona
The operational and thermal performance of the Decade 80 solar energy system is described. The system was designed by Cooper Development Association, Inc. with space heating and space cooling to a one-story, single family residence located in Tucson, Arizona. The Decade 80 House was designed and built in the mid-70's to be a showplace/workshop for solar energy utilization. Superior construction techniques, the use of quality materials and a full time maintenance staff have served to make the entire system an outstanding example of the application of solar energy for residential purposes. The luxury of a full time, on-site maintenance person is perhaps the single most important aspect of this program. While most installations cannot support this level of maintenance, it was very useful in keeping all subsystems operating in top form and allowing for a full season data collection to be obtained. Several conclusions were drawn from the long term monitoring effort, among which are: (1) flat plate collectors will support cooling; (2) definite energy savings can be realized; and (3) more frequent periodic maintenance may be required on solar energy systems that are not custom built.
Source record↗
Solar energy system performance evaluation: Seasonal report for IBM system 1A, Huntsville, Alabama
The operational and thermal performance of the solar energy system, Sims Prototype System 1A, is described. The system was designed by IBM to provide 50 to 60 percent of the space heating and domestic hot water preheating load to a 2,000 square foot floor space single family residence in the Huntsville area. The load design temperature inside the building was to be maintained at 70 degrees fahrenheit with auxiliary energy for heating supplied by an electric heat pump assisted by an electric resistance strip heater. In general the disappointing operation of this system is attributed to the manner in which it was used. The system was designed for residential application and used to satisfy the demands of an office environment. The differences were: (1) inside temperature was not maintained at 70 F as expected; and (2) hot water usage was much lower than expected. The conclusion is that the solar energy system must be designed for the type of application in which it is used. Misapplication usually will have an adverse affect on system performance.
Source record↗
Performance Comparison Between NiH2 Dry Sinter and Slurry Electrode Cells
The electrical and thermal performance of dry sinter and slurry process electrode cells manufactured for the Hubble Space Telescope (HST) batteries have been characterized for a matrix of operating conditions over the temperature range from 14 to 86 F at various charge control levels. The dry sinter process electrode cells tested are similar to the onboard HST NiH2 cells. The slurry process electrode cells were developed to be less susceptible to electrode expansion and impedance changes with life. Both cell types were impregnated by the aqueous electrochemical process. Test conditions included standard capacity tests and electrical cycling using 96-minute cycling regimens incorporating gr depth-of-discharge (DOD) cycles. The dry sinter process electrodes have higher operating capacities to 1.20V/cell, but both electrode types have similar heat dissipation for the conditions tested. The results of the testing included cyclic heat generation during a typical 96-minute cycle, operating capacity data vs. cutoff voltage to generate a temperature-compensated voltage curve, and voltage characteristics suitable to develop a voltage prediction model. Analysis of data shows differences in the discharge voltage plateaus operating conditions evaluated. This is the basis for recommended changes in the battery charge control.
Armantrout, J. D.↗
Integration of thermal and environmental control systems during Space Station Freedom early assembly phase
An overview of Space Station Freedom Thermal Control System (TCS) and Environmental Control and Life Support System (ECLSS) integration is presented for Stages 2-6. Particular attention is given to issues associated with integrating five distinct, functioning spacecraft with hardware not specifically designed for intermediate stages. Areas specifically addressed include integrated ECLSS temperature and humidity control performance, thermal load balancing, performance and verification requirements, interface verification procedures, TCS activation sequence, resource allocation and Space Shuttle integration.
Di Pietro, David A.↗
Solar energy system performance evaluation: Seasonal report for Contemporary-Manchester, Manchester, New Hampshire
The operational and thermal performance of the solar energy system, Contemporary-Manchester, is described. The system was designed by Contemporary Systems Incorporated to provide space heating and domestic hot water preheating for a three story dwelling located on the New Hampshire Vocational Technical College campus, Manchester, New Hampshire. The net fossil energy savings for the period from March, 1979 to February, 1980 was 14.52 million Btu. However, the performance of the system must be degraded due to the fact that the building was unoccupied throughout the data assessment and analysis period. The unoccupied status prevented the normal adjustment of heating and ventilating controls for maintenance of comfort levels within the building. This lack of occupancy also prevented the typical family hot water usage, which would have allowed for more realistic evaluation of the hot water subsystem.
Source record↗
Final cryogenic performance report for the NASA Cosmic Background Explorer (COBE)
The cryogenic operation of NASA's Cosmic Background Explorer (COBE) ended on September 21, 1990, with the depletion of the liquid helium cryogen. The COBE had successfully completed more than 10 months of dewar and instrument operation. We report on the cryogenic performance of the COBE dewar and of the two cryogenic instruments throughout the mission lifetime. We discuss the steady state dewar performance, and the dewar and instrument response to a variety of transient thermal phenomena, including external radiation (from the earth and the sun) and instrument power variation. We present the effectiveness of using approximate mass gauging techniques in determining the liquid helium content. Finally we discuss the dewar behavior during the depletion of the helium, and the expected thermal performance of the dewar cryogen tank and the cryogenic instruments as they approach final thermal equilibrium.
Volz, S. M.↗
Using Models to Predict the Hygrothermal Performance of Equipment and Piping Insulation
The development of hygrothermal models began in earnest in the 1990s, with the initial emphasis on the performance of building envelope systems. Numerous large-scale building envelope failures associated with water intrusion drove this development. The physical principles of moisture transfer that apply to building envelopes are equally valid for equipment and piping insulation systems. The main advantage of modeling is that carefully characterized models can predict the long-term hygrothermal performance of any system under different climatic and interior conditions. Thermal insulations are commonly used on outdoor equipment and piping for different applications, such as thermal energy conservation and freeze protection. The insulated equipment usually experiences moisture intrusion due to many factors, such as the duration and frequency of moisture exposure, equipment operating temperature, insulation type, exposure temperature, weather conditions, equipment thermal cycling, and weatherproofing condition. Hygrothermal models have been employed to estimate the moisture pickup of insulated equipment and piping systems, as well as the moisture redistribution and subsequent change in thermal performance as these systems become contaminated with moisture. The hygrothermal model provides insights on the parameters influencing the time of wetness, the lateral redistribution of moisture along the pipe away from the leak, and the ease by which water escapes the insulation/jacketing systems. It has been shown that the moisture leak effect decreases rapidly with distance from the leak and that one- and two-dimensional hygrothermal simulations help to identify solutions to reduce conditions that support corrosion under insulation (CUI).
Shrestha, Som↗
High-temperature thermal conductivity measurements of macro-porous graphite
Graphite is a unique material for high temperature applications and will likely become increasingly important as we attempt to electrify industrial applications. Here, we investigate the thermal properties of low-quality, macro-porous graphite to determine the tradeoff between quality and thermal performance. We use laser flash analysis (LFA) to measure the thermal diffusivity of graphite at high temperatures. Due to the large pores in the graphite samples preventing uniform laser flash heating, we first apply a thick coating to achieve the required flat, parallel surfaces for LFA measurements. We then develop a methodology to extract properties of the sample from the diffusivity measurements, based on finite element modeling of a variety of sample/coating interface profiles. Validating the methodology against a reference sample demonstrates a mean absolute percentage error of 8.5%, with potential improvement with better sample characterization. We show low-quality graphite has a thermal conductivity of ~10 W/m/K up to 1000 °C, which is an order of magnitude lower than high-quality graphite, but contributions from photon conductivity may result in higher conductivities at higher temperatures. Overall, we demonstrate an approach for measuring thermal properties of macro-porous materials at high temperatures, and apply the approach to measuring thermal conductivity of porous graphite, which will aid in the design of hightemperature systems for cost-competitive decarbonization.
Verma, Shomik↗
Analytic and experimental evaluation of shadow shields and their support members for thermal control of space vehicles
The thermal performance of shadow shields, and their support struts, for the thermal protection of cryogenic propellants in a simulated deep-space environment was investigated analytically and experimentally. Very low overall heat-transfer rates were obtained when highly reflective aluminized Mylar shadow shields were used. The thermal interactions between the shields and support struts were investigated with fair to good agreement between the analysis and experimental data. The exterior surface of both fiberglass and titanium struts was coated to reduce the heat input into the test tank. The vacuum level inside the test facility strongly influenced the heat-transfer rates.
Boyle, R. J.↗
Further study for fabrication, evaluation, and testing of monolayer woven materials for space suit insulation
Improvements to the monolayer woven pile concept were evaluated in terms of increased durability and thermal performance. Three varieties of the monolayer material were tested for thermal conductance under various conditions simulating those which occur in space. In addition, the tendency of the pile to unravel was subjectively evaluated.
Short, R.↗
Apparatus for measurement of thermal conductivity of insulation systems subjected to extreme temperature differences
Advanced aerospace designs require thermal insulation systems which are consistent with cryogenic fluids, high thermal loads, and design restrictions such as weight and volume. To evaluate the thermal performance of these insulating systems, an apparatus capable of measuring thermal conductivity using extreme temperature differences (27 to 1100 K) is being developed. This system is described along with estimates of precision and accuracy in selected operating conditions. Preliminary data are presented.
Dube, W. P.↗
Effect of Cyclic Aeroconvective Heating on Flexible Thermal Insulations
This paper describes the effect of cyclic aeroconvective heating on the thermal performance of ceramic flexible insulations considered for potential use as thermal protection systems or thermal insulations for future hypersonic vehicles such as the Reusable Launch Vehicles (RLV's) and other applications where structures require thermal protection from severe heating. The thermal response of these materials after exposure to cyclic aeroconvective heating from a plasma arc is described. The thermal insulations evaluated were Composite Flexible Blanket Insulations composed of an outer layer of aluminoborosilicate fabric and alumina insulation. The insulations were evaluated with and without a high emissivity coating. These insulations were exposed to the plasma arc stream for nine minutes reaching surface temperatures of 1150 C and a heat flux of 10.5 W/sq cm. Insulations were exposed three, six, or nine times in order to demonstrate reusability and to determine the effect oi coatings on the surface durability of these insulations. Test results demonstrated the capability of these insulations to protect either composite or metallic structures from high heating environments. It is shown that high emittance coatings reduce backface temperatures. The durability of these insulations when impacted at low velocities was also demonstrated. The interaction of the coatings with the ceramic fibers was characterized. An analytical thermal model was utilized to correlate experimental thermal test results with calculated values.
Kourtides, Demetrius A.↗
Results of Use of Heat Flux Sensors on Liquid Hydrogen Tanks
Heat flux sensors were used to characterize the performance of insulation on the Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER), a large-scale test article designed to simulate upper stage cryogenic propellant tank thermal performance in simulated space environments. Usually, the insulation heat loads are derived from calculations removing all other heat sources and attributing the residual heat load to the insulation system. Testing for SHIIVER included the tank being just insulated with spray-on-foam insulation as well as covering the domes with multilayer insulation while leaving the barrel section insulated with spray-on-foam. Heat flux sensors were located at multiple locations on both domes as well as on the barrel section of the tank. Results from the SHIIVER testing using the heat flux sensors are compared to other calculated heat inputs for both liquid nitrogen and liquid hydrogen testing as a function of tank fill level. Further investigation into the transient nature of the SHIIVER testing including the heat flux sensors provided insight into heat flow patterns that may not have been otherwise seen using temperature sensors and calculated insulation heat loads. While the demonstrated uncertainties in the absolute values in the heat flux sensors are high, the values and the trends match well with other calculation methods. The results of SHIIVER allow for the use of heat flux sensors for measurements of insulation performance and dynamic system thermal response for future applications.
Cryogenic Fluid Management↗
Results of Use of Heat Flux Sensors on Liquid Hydrogen Tanks
ABSTRACT: Heat flux sensors were used to characterize the performance of insulation on the Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER), a large-scale test article designed to simulate upper stage cryogenic propellant tank thermal performance in simulated space environments. Usually, the insulation heat loads are derived from calculations removing all other heat sources and attributing the residual heat load to the insulation system. Testing for SHIIVER included the tank being just insulated with spray-on-foam insulation as well as covering the domes with multilayer insulation while leaving the barrel section insulated with spray-on-foam. Heat flux sensors were located at multiple locations on both domes as well as on the barrel section of the tank. Results from the SHIIVER testing using the heat flux sensors are compared to other calculated heat inputs for both liquid nitrogen and liquid hydrogen testing as a function of tank fill level. Further investigation into the transient nature of the SHIIVER testing including the heat flux sensors provided insight into heat flow patterns that may not have been otherwise seen using temperature sensors and calculated insulation heat loads. While the demonstrated uncertainties in the absolute values in the heat flux sensors are high, the values and the trends match well with other calculation methods. The results of SHIIVER allow for the use of heat flux sensors for measurements of insulation performance and dynamic system thermal response for future applications.
Cryogenic Fluid Management↗
Thermal Management Key Performance Parameter Development and System Analysis for the SUSAN Electrofan Aircraft
A set of key performance parameters (KPPs) for thermal management system (TMS) components was developed for use in system sizing and analysis. These KPPs were defined at three different levels of performance corresponding to different ranges of Technology Readiness Levels. KPP values were determined based on a large dataset that includes analysis and testing data from literature, NASA-funded research, and commercial product datasheets. These KPPs were then used to perform a TMS sizing and analysis of the SUbsonic Single Aft eNgine (SUSAN) aircraft. Total TMS mass, power consumption, and drag is quantified at each KPP level, showing decreasing trends as the level of technology improves.
thermal management↗
Performance map of the SNAP-8-1 model condenser, P/N 092500-1, S/N A-2
Thermal performance of SNAP-8 model condenser
PERFORMANCE CHARACTERISTICS↗