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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRS1982

An overview of Spacelab capabilities

The crew functions, instrumentation, and mission profiles for the Spacelab to be flown on board the Shuttle are described. The Spacelab will be operated by up to four scientists or engineers who are not pilots, and who are required to pass only an FAA Class III physical examination to qualify for flight. Of modular design, the Spacelab pallets can house a laboratory for human operation, or experimental pallets for control by either the ground or the Orbiter crew. A shirt sleeve environment is provided by the manned laboratory version, with the crew staying in the Orbiter mid-deck during launch and landing. Electrical power is derived from the Orbiter fuel cells, up to 12 kW for 15 min every three hours and to a total of 890 kWh. Features of the Instrument Pointing System are outlined, along with the data transmission and relay systems and the on-ground check-out facilities.

Harrington, J. C.↗
NASA NTRS1991

Sunmaster: An SEP cargo vehicle for Mars missions

Options are examined for an unmanned solar powered electric propulsion cargo vehicle for Mars missions. The 6 prime areas of study include: trajectory, propulsion system, power system, supporting structure, control system, and launch consideration. Optimization of the low thrust trajectory resulted in a total round trip mission time just under 4 years. The argon propelled electrostatic ion thruster system consists of seventeen 5 N engines and uses a specific impulse of 10,300 secs. At Earth, the system uses 13 engines to produce 60 N of thrust; at Mars, five engines are used, producing 25 N thrust. The thrust of the craft is varied between 60 N at Earth and 24 N at Mars due to reduced solar power available. Solar power is collected by a Fresnel lens concentrator system using a multistacked cell. This system provides 3.5 MW to the propulsion system after losses. Control and positioning to the craft are provided by a system of three double gimballed control moment gyros. Four shuttle 'C' launches will be used to transport the unassembled vehicle in modular units to low Earth orbit where it will be assembled using the Mobile Transporter of the Space Station Freedom.

Chiles, Aleasa↗
DOE OSTI2022

Salt Sampling FY21 Technical Report

The goal of the salt sampling program at Argonne is to develop and deploy automated molten salt sampling approaches to enable high-precision in-process salt sample analysis to improve the timeliness of sampling-based accountancy measurements. Tools currently under development in support of this goal include (1) a modular vacuum sampler with an accompanying sample handling method for coupling vacuum sampling with high-precision at-line sample analysis, (2) a pneumatic sample generator that enables high-throughput sample analysis to improve the precision of existing analytical techniques, and (3) a windowless flow cell to enable on-line optical analysis of molten salt in a sampling loop. Compared to point sampling approaches (i.e., dip probes), vacuum sampling systems and on-line sampling loops facilitate access to a larger cross-section of a process fluid. This is known to improve the characterization of the process fluid by producing more representative samples and by enabling the analysis of a larger cross section of the fluid. A vacuum sampling approach for molten salts eliminates the risk of dross contamination of samples and avoids the use of moving parts in the salt. In FY21, two methods for integrating a vacuum sampler with a pneumatic sample generator were tested. These included direct fluidic coupling and coupling using a solid salt transfer mechanism. Solid salt transfer was ultimately selected over fluidic coupling, primarily to enable the transport of samples over longer distances to support automated at-line integration with high-precision techniques (such as microcalorimetry) that cannot withstand the extreme conditions near an electrorefining process. To facilitate rapid solid salt coupling, new mechanisms were developed for rapidly charging and discharging salt sample tubes at the vacuum sampler and pneumatic sample generator, respectively. While the charging mechanism will be deployed in FY22, the tube transfer method and discharge mechanism were tested in FY21. These were deployed at one of Argonne’s engineering-scale electrorefiners to implement at-line high-throughput pneumatic micro-sample generation capabilities. The method was used to generate precise uranium- and lanthanide-bearing electrorefiner micro-samples with the specific dimensions requested by researchers at Los Alamos National Laboratory for use in testing their novel microcalorimeter x-ray techniques. The solid salt transfer mechanism proved not only to be an effective means of integrating the precision sample generator with vacuum sampling, but also improved the performance of the sampler generator. Because the modular sampling approach described here eliminates the need for new high-radiation sample handling capabilities, salt-wetted seals, salt-wetted moving parts, and heated transfer lines outside the electrorefiner, it will address most of the remaining technical challenges for the at-line deployment of high-precision analytical techniques. This will enable significant reductions in the time delay for sampling-based accountancy measurements by eliminating the need for manual off-line sample processing and analysis. On-line optical analysis of molten salt in a sampling loop would provide complementary information to at-line and in-situ techniques. In FY21, an open-aperture molten salt gravity flow cell with windowless optical access to flowing salt was successfully demonstrated. Future work should include the refinement and performance testing of the on-line and at-line sampling tools, integration of additional analysis techniques, stakeholder outreach and collaboration, evaluation of the integrated methods, and analyses to determine how the various tools might fit into an integrated safeguards monitoring system of unattended near real time monitoring tools.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2017

Optical Design and Validation of an Infrared Transmissive Spectrum Splitting Concentrator Photovoltaic Module

A new modular, hybrid solar power system is designed to generate both electrical and thermal energy by utilizing the full solar spectrum. The key element, an infrared-transparent concentrator photovoltaic (CPV) module, acts as a spectrum splitter, dividing solar radiation into two parts. The ultraviolet and visible light (“in-band”) are converted to electricity with high efficiency in CPV cells, while the infrared light (“out-of-band”) is transmitted directly to a thermal receiver, where thermal power may be converted to electricity by a suitable heat engine or used directly for industrial process heat applications whenever needed. Here, we describe the optical design, modeling, fabrication, and performance validation of this novel spectrum splitting CPV module. A transfer matrix style approach, cumulative transmission model, is built to study the reflection, absorption, and transmission in each layer of the CPV module. To optimize the optical performance, different materials for module superstrate/substrate, encapsulant, cell substrate, and cooling fluids are compared in order to enhance the transmission of out-of-band light through the CPV module by minimizing absorption. Six antireflection coatings along with front and backside electrical contact grids are designed to maximize transmittance of in-band light to the cell and out-of-band light to the thermal receiver. Here, the final design, currently being prototyped, predicts out-of-band light transmission to the thermal receiver of 74.1% (for the passively cooled version) and 65.3% (for the actively cooled version). When epitaxial liftoff technology is applied, the transmission will change to 80.8% (passively cooled) and 71.9% (actively cooled). Experimental prototypes show good agreement with modeled optical performance.

14 SOLAR ENERGY↗
DOE OSTI2017

A bioarchitectonic approach to the modular engineering of metabolism

Dissociating the complexity of metabolic processes into modules is a shift in focus from the single gene/gene product to functional and evolutionary units spanning the scale of biological organization. When viewing the levels of biological organization through this conceptual lens, modules are found across the continuum: domains within proteins, co-regulated groups of functionally associated genes, operons, metabolic pathways and (sub)cellular compartments. Combining modules as components or subsystems of a larger system typically leads to increased complexity and the emergence of new functions. By virtue of their potential for 'plug and play' into new contexts, modules can be viewed as units of both evolution and engineering. Through consideration of lessons learned from recent efforts to install new metabolic modules into cells and the emerging understanding of the structure, function and assembly of protein-based organelles, bacterial microcompartments, a structural bioengineering approach is described: one that builds from an architectural vocabulary of protein domains. Further, this bioarchitectonic approach to engineering cellular metabolism can be applied to microbial cell factories, used in the programming of members of synthetic microbial communities or used to attain additional levels of metabolic organization in eukaryotic cells for increasing primary productivity and as the foundation of a green economy.This article is part of the themed issue 'Enhancing photosynthesis in crop plants: targets for improvement'.

59 BASIC BIOLOGICAL SCIENCES↗
NASA NTRS2012

NASA Tech Briefs, September 2012

Topics covered include: Beat-to-Beat Blood Pressure Monitor; Measurement Techniques for Clock Jitter; Lightweight, Miniature Inertial Measurement System; Optical Density Analysis of X-Rays Utilizing Calibration Tooling to Estimate Thickness of Parts; Fuel Cell/Electrochemical Cell Voltage Monitor; Anomaly Detection Techniques with Real Test Data from a Spinning Turbine Engine-Like Rotor; Measuring Air Leaks into the Vacuum Space of Large Liquid Hydrogen Tanks; Antenna Calibration and Measurement Equipment; Glass Solder Approach for Robust, Low-Loss, Fiber-to-Waveguide Coupling; Lightweight Metal Matrix Composite Segmented for Manufacturing High-Precision Mirrors; Plasma Treatment to Remove Carbon from Indium UV Filters; Telerobotics Workstation (TRWS) for Deep Space Habitats; Single-Pole Double-Throw MMIC Switches for a Microwave Radiometer; On Shaft Data Acquisition System (OSDAS); ASIC Readout Circuit Architecture for Large Geiger Photodiode Arrays; Flexible Architecture for FPGAs in Embedded Systems; Polyurea-Based Aerogel Monoliths and Composites; Resin-Impregnated Carbon Ablator: A New Ablative Material for Hyperbolic Entry Speeds; Self-Cleaning Particulate Prefilter Media; Modular, Rapid Propellant Loading System/Cryogenic Testbed; Compact, Low-Force, Low-Noise Linear Actuator; Loop Heat Pipe with Thermal Control Valve as a Variable Thermal Link; Process for Measuring Over-Center Distances; Hands-Free Transcranial Color Doppler Probe; Improving Balance Function Using Low Levels of Electrical Stimulation of the Balance Organs; Developing Physiologic Models for Emergency Medical Procedures Under Microgravity; PMA-Linked Fluorescence for Rapid Detection of Viable Bacterial Endospores; Portable Intravenous Fluid Production Device for Ground Use; Adaptation of a Filter Assembly to Assess Microbial Bioburden of Pressurant Within a Propulsion System; Multiplexed Force and Deflection Sensing Shell Membranes for Robotic Manipulators; Whispering Gallery Mode Optomechanical Resonator; Vision-Aided Autonomous Landing and Ingress of Micro Aerial Vehicles; Self-Sealing Wet Chemistry Cell for Field Analysis; General MACOS Interface for Modeling and Analysis for Controlled Optical Systems; Mars Technology Rover with Arm-Mounted Percussive Coring Tool, Microimager, and Sample-Handling Encapsulation Containerization Subsystem; Fault-Tolerant, Real-Time, Multi-Core Computer System; Water Detection Based on Object Reflections; SATPLOT for Analysis of SECCHI Heliospheric Imager Data; Plug-in Plan Tool v3.0.3.1; Frequency Correction for MIRO Chirp Transformation Spectroscopy Spectrum; Nonlinear Estimation Approach to Real-Time Georegistration from Aerial Images; Optimal Force Control of Vibro-Impact Systems for Autonomous Drilling Applications; Low-Cost Telemetry System for Small/Micro Satellites; Operator Interface and Control Software for the Reconfigurable Surface System Tri-ATHLETE; and Algorithms for Determining Physical Responses of Structures Under Load.

Source record↗
NASA NTRS1974

Space processing applications payload equipment study. Volume 2B: Payload interface analysis (power/thermal/electromagnetic compatibility)

As a part of the task of performing preliminary engineering analysis of modular payload subelement/host vehicle interfaces, a subsystem interface analysis was performed to establish the integrity of the modular approach to the equipment design and integration. Salient areas that were selected for analysis were power and power conditioning, heat rejection and electromagnetic capability (EMC). The equipment and load profiles for twelve representative experiments were identified. Two of the twelve experiments were chosen as being representative of the group and have been described in greater detail to illustrate the evaluations used in the analysis. The shuttle orbiter will provide electrical power from its three fuel cells in support of the orbiter and the Spacelab operations. One of the three shuttle orbiter fuel cells will be dedicated to the Spacelab electrical power requirements during normal shuttle operation. This power supplies the Spacelab subsystems and the excess will be available to the payload. The current Spacelab sybsystem requirements result in a payload allocation of 4.0 to 4.8 kW average (24 hour/day) and 9.0 kW peak for 15 minutes.

Hammel, R. L.↗
DOE OSTI2025

Rational Modulation of Plant Root Development Using Engineered Cytokinin Regulators

Achieving precise control over quantitative developmental phenotypes is a key objective in plant biology. Recent advances in synthetic biology have enabled tools to reprogram entire developmental pathways; however, the complexity of designing synthetic genetic programs and the inherent interactions between various signaling processes remains a critical challenge. Here, we leverage Type-B response regulators to modulate the expression of genes involved in cytokinin-dependent growth and development processes. We rationally engineered these regulators to modulate their transcriptional activity (i.e., repression or activation) and potency while reducing their sensitivity to cytokinin. By localizing the expression of these engineered transcription factors using tissue-specific promoters, we can predictably tune cytokinin-regulated traits. As a proof of principle, we deployed this synthetic system in Arabidopsis thaliana to either decrease or increase the number of lateral roots. The simplicity and modularity of our approach makes it an ideal system for controlling other developmental phenotypes of agronomic interest in plants.

Cell signaling↗
DOE OSTI2020

A New Configuration of Paralleled Modular ANPC Multilevel Converter Controlled by an Improved Modulation Method for 1 MHz, 1 MW EV Charger

In this work, a new configuration of the modular multilevel converter (MLC) based on the parallel connection of three-level active-neutral-point-clamped (3L-ANPC) cells as well as its improved modulation method is proposed for 1 MHz, 1 MW electric vehicle (EV) megacharger. In the proposed paralleled modular ANPC-MLC, only six high-frequency silicon carbide (SiC) power switches operating at 333 kHz are required to generate 1 MHz switching frequency spectrum. Moreover, the operating voltage of all power devices is halved, the magnitude of the first switching frequency harmonic cluster is decreased by the factor of five, and the load current is equally distributed between the 3L-ANPC legs by employing the proposed improved modulation method. Hence, the modularity, efficiency, and power density of the proposed converter are notably increased, whereas the value of passive components and the overall switching loss are remarkably decreased. In addition, an optimized design of the one 3L-ANPC cell of the proposed paralleled modular ANPC-MLC for 1 MHz, 1MW EV megacharger using Ansys SIwave, Icepak, and Q3D finite element method platforms is presented and analyzed in detail. The provided experimental results of the down-scaled setup verify the feasibility and viability of the proposed configuration as well as its improved switching pattern.

42 ENGINEERING↗
DOE OSTI2019

Rocket Engine Test System for Development of Novel Propulsion Technologies

A 150 lb f thrust class, modular, bi-propellant, rocket engine/gas-generator and supporting test infrastructure has been developed in a cooperative effort between Sandia National Laboratories and the New Mexico Institute of Mining and Technology’s (NMIMT’s) Energetic Materials Research and Testing Center (EMRTC). This modular test engine design consists of a head end fuel-oxidizer injector, a spark ignition gaseous H 2 /O 2 torch igniter, combustion chamber and nozzle module. This robust design allows for rapid configuration changes as well as economical repair should hardware become damaged in testing. The engine interfaces with a permanently installed pressurizing system capable of delivering liquid nitrous oxide and a variety of liquid fuels for both rocket engine development and propellant performance evaluation. The regulated high pressure systems allow for delivery of liquefied gases above their saturation pressure as well as allowing for high pressure rocket engine/gas-generator operation. The facility test cell houses a 1 ton thrust capacity test stand leaving room for larger scale engine development.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Modular 5'-UTR hexamers for context-independent tuning of protein expression in eukaryotes

Functional characterization of regulatory DNA elements in broad genetic contexts is a prerequisite for forward engineering of biological systems. Translation initiation site (TIS) sequences are attractive to use for regulating gene activity and metabolic pathway fluxes because the genetic changes are minimal. However, limited knowledge is available on tuning gene outputs by varying TISs in different genetic and environmental contexts. Here, we created TIS hexamer libraries in baker’s yeast Saccharomyces cerevisiae directly 5' end of a reporter gene in various promoter contexts and measured gene activity distributions for each library. Next, selected TIS sequences, resulted in almost 10-fold changes in reporter outputs, were experimentally characterized in various environmental and genetic contexts in both yeast and mammalian cells. From our analyses, we observed strong linear correlations (R 2 = 0.75–0.98) between all pairwise combinations of TIS order and gene activity. Finally, our analysis enabled the identification of a TIS with almost 50% stronger output than a commonly used TIS for protein expression in mammalian cells, and selected TISs were also used to tune gene activities in yeast at a metabolic branch point in order to prototype fitness and carotenoid production landscapes. Taken together, the characterized TISs support reliable context-independent forward engineering of translation initiation in eukaryotes.

Biochemistry & Molecular Biology↗
DOE OSTI2018

Controllable protein phase separation and modular recruitment to form responsive membraneless organelles

Abstract Many intrinsically disordered proteins self-assemble into liquid droplets that function as membraneless organelles. Because of their biological importance and ability to colocalize molecules at high concentrations, these protein compartments represent a compelling target for bio-inspired materials engineering. Here we manipulated the intrinsically disordered, arginine/glycine-rich RGG domain from the P granule protein LAF-1 to generate synthetic membraneless organelles with controllable phase separation and cargo recruitment. First, we demonstrate enzymatically triggered droplet assembly and disassembly, whereby miscibility and RGG domain valency are tuned by protease activity. Second, we control droplet composition by selectively recruiting cargo molecules via protein interaction motifs. We then demonstrate protease-triggered controlled release of cargo. Droplet assembly and cargo recruitment are robust, occurring in cytoplasmic extracts and in living mammalian cells. This versatile system, which generates dynamic membraneless organelles with programmable phase behavior and composition, has important applications for compartmentalizing collections of proteins in engineered cells and protocells.

59 BASIC BIOLOGICAL SCIENCES↗
NASA NTRS2012

NASA Tech Briefs, April 2012

Topics include: Computational Ghost Imaging for Remote Sensing; Digital Architecture for a Trace Gas Sensor Platform; Dispersed Fringe Sensing Analysis - DFSA; Indium Tin Oxide Resistor-Based Nitric Oxide Microsensors; Gas Composition Sensing Using Carbon Nanotube Arrays; Sensor for Boundary Shear Stress in Fluid Flow; Model-Based Method for Sensor Validation; Qualification of Engineering Camera for Long-Duration Deep Space Missions; Remotely Powered Reconfigurable Receiver for Extreme Environment Sensing Platforms; Bump Bonding Using Metal-Coated Carbon Nanotubes; In Situ Mosaic Brightness Correction; Simplex GPS and InSAR Inversion Software; Virtual Machine Language 2.1; Multi-Scale Three-Dimensional Variational Data Assimilation System for Coastal Ocean Prediction; Pandora Operation and Analysis Software; Fabrication of a Cryogenic Bias Filter for Ultrasensitive Focal Plane; Processing of Nanosensors Using a Sacrificial Template Approach; High-Temperature Shape Memory Polymers; Modular Flooring System; Non-Toxic, Low-Freezing, Drop-In Replacement Heat Transfer Fluids; Materials That Enhance Efficiency and Radiation Resistance of Solar Cells; Low-Cost, Rugged High-Vacuum System; Static Gas-Charging Plug; Floating Oil-Spill Containment Device; Stemless Ball Valve; Improving Balance Function Using Low Levels of Electrical Stimulation of the Balance Organs; Oxygen-Methane Thruster; Lunar Navigation Determination System - LaNDS; Launch Method for Kites in Low-Wind or No-Wind Conditions; Supercritical CO2 Cleaning System for Planetary Protection and Contamination Control Applications; Design and Performance of a Wideband Radio Telescope; Finite Element Models for Electron Beam Freeform Fabrication Process Autonomous Information Unit for Fine-Grain Data Access Control and Information Protection in a Net-Centric System; Vehicle Detection for RCTA/ANS (Autonomous Navigation System); Image Mapping and Visual Attention on the Sensory Ego-Sphere; HyDE Framework for Stochastic and Hybrid Model-Based Diagnosis; and IMAGESEER - IMAGEs for Education and Research.

Source record↗
DOE OSTI2020

High flux thermal receiver and method of use

A thermal receiver, such as a solar flux thermal receiver, is disclosed comprising a modular arrangement of arrayed microchannels or micropins to heat a working fluid by heat transfer. Disclosed solar receivers provide a much higher solar flux and consequently a significant reduction in thermal losses, size, and cost, relative to known receivers. Unit cell receivers can be numbered up and combined in parallel to form modules, and modules combined to form full scale receivers.

14 SOLAR ENERGY↗
NASA NTRS1994

Electrochemical Technology for Oxygen Removal and Measurement in the CELSS Test Facility, Engineering Development Unit

The Life Support Flight Program is evaluating regenerative technologies, including those that utilize higher plants, as a means to reduce resupply over long duration space missions. Constructed to assist in the evaluation process is the CELSS Test Facility Engineering Development Unit (CTF-EDU) an environmentally closed (less than 1% mass and thermal leakage) technology test bed. This ground based fully functional prototype is currently configured to support crop growth, utilizing the power, volume and mass resources allocated for two space station racks. Sub-system technologies were selected considering their impact on available resources, their ability to minimize integration issues, and their degree of modularity. Gas specific mass handling is a key sub-system technology for both biological and physical/chemical life support technologies. The CTF-EDU requires such a system to accommodate non-linear oxygen production from crops, by enabling the control system to change and sustain partial pressure set points in the growth volume. Electrochemical cells are one of the technologies that were examined for oxygen handling in the CTF-EDU. They have been additionally considered to meet other regenerative life support functions, such as oxygen generation, the production of potable water from composite waste streams, and for having the potential to integrate life support functions with those of propulsion and energy storage. An oxygen removal system based on an electrochemical cell was chosen for the EDU due to it's low power, volume and mass requirements (10W, 0.000027 cu m, 4.5 kg) and because of the minimal number of integration considerations. Unlike it's competitors, the system doesn't require post treatments of its byproducts, or heat and power intensive regenerations, that also mandate system redundancy or cycling. The EDUs oxygen removal system only requires two resources, which are already essential to controlled plant growth: electricity and water. Additionally, the amount of oxygen that is removed from the EDU is directly proportional to the cell input current via Faraday's constant, potentially allowing for a mol/electron measurement of photosynthetic rate. The currently operative oxygen removal system has maintained reduced oxygen set points within the EDU, and preparation is underway to verify of the accuracy of electrochemical measurement of oxygen production and hence, photosynthesis. This paper examines the working principles of the electrochemical cell, outlines the overall design of the oxygen removal system and its integration with other EDU subsystems, and summarizes test results obtained over crop growth cycles in the CTF-EDU.

Drews, Michael E.↗
DOE OSTI2019

Modular Metal–Organic Polyhedra Superassembly: From Molecular‐Level Design to Targeted Drug Delivery

Abstract Targeted drug delivery remains at the forefront of biomedical research but remains a challenge to date. Herein, the first superassembly of nanosized metal–organic polyhedra (MOP) and their biomimetic coatings of lipid bilayers are described to synergistically combine the advantages of micelles and supramolecular coordination cages for targeted drug delivery. The superassembly technique affords unique hydrophobic features that endow individual MOP to act as nanobuilding blocks and enable their superassembly into larger and well‐defined nanocarriers with homogeneous sizes over a broad range of diameters. Various cargos are controllably loaded into the MOP with high payloads, and the nanocages are then superassembled to form multidrug delivery systems. Additionally, functional nanoparticles are introduced into the superassemblies via a one‐pot process for versatile bioapplications. The MOP superassemblies are surface‐engineered with epidermal growth factor receptors and can be targeted to cancer cells. In vivo studies indicated the assemblies to have a substantial circulation half‐life of 5.6 h and to undergo renal clearance—characteristics needed for nanomedicines.

Zhu, Wei↗
DOE OSTI2017

Development of a reactor with carbon catalysts for modular-scale, low-cost electrochemical generation of H 2 O 2

The development of small-scale, decentralized reactors for H 2 O 2 production that can couple to renewable energy sources would be of great benefit, particularly for water purification in the developing world. Herein, we describe our efforts to develop electrochemical reactors for H 2 O 2 generation with high Faradaic efficiencies of >90%, requiring cell voltages of only ~1.6 V. The reactor employs a carbon-based catalyst that demonstrates excellent performance for H 2 O 2 production under alkaline conditions, as demonstrated by fundamental studies involving rotating-ring disk electrode methods. Finally, the low-cost, membrane-free reactor design represents a step towards a continuous, modular-scale, de-centralized production of H 2 O 2 .

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2011

Advances in the Lightweight Air-Liquid Composite Heat Exchanger Development for Space Exploration Applications

An advanced, lightweight composite modular Air/Liquid (A/L) Heat Exchanger (HX) Prototype for potential space exploration thermal management applications was successfully designed, manufactured, and tested. This full-scale Prototype consisting of 19 modules, based on recommendations from its predecessor Engineering Development unit (EDU) but with improved thermal characteristics and manufacturability, was 11.2 % lighter than the EDU and achieves potentially a 42.7% weight reduction from the existing state-of-the-art metallic HX demonstrator. However, its higher pressure drop (0.58 psid vs. 0.16 psid of the metal HX) has to be mitigated by foam material optimizations and design modifications including a more systematic air channel design. Scalability of the Prototype design was validated experimentally by comparing manufacturability and performance between the 2-module coupon and the 19-module Prototype. The Prototype utilized the thermally conductive open-cell carbon foam material but with lower density and adopted a novel high-efficiency cooling system with significantly increased heat transfer contact surface areas, improved fabricability and manufacturability compared to the EDU. Even though the Prototype was required to meet both the thermal and the structural specifications, accomplishing the thermal requirement was a higher priority goal for this first version. Overall, the Prototype outperformed both the EDU and the corresponding metal HX, particularly in terms of specific heat transfer, but achieved 93.4% of the target. The next generation Prototype to achieve the specification target, 3,450W would need 24 core modules based on the simple scaling factor. The scale-up Prototype will weigh about 14.7 Kg vs. 21.6 Kg for the metal counterpart. The advancement of this lightweight composite HX development from the original feasibility test coupons to EDU to Prototype is discussed in this paper.

Shin, E. Eugene↗