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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 73 records · Page 4

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↗

Enhancements of Nucleate Boiling Under Microgravity Conditions

This paper presents two means for enhancing nucleate boiling and critical heat flux under microgravity conditions: using micro-configured metal-graphite composites as the boiling surface and dilute aqueous solutions of long-chain alcohols as the working fluid. In the former, thermocapillary force induced by temperature difference between the graphite-fiber tips and the metal matrix plays an important role in bubble detachment. Thus boiling-heat transfer performance does not deteriorate in a reduced-gravity environment. In the latter cases, the surface tension-temperature gradient of the long-chain alcohol solutions turns positive as the temperature exceeds a certain value. Consequently, the Marangoni effect does not impede, but rather aids in bubble departure from the heating surface. This feature is most favorable in microgravity. As a result, the bubble size of departure is substantially reduced at higher frequencies. Based on the existing experimental data, and a two-tier theoretical model, correlation formulas are derived for nucleate boiling on the copper-graphite and aluminum-graphite composite surfaces, in both the isolated and coalesced bubble regimes. In addition, performance equations for nucleate boiling and critical heat flux in dilute aqueous solutions of long-chain alcohols are obtained.

Zhang, Nengli↗

Magnetothermal Convection in Nonconducting Diamagnetic and Paramagnetic Fluids

Nonuniform magnetic fields exert a magnetic body force on electrically nonconducting classical fluids. These include paramagnetic fluids such as gaseous and liquid oxygen and diamagnetic fluids such as helium. Recent experiments show that this force can overwhelm the force of gravity even at the surface of the earth; it can levitate liquids and gases, quench candle flames, block gas flows, and suppress heat transport. Thermal gradients render the magnetic force nonuniform through the temperature-dependent magnetic susceptibility. These thermal gradients can therefore drive magnetic convection analogous to buoyancy-driven convection. This magnetothermal convection can overwhelm convection driven by gravitational buoyancy in terrestrial experiments. The objectives of the proposed ground-based theoretical study are (a) to supply the magnetothermohydrodynamic theory necessary to understand these recent experiments and (b) to explore the consequences of nonuniform magnetic fields in microgravity. Even the linear theory for the onset of magnetothermal convection is lacking in the literature. We intend to supply the linear and nonlinear theory based on the thermohydrodynamic equations supplemented by the magnetic body force. We intend to investigate the effect of magnetic fields on gas blockage and heat transport in microgravity. Since magnetic fields provide a means of creating arbitrary, controllable body force distributions, we intend to investigate the possibility of using magnetic fields to position and control fluids in microgravity. We also intend to investigate the possibility of creating stationary terrestrial microgravity environments by using the magnetic force to effectively cancel gravity. These investigations may aid in the design of space-based heat-transfer, combustion, and human-life-support equipment.

Edwards, Boyd F.↗

The materials processing research base of the Materials Processing Center

An annual report of the research activities of the Materials Processing Center of the Massachusetts Institute of Technology is given. Research on dielectrophoresis in the microgravity environment, phase separation kinetics in immiscible liquids, transport properties of droplet clusters in gravity-free fields, probes and monitors for the study of solidification of molten semiconductors, fluid mechanics and mass transfer in melt crystal growth, and heat flow control and segregation in directional solidification are discussed.

Latanision, R. M.↗

Computations of Boiling in Microgravity

The absence (or reduction) of gravity, can lead to major changes in boiling heat transfer. On Earth, convection has a major effect on the heat distribution ahead of an evaporation front, and buoyancy determines the motion of the growing bubbles. In microgravity, convection and buoyancy are absent or greatly reduced and the dynamics of the growing vapor bubbles can change in a fundamental way. In particular, the lack of redistribution of heat can lead to a large superheat and explosive growth of bubbles once they form. While considerable efforts have been devoted to examining boiling experimentally, including the effect of microgravity, theoretical and computational work have been limited. Here, the growth of boiling bubbles is studied by direct numerical simulations where the flow field is fully resolved and the effects of inertia, viscosity, surface deformation, heat conduction and convection, as well as the phase change, are fully accounted for. Boiling involves both fluid flow and heat transfer and thus requires the solution of the Navier-Stokes and the energy equations. The numerical method is based on writing one set of governing transport equations which is valid in both the liquid and vapor phases. This local, single-field formulation incorporates the effect of the interface in the governing equations as source terms acting only at the interface. These sources account for surface tension and latent heat in the equations for conservation of momentum and energy as well as mass transfer across the interface due to phase change. The single-field formulation naturally incorporates the correct mass, momentum and energy balances across the interface. Integration of the conservation equations across the interface directly yields the jump conditions derived in the local instant formulation for two-phase systems. In the numerical implementation, the conservation equations for the whole computational domain (both vapor and liquid) are solved using a stationary grid and the phase boundary is followed by a moving unstructured two-dimensional grid. While two-dimensional simulations have been used for preliminary studies and to examine the resolution requirement, the focus is on fully three-dimensional simulations. The numerical methodology, including the parallelization and grid refinement strategy is discussed, and preliminary results shown. For buoyancy driven flow, the heat transfer is in good agreement with experimental correlations. The changes when gravity is turned off and/or fluid shear is added are discussed, as well as the difference between simulations of a layer freely releasing bubbles versus simulations using only one wavelength initial perturbation. Figure 1 shows the early stages of the formation of a three-dimensional bubble from a thin vapor layer. The boundary conditions are periodic in the x and y direction, the bottom is a hot and the top allows a free outflow. The jagged edge of the surface close to the bottom of the computational domain is due to some of the surface elements being on the other side of the domain and some elements not plotted by our plotting routine. In the second figure, we show the temperature distribution through two perpendicular planes.

Tryggvason, G.↗

Issues of Long-Term Cryogenic Propellant Storage in Microgravity

Modern multi-layer insulation (MLI) allows to sharply reduce the heat leak into cryogenic propellant storage tanks through the tank surface and, as a consequence, significantly extend the storage duration. In this situation the MLI penetrations, such as support struts, feed lines, etc., become one of the most significant challenges of the tanks heat management. This problem is especially acute for liquid hydrogen (LH2) storage, since currently no efficient cryocoolers exist that operate at very low LH2 temperatures (20K). Even small heat leaks under microgravity conditions and over the period of many months give rise to a complex slowly-developing, large-scale spatiotemporal physical phenomena in a multi-phase liquid-vapor mixture. These phenomena are not well-understood nor can be easily controlled. They can be of a potentially hazardous nature for long-term on-orbital cryogenic torage, propellant loading, tank chilldown, engine restart, and other in-space cryogenic fluid management operations. To support the engineering design solutions that would mitigate these effects a detailed physics-based analysis of heat transfer, vapor bubble formation, growth, motion, coalescence and collapse is required in the presence of stirring jets of different configurations and passive cooling devices such as MLI, thermodynamic vent system, and vapor-cooled shield. To develop physics-based models and correlations reliable for microgravity conditions and long-time scales there is a need for new fundamental data to be collected from on-orbit cryogenic storage experiments. Our report discusses some of these physical phenomena and the design requirements and future studies necessary for their mitigation. Special attention is payed to the phenomena occurring near MLI penetrations.

Muratov, C. B.↗

Heat Transfer and Interfacial Flow Physics of Microgravity Flow Boiling in Single-Side-Heated Rectangular Channel with Subcooled Inlet Conditions – Experiments Onboard the International Space Station

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.

flow boiling↗

Flow Boiling and Condensation Experiment: Payload Design Overview

The Flow Boiling and Condensation Experiment (FBCE) is a flight experiment that is designed to operate in the Fluids Integrated Rack (FIR) on the International Space Station (ISS). The objective of the FBCE is to develop an integrated two-phase flow experiment that will serve as a primary platform for obtaining flow boiling and condensation heat transfer data in microgravity. This presentation discusses the overall design of the FBCE payload, as well as the status of the FBCE hardware as it continues through final verification testing.

Guzik, Monica C.↗

R and D work on the constrained vapor bubble system for a microgravity experiment

We are working with Project Scientists R. Balasubramanian and Sang Young Son, and a NASA Projects Team headed by Sue Motil at the Glenn Research Center on the design and development of an experimental system for use on the International Space Station during the year 2006. John Eustace is the coordinator for the flight experiment at Zin-Tech (previously Northrop-Grumman) for the design and development of the Constrained Vapor Bubble Heat Exchanger, CVBHX, cell which will fit into the Light Microscope Module, LMM. Good progress is being made. The CDR for the LMM being developed was held on December 10-1 1,2003. Experimental results obtained under microgravity conditions will be compared with those obtained at Rensselaer. Basic and applied research at Rensselaer continues on the experimental and theoretical details associated with passive phase change heat transfer processes controlled by interfacial forces in the CVBHX. The extensive results of our current research are presented in the 23 external publications listed below. Twenty-two external presentations have been given. Briefly, evaporation/condensation data from both vertical and horizontal CVBHX systems were obtained and analyzed for both polar (wetting) and apolar (partially wetting) fluids. The vertical system is axi-symmetric, but strongly effected by gravity. Whereas, the horizontal system is asymmetric, but weakly effected by gravity. Therefore, there will be significant differences in the operation of the cell in the earth s environment versus the operation under microgravity conditions. Due to its relative large size, the system s performance should be optimum under micro-gravity conditions, where the CVBHX should be a very effective passive heat exchanger. The CVBHX was found to be an ideal experimental setup in which to study the effects of interfacial phenomena on both the evaporation and drop-wise condensation processes. The optical technique (Image Analyzing Interferometry, IAI), which is based on the measurement and analysis of the reflectivity pattern of a thin film, was significantly improved. The accuracy of the IAI system is of critical importance to the success of the mission because it is used to measure the details of the pressure field in the liquid by measuring the film thickness profile. The accuracy was found to be excellent and various publications/presentations documenting these new results were written. Significant new results were also obtained for the effect of the oscillating contact line region on evaporation. Three doctoral students graduated under this grant. All three work in US industry, two for Intel. Another doctoral student is in his third year of study and will finish under an extension of the NASA grant: # NNC05GA27G.

Wayner, P. C., Jr.↗

Condenser design for AMTEC power conversion

The condenser and the electrodes are the two elements of an alkali metal thermal-to-electric conversion (AMTEC) cell which most greatly affect the energy conversion performance. A condenser is described which accomplishes two critical functions in an AMTEC cell: management of the fluid under microgravity conditions and optimization of conversion efficiency. The first function is achieved via the use of a controlled surface shape, along with drainage grooves and arteries to collect the fluid. Capillary forces manage the fluid in microgravity and dominate hydrostatic effects on the ground so the device is ground-testable. The second function is achieved via a smooth film of highly reflective liquid sodium on the condensing surface, resulting in minimization of parasitic heat losses due to radiation heat transfer. Power conversion efficiencies of 25 percent to 30 percent are estimated with this condenser using present technology for the electrodes.

Crowley, Christopher J.↗

AIAA/IKI Microgravity Science Symposium, 1st, Moscow, USSR, May 13-17, 1991, Proceedings

The state of the art of microgravity science is examined in reviews and reports. Consideration is given to fluid physics; modeling and numerical analysis; crystal growth of electronic materials, proteins, metals, alloys, glasses, and ceramics; biotechnology, combustion science, microgravity hardware, and fundamental phenomena; and education. Particular attention is given to containerless science and technology, a low-gravity two-phase flow with heat transfer, numerical investigation on Benard instability in a finite liquid layer, synthesis and crystallization of refractory compounds from solutions in metallic melts under microgravitation conditions, the long duration protein crystallization experiment aboard the Mir Space Station, directional solidification in immiscible systems, formation of periodic layer structure in oxide melts under different gravity values, opposed flow flame spread in normal, enhanced, and reduced gravity, automatic equipment for semiconductor production in space, and consort and joust sounding rocket missions.

Source record↗

Advanced long term cryogenic storage systems

Long term, cryogenic fluid storage facilities will be required to support future space programs such as the space-based Orbital Transfer Vehicle (OTV), Telescopes, and Laser Systems. An orbital liquid oxygen/liquid hydrogen storage system with an initial capacity of approximately 200,000 lb will be required. The storage facility tank design must have the capability of fluid acquisition in microgravity and limit cryogen boiloff due to environmental heating. Cryogenic boiloff management features, minimizing Earth-to-orbit transportation costs, will include advanced thick multilayer insulation/integrated vapor cooled shield concepts, low conductance support structures, and refrigeration/reliquefaction systems. Contracted study efforts are under way to develop storage system designs, technology plans, test article hardware designs, and develop plans for ground/flight testing.

Brown, Norman S.↗

Hybrid Modeling Study on Grain Evolution in the Metal Welding Process and Its Potential Lunar Application

Metal is most commonly used structural material in a wide range of spacecraft, and welding is the principal method for joining metal components into functional systems. However, conducting welding experiments under extreme environments—such as microgravity or vacuum conditions in space—is prohibitively expensive and experimentally challenging. To overcome these limitations, multi-physics computational welding models provide a cost-effective and versatile alternative. In this work, the authors have developed a coupled thermal (fluid) microstructure simulation framework to model metal welding under varying gravity conditions. The framework integrates a mixed-mode heat transfer formulation (conduction, convection, and radiation) with molten pool fluid dynamics, enabling accurate prediction of temperature fields and weld-pool geometry. A grain growth model is further incorporated to capture the spatial and temporal evolution of microstructure, including grain size distribution and morphological transitions during solidification. This approach provides detailed insight into molten pool evolution and grain-level microstructure development throughout the welding process. By explicitly parameterizing environmental conditions, the model supports extrapolation to off-Earth manufacturing scenarios such as welding on the lunar surface. Tantalum—chosen in this study due to its high melting point, oxidation resistance, and mechanical stability at elevated temperatures—serves as the material system for model demonstration. Beyond Tantalum, the integrated multi-physics framework offers broad applicability for predictive welding simulations of various structural and refractory metals or alloys used in extreme terrestrial or extraterrestrial environments.

kinetic Monte Carlo (SPPARKS)↗

Miniature Heat Transport System for Spacecraft Thermal Control

Loop heat pipes (LHP) are efficient devices for heat transfer and use the basic principle of a closed evaporation-condensation cycle. The advantage of using a loop heat pipe over other conventional methods is that large quantities of heat can be transported through a small cross-sectional area over a considerable distance with no additional power input to the system. By using LHPs, it seems possible to meet the growing demand for high-power cooling devices. Although they are somewhat similar to conventional heat pipes, LHPs have a whole set of unique properties, such as low pressure drops and flexible lines between condenser and evaporator, that make them rather promising. LHPs are capable of providing a means of transporting heat over long distances with no input power other than the heat being transported because of the specially designed evaporator and the separation of liquid and vapor lines. For LHP design and fabrication, preliminary analysis on the basis of dimensionless criteria is necessary because of certain complicated phenomena that take place in the heat pipe. Modeling the performance of the LHP and miniaturizing its size are tasks and objectives of current research. In the course of h s work, the LHP and its components, including the evaporator (the most critical and complex part of the LHP), were modeled with the corresponding dimensionless groups also being investigated. Next, analysis of heat and mass transfer processes in the LHP, selection of the most weighted criteria from known dimensionless groups (thermal-fluid sciences), heat transfer rate limits, (heat pipe theory), and experimental ratios which are unique to a given heat pipe class are discussed. In the third part of the report, two-phase flow heat and mass transfer performances inside the LHP condenser are analyzed and calculated for Earth-normal gravity and microgravity conditions. On the basis of recent models and experimental databanks, an analysis for condensing two-phase flow regimes, pressure gradients, and local heat transfer coefficients using ammonia, propylene, and R134, are carried out.

Ochterbeck, Jay M.↗

The Dynamics of Vapor Bubbles in Acoustic Pressure Fields

In spite of a superficial similarity with gas bubbles, the intimate coupling between dynamical and thermal processes confers to oscillating vapor bubbles some unique characteristics. This paper examines numerically the validity of some asymptotic-theory predictions such as the existence of two resonant radii and a limit size for a given sound amplitude and frequency. It is found that a small vapor bubble in a sound field of sufficient amplitude grows quickly through resonance and continues to grow thereafter at a very slow rate, seemingly indefinitely. Resonance phenomena therefore play a role for a few cycles at most, and reaching a limit size-if one exists at all-is found to require far more than several tens of thousands of cycles. It is also found that some small bubbles may grow or collapse depending on the phase of the sound field. The model accounts in detail for the thermo-fluid-mechanic processes in the vapor. In the second part of the paper, an approximate formulation valid for bubbles small with respect to the thermal penetration length in the vapor is derived and its accuracy examined, The present findings have implications for acoustically enhanced boiling heat transfer and other special applications such as boiling in microgravity.

Hao, Y.↗

Experimental, Computational, Theoretical and Analytical Investigation of Flow Boiling in Reduced Gravity

Two-phase thermal management systems are far superior to their single-phase counterparts because of their ability to capitalize on the coolant’s both sensible and latent heats, thereby yielding orders of magnitude higher heat transfer coefficients and smaller system footprints. A vital knowledge necessary for their implementation in future space systems is performance in microgravity. Long-duration microgravity experiments are necessary to obtain reliable databases, which would then be used to build reliable predictive tools. To achieve this goal, investigators at the Purdue University Boiling and Two-Phase Flow Laboratory (PU-BTPFL) and the NASA Glenn Research Center (NASA-GRC) have been collaborating towards the development of the Flow Boiling and Condensation Experiment (FBCE) and eventual execution onboard the International Space Station (ISS). FBCE has now matured to a point where it is ready for transport to the ISS, where first tests will be conducted using the Flow Boiling Module (FBM). In preparation for the ISS tests, a series of pre-launch Mission Sequence Tests (MSTs) was performed at GRC in Earth gravity with FBM mounted in a vertical upflow orientation using n-perfluorohexane as working fluid. The pre-launch tests included variations of flow rate, surface heat flux, inlet conditions, and both single-sided and double-sided wall heating. This presentation will summarize experimental results from these tests as well as both analytic and theoretical tools for prediction of two-phase heat transfer coefficient and critical heat flux (CHF). Also discussed will be an assessment of predictive accuracy of these tools against the experimental data.

Mission Sequence tests↗

Experimental Studies on the Effect of Inlet Liquid Subcooling on the Chilldown Characteristics of Stainless Steel Tubes

Understanding transfer line chilldown process under microgravity is important for the efficient transfer of cryogenic propellants in space fuel depots to facilitate future long duration space missions. The present work is part of the ongoing efforts to develop and test a two-phase flow chilldown test section to study the complete chilldown process under sustained microgravity conditions onboard the International Space Station. In this study, ground-based chilldown experiments are carried out on a 60 cm long SS-316 test section with PF-5060 as the working fluid. The complete chilldown curve was obtained including the film, transition and nucleate boiling regimes along with the temperature transition points. The effect of inlet liquid subcooling on the behavior of the chilldown curves are presented. Further, the chilldown and heat flux curves are analyzed to obtain re-wetting/Leidenfrost and onset of nucleate boiling temperature transition points as well as the critical heat flux values. The effect of inlet liquid subcooling on regime-specific heat flux and heat transfer coefficients are also examined.

CFD↗

Visible and Infrared Imaging of Various Flow Regimes in the Flow Boiling and Condensation Experiment Transfer Line

The Flow Boiling and Condensation Experiment (FBCE) Transfer Line (TL) test module is being developed to study fluid physics of cryogenic transfer lines in microgravity. The TL module will reside in the FBCE facility located within the Fluids Integration Rack (FIR) aboard the International Space Station (ISS). TL will use the same normal perfluoro hexane (nPFH) used in the previous FBCE test sections. To simulate cryogenic line transfer in the visualization section, a sapphire tube coated with indium tin oxide (ITO) is heated via Joule heated while a bypass line is used to flow liquid nPFH at the desired inlet conditions. Once the visualization line reaches steady-state temperature and pressure conditions, flow is diverted through the heated line and chilldown begins. All flow regimes observed within a cryogenic TL are created and studied using visible imaging with diffuse backlighting to image inverted annular flow, transition, and nucleate boiling. A visible laser light sheet provided by FIR will provide a means to observe and track droplets in the dispersed flow regime. IR imaging of the visualization tube outer surface with the emissivity of the ITO coating provides the surface chilldown temperature profile. Preliminary imaging system development includes some of the components used in the Flow Boiling Module (FBM) and some new components that are easily integrated into the PC-based system but will require some refinement to operate properly on the FIR PCIe/104 imaging system. Optical design and packaging within the limited volume of the module enclosure is also presented. This paper presents FBCE-TL visible and infrared laboratory-based imaging studies and anticipated visualization capabilities of the TL module under preliminary breadboard development and under the utilization constraints within the FBCE/FIR host facility.

transfer line↗