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At least 91 records · Page 5

Finite element thermal analysis of convectively-cooled aircraft structures

The design complexity and size of convectively-cooled engine and airframe structures for hypersonic transports necessitate the use of large general purpose computer programs for both thermal and structural analyses. Generally thermal analyses are based on the lumped-parameter finite difference technique, and structural analyses are based on the finite element technique. Differences in these techniques make it difficult to achieve an efficient interface. It appears, therefore, desirable to conduct an integrated analysis based on a common technique. A summary is provided of efforts by NASA concerned with the development of an integrated thermal structural analysis capability using the finite element method. Particular attention is given to the development of conduction/forced-convection finite element methodology and applications which illustrate the capabilities of the developed concepts.

Wieting, A. R.↗

Rudder/Fin Seal Investigations for the X-38 Re-Entry Vehicle

NASA is currently developing the X-38 vehicle that will be used to demonstrate the technologies required for a crew return vehicle (CRV) for the International Space Station. The X-38 control surfaces require high temperature seals to limit hot gas ingestion and transfer of heat to underlying low-temperature structures to prevent over-temperature of these structures and possible loss of the vehicle. This paper presents results for thermal analyses and flow and compression tests conducted on as-received and thermally exposed seals for the rudder/fin location of the X-38. A thermal analysis of the rudder/fin dual seal assembly based on representative heating rates on the windward surface of the rudder/fin area predicted a peak seal temperature of 1900 F. The temperature-exposed seals were heated in a compressed state at 1900 F corresponding to the predicted peak temperature. Room temperature compression tests were performed to determine load versus linear compression, preload, contact area, stiffness, and resiliency characteristics for the as-received and temperature-exposed seals. Temperature exposure resulted in permanent set and loss of resiliency in these seals. Unit loads and contact pressures for the seals were below the 5 lb/in. and 10 psi limits set to limit the loads on the Shuttle thermal tiles that the seals seal against in the rudder/fin location. Measured seal flow rates for a double seal were about 4.5 times higher than the preliminary seal flow goal. The seal designs examined in this study are expected to be able to endure the high temperatures that they will be exposed to for a single-use life. Tests performed herein combined with future analyses, arc jet tests, and scrubbing tests will be used to select the final seal design for this application.

Dunlap, Patrick H., Jr.↗

Rudder/Fin Seal Investigations for the X-38 Re-Entry Vehicle

NASA is currently developing the X-38 vehicle that will be used to demonstrate the technologies required for a crew return vehicle (CRV) for the International Space Station. The X-38 control surfaces require high temperature seals to limit hot gas ingestion and transfer of heat to underlying low-temperature structures to prevent over-temperature of these structures and possible loss of the vehicle. This paper presents results for thermal analyses and flow and compression tests conducted on as-received and thermally exposed seals for the rudder/fin location of the X-38. A thermal analysis of the rudder/fin dual seal assembly based on representative heating rates on the windward surface of the rudder/fin area predicted a peak seal temperature of 1900 F. The temperature-exposed seals were heated in a compressed state at 1900 F corresponding to the predicted peak temperature. Room temperature compression tests were performed to determine load versus linear compression, preload, contact area, stiffness, and resiliency characteristics for the as-received and temperature-exposed seals. Temperature exposure resulted in permanent set and loss of resiliency in these seals. Unit loads and contact pressures for the seals were below the five pounds/inch and ten psi limits set to limit the loads on the Shuttle thermal tiles that the seals seal against in the rudder/fin location. Measured seal flow rates for a double seal were about 4.5 times higher than the preliminary seal flow goal. The seal designs examined in this study are expected to be able to endure the high temperatures that they will be exposed to for a single-use life. Tests performed herein combined with future analyses, arc jet tests, and scrubbing tests will be used to select the final seal design for this application.

Dunlap, Patrick H., Jr.↗

Predicting the performance of solar illuminated thermal louvers for the GOES I, J, K instruments

The new series of Geostationary Operational Environmental Satellites (GOES I,J,K,L/M) will have two earth viewing optical instruments which use passive, bi-metallic actuated, blade-type louvers for their thermal control. GOES is a three-axis stabilized spacecraft in geostationary orbit, which means that sun can enter the instrument apertures for several hours before and after local midnight. The solar heat absorbed in the instruments causes the louvers to open thus allowing the radiators to reject the heat. These louvered radiators are located on the north face of the instruments. To perform thermal analyses of the instruments, a modeling method was needed for predicting the thermal characteristics of the louvers. This task was complicated by the fact that sun shines on the louvers during the summer season. A Monte Carlo analytical technique was used to develop absorbed power and effective emissivity tables for the louvers. These tables could be used with the instrument math models to predict the thermal behavior of the instruments. Data from the Monte Carlo analysis showed that solar entrapment could have a significant effect on the heat rejection capability of the louvered radiators.

Mengers, David↗

Doppler Lidar System Design via Interdisciplinary Design Concept at NASA Langley Research Center - Part II

Optimized designs of the Navigation Doppler Lidar (NDL) instrument for Autonomous Landing Hazard Avoidance Technology (ALHAT) were accomplished via Interdisciplinary Design Concept (IDEC) at NASA Langley Research Center during the summer of 2013. Three branches in the Engineering Directorate and three students were involved in this joint task through the NASA Langley Aerospace Research Summer Scholars (LARSS) Program. The Laser Remote Sensing Branch (LRSB), Mechanical Systems Branch (MSB), and Structural and Thermal Systems Branch (STSB) were engaged to achieve optimal designs through iterative and interactive collaborative design processes. A preliminary design iteration was able to reduce the power consumption, mass, and footprint by removing redundant components and replacing inefficient components with more efficient ones. A second design iteration reduced volume and mass by replacing bulky components with excessive performance with smaller components custom-designed for the power system. Thermal modeling software was used to run steady state thermal analyses, which were used to both validate the designs and recommend further changes. Analyses were run on each redesign, as well as the original system. Thermal Desktop was used to run trade studies to account for uncertainty and assumptions about fan performance and boundary conditions. The studies suggested that, even if the assumptions were significantly wrong, the redesigned systems would remain within operating temperature limits.

Crasner, Aaron I.↗

Coupling a Computational Fluid Dynamics Model to a Spacecraft Thermal System Model for the DraMS Instrument Thermal Analysis

The Dragonfly Mass Spectrometer (DraMS) is an instrument on the Dragonfly mission, which will spend 7 years in deep space cruise before landing and operating on the surface of Titan. Vacuum thermal analyses are required for deep space cruise, and convection analyses are required for the Titan surface operations. Model exchanges across multiple thermal teams are needed for all phases of the mission. For DraMS, Thermal Desktop® (TD) has been the main thermal analytical tool of choice due to its capability in modeling complex thermal systems with relatively low computational power and for its availability across thermal teams. However, TD does not have computational fluid dynamics (CFD) capability and struggles to accurately capture complex convective behavior. DraMS has fans operating in tandem and gas flow behaviors are not easily predicted due to its complex flow paths. CFD software, such as Fluent, can model and predict such complex flow behaviors, but CFD models are computationally expensive, and its workflow processes are not tailored towards simulating large and complex systems. Therefore, a coupled modeling approach was chosen for DraMS: A TD model was used for simulating all the conductive, radiative, and source terms, while a Fluent CFD model was added on, as needed, to the TD model to provide the convective boundary conditions using the System Coupling software. The coupling software allows the TD and Fluent models to communicate data and arrive at a co-solved and co-converged solution. Furthermore, Thermal Iso-value Exchange (TIE) method was developed to facilitate and improve the TD-Fluent data exchange process. This paper will discuss the analytical studies that were done to verify the accuracy and usability of the coupled approach and the challenges associated, which lead to the development of the TIE approach. DraMS thermal design and co-solved analysis results will also be discussed.

Heat transfer↗

Coupling a Computational Fluid Dynamics (CFD) Model to a Spacecraft Thermal System Model for the DraMS Instrument Thermal Analysis

The Dragonfly Mass Spectrometer (DraMS) is an instrument on the Dragonfly mission, which will spend 7 years in deep space cruise before landing and operating on the surface of Titan. Vacuum thermal analyses are required for deep space cruise, and convection analyses are required for the Titan surface operations. Model exchanges across multiple thermal teams are needed for all phases of the mission. For DraMS, Thermal Desktop (TD) has been the main thermal analytical tool of choice due to its capability in modeling complex thermal systems with relatively low computational power and for its availability across thermal teams. However, TD does not have computational fluid dynamics (CFD) capability and struggles to accurately capture complex convective behavior. DraMS has fans operating in tandem and gas flow behaviors are not easily predicted due to its complex flow paths. CFD software, such as Fluent, can model and predict such complex flow behaviors, but CFD models are computationally expensive, and its workflow processes are not tailored towards simulating large and complex systems. Therefore, a coupled modeling approach was chosen for DraMS: A TD model was used for simulating all the conductive, radiative, and source terms, while a Fluent CFD model was added on, as needed, to the TD model to provide the convective boundary conditions using the System Coupling software. The coupling software allows the TD and Fluent models to communicate data and arrive at a co-solved and co-converged solution. Furthermore, Thermal Iso-value Exchange (TIE) method was developed to facilitate and improve the TD-Fluent data exchange process. This paper will discuss the analytical studies that were done to verify the accuracy and usability of the coupled approach and the challenges associated, which lead to the development of the TIE approach. DraMS thermal design and co-solved analysis results will also be discussed.

heat transfer↗

Parametric studies of phase change thermal energy storage canisters for Space Station Freedom

Phase Change Materials (PCM) canister parametric studies are discussed wherein the thermal-structural effects of changing various canister dimensions and contained PCM mass values are examined. With the aim of improving performance, 11 modified canister designs are analyzed and judged relative to a baseline design using five quantitative performance indicators. Consideration is also given to qualitative factors such as fabrication/inspection, canister mass production, and PCM containment redundancy. Canister thermal analyses are performed using the finite-difference based computer program NUCAM-2DV. Thermal-stresses are calculated using closed-form solutions and simplifying assumptions. Canister wall thickness, outer radius, length, and contained PCM mass are the parameters considered for this study. Results show that singular canister design modifications can offer improvements on one or two performance indicators. Yet, improvement in one indicator is often realized at the expense of another. This confirms that the baseline canister is well designed. However, two alternative canister designs, which incorporate multiple modifications, are presented that offer modest improvements in mass or thermal performance, respectively.

Kerslake, Thomas W.↗

Finite-element methodology for thermal analysis of convectively cooled structures

A finite-element method for steady-state thermal analysis of convectively cooled structures is presented. The method is based on representing the coolant passages by finite elements with fluid bulk temperature nodes and fluid/structure interface modes. Four finite elements are described: two basic elements (mass transport and surface convection) and two integrated elements for applications to discrete tube and plate-fin convectively cooled structural configurations. Comparative finite-element and lumped-parameter thermal analyses of several convectively cooled structures demonstrate the practicality of utilizing finite-element methodology for thermal analysis of realistic convectively cooled structures.

Source record↗

Thermal design of composite materials high temperature attachments

The thermal aspects of using filamentary composite materials as primary airframe structures on advanced atmospheric entry spacecraft such as the space shuttle vehicle were investigated to identify and evaluate potential design approaches for maintaining composite structures within allowable temperature limits at thermal protection system (TPS) attachments and/or penetrations. The investigation included: (1) definition of thermophysical data for composite material structures; (2) parametric characterization and identification of the influence of the aerodynamic heating and attachment design parameters on composite material temperatures; (3) conceptual design, evaluation, and detailed thermal analyses of temperature limiting design concepts; and (4) the development of experimental data for assessment of the thermal design methodologies and data used for evaluation of the temperature-limiting design concepts. Temperature suppression attachment concepts were examined for relative merit. The simple isolator was identified as the most weight-effective concept and was selected for detail design, thermal analysis, and testing. Tests were performed on TPS standoff attachments to boron/aluminum, boron/polyimide and graphite/epoxy composite structures.

Source record↗

Laser-zone growth in a Ribbon-To-Ribbon (RTR) process silicon sheet growth development for the large area silicon sheet task of the low cost silicon solar array project

The Ribbon-to-Ribbon (RTR) approach to silicon ribbon growth was investigated. An existing RTR apparatus, RTR#1, was upgraded to allow for 5 cm wide ribbon growth with a finite stroke length of at least 15 cm. A second RTR apparatus, RTR#2, was designed, built, and operated which utilizes continuous feed mechanisms and allows continuous growth of 7.5 cm wide ribbons. RTR#2 includes development and utilization of advanced beam scanning (or shaping), high power lasers, and thermal profile modification elements to attain maximum growth velocities (with a design goal of 18 cm/min). Materials studies, process development, and thermal analyses are also described. Residual stresses and dislocation densities were minimized through theoretical and experimental efforts towards optimization of thermal profiles. Growth runs were performed on RTR#2 and solar cells were fabricated which demonstrated efficiencies greater than 10%.

Gurtler, R. W.↗

High temperature polymers - A review of novel thermally stable hexafluoroisopropylidene-containing polymers

The synthesis and properties to date of several novel HFIP-containing polymers and copolymers are presented. Thermal analyses of polyether ketones (PEK), aromatic polyesters, and polymers from a novel 18F-diacid were performed on a thermal analyzer. All three polymer types exhibited enhanced solubility, thermal stability, and low dielectric constants that are predicted for polymers containing the HFIP moiety. The moderate thermal stability observed in the polymers derived from the 18F-diacid is attributed to the oxidatively weak methylene linkage between the HFIP groups and the phenyl rings. PEKs and polyarylates show potential as high emissivity coatings under conditions where atomic oxygen is present.

Kane, K. M.↗

A conceptual design study for a two-dimensional, electronically scanned thinned array radiometer

A conceptual design for the Two-Dimensional, Electronically Steered Thinned Array Radiometer (ESTAR) is described. This instrument is a synthetic aperture microwave radiometer that operates in the L-band frequency range for the measurement of soil moisture and ocean salinity. Two auxiliary instruments, an 8-12 micron, scanning infrared radiometer and a 0.4-1.0 micron, charge coupled device (CCD) video camera, are included to provided data for sea surface temperature measurements and spatial registration of targets respectively. The science requirements were defined by Goddard Space Flight Center. Instrument and the spacecraft configurations are described for missions using the Pegasus and Taurus launch vehicles. The analyses and design trades described include: estimations of size, mass and power, instrument viewing coverage, mechanical design trades, structural and thermal analyses, data and communications performance assessments, and cost estimation.

Mutton, Philip↗

The nanosphere iron mineral(s) in Mars soil

A series of surface-modified clays containing nanophase (np) iron/oxyhydroxides of extremely small particle sizes, with total iron contents as high as found in Mars soil, were prepared by iron deposition on the clay surface from ferrous chloride solution. Comprehensive studies of the iron mineralogy in these 'Mars-soil analogs' were conducted using chemical extractions, solubility analyses, pH and redox, x ray and electron diffractometry, electron microscopic imaging specific surface area and particle size determinations, differential thermal analyses, magnetic properties characterization, spectral reflectance, and Viking biology simulation experiments. The clay matrix and the procedure used for synthesis produced nanophase iron oxides containing a certain proportion of divalent iron, which slowly converts to more stable, fully oxidized iron minerals. The noncrystalline nature of the iron compounds precipitated on the surface of the clay was verified by their complete extractability in oxalate. Lepidocrocite (gamma-FeOOH) was detected by selected area electron diffraction. It is formed from a double iron Fe(II)/Fe(III) hydroxyl mineral such as 'green rust', or ferrosic hydroxide. Magnetic measurements suggested that lepidocrocite converted to the more stable meaghemite (gamma-Fe203) by mild heat treatment and then to nanophase hematite (aplha-Fe203) by extensive heat treatment. Their chemical reactivity offers a plausible mechanism for the somewhat puzzling observations of the Viking biology experiments. Their unique chemical reactivities are attributed to the combined catalytic effects of the iron oxide/oxyhydroxide and silicate phase surfaces. The mode of formation of these (nanophase) iron oxides on Mars is still unknown.

Banin, A.↗

The nanophase iron mineral(s) in Mars soil

A series of surface-modified clays containing nanophase (np) iron oxide/oxyhydroxides of extremely small particle sizes, with total iron contents as high as found in Mars soil, were prepared by iron deposition on the clay surface from ferrous chloride solution. Comprehensive studies of the iron mineralogy in these "Mars-soil analogs" were conducted using chemical extractions, solubility analyses, pH and redox, x ray and electron diffractometry, electron microscopic imaging, specific surface area and particle size determinations, differential thermal analyses, magnetic properties characterization, spectral reflectance, and Viking biology simulation experiments. The clay matrix and the procedure used for synthesis produced nanophase iron oxides containing a certain proportion of divalent iron, which slowly converts to more stable, fully oxidized iron minerals. The clay acted as an effective matrix, both chemically and sterically, preventing the major part of the synthesized iron oxides from ripening, i.e., growing and developing larger crystals. The precipitated iron oxides appear as isodiametric or slightly elongated particles in the size range 1-10 nm, having large specific surface area. The noncrystalline nature of the iron compounds precipitated on the surface of the clay was verified by their complete extractability in oxalate. Lepidocrocite (gamma-FeOOH) was detected by selected area electron diffraction. It is formed from a double iron Fe(II)/Fe(III) hydroxy mineral such as "green rust," or ferrosic hydroxide. Magnetic measurements suggested that lepidocrocite converted to the more stable maghemite (gamma-Fe2O3) by mild heat treatment and then to nanophase hematite (alpha-Fe2O3) by extensive heat treatment. After mild heating, the iron-enriched clay became slightly magnetic, to the extent that it adheres to a hand-held magnet, as was observed with Mars soil. The chemical reactivity of the iron-enriched clays strongly resembles, and offers a plausible mechanism for, the somewhat puzzling observations of the Viking biology experiments. Their unique chemical reactivities are attributed to the combined catalytic effects of the iron oxide/oxyhydroxides and silicate phase surfaces. The reflectance spectrum of the clay-iron preparations in the visible range is generally similar to the reflectance curves of bright regions on Mars. This strengthens the evidence for the predominance of nanophase iron oxides/oxyhydroxides in Mars soil. The mode of formation of these nanophase iron oxides on Mars is still unknown. It is puzzling that despite the long period of time since aqueous weathering took place on Mars, they have not developed from their transitory stage to well-crystallized end-members. The possibility is suggested that these phases represent a continuously on-going, extremely slow weathering process.

NASA Program Exobiology↗

Aeroheating Measurements of BOLT Aerodynamic Fairings and Transition Module

The Air Force Office of Scientific Research (AFOSR) has sponsored the Boundary Layer Transition (BOLT) Experiments to investigate hypersonic boundary layer transition on a low-curvature, concave surface with swept leading edges. This paper presents aeroheating measurements on a subscale model of the BOLT Flight Geometry, aerodynamic fairings, and Transition Module (TSM) in the NASA Langley 20-Inch Mach 6 Air Tunnel. The purpose of the test was to investigate and identify any areas of localized heating on the TSM for inclusion in the BOLT Critical Design Review (CDR). Surface heating distributions were measured using global phosphor thermography, and data were obtained for a range of model attitudes and free stream Reynolds numbers. Measurements showed low heating on the fairings and TSM. Additional analysis was completed after the CDR to compare heating on the TSM for the nominal BOLT vehicle reentry angle-of-attack with heating on the TSM for possible reentry angle-of-attack excursions. The results of this analysis were used in conjunction with thermal analyses from Johns Hopkins Applied Physics Lab (JHU/APL) and the Air Force Research Laboratory (AFRL) to assess the need for thermal protection on the flight vehicle TSM.

Rieken, Elizabeth F.↗

Thermal Analysis of a High-Speed Aircraft Wing Using p-Version Finite Elements

This paper presents the results of conceptual level thermal analyses of a High Speed Civil Transport (HSCT) wing using p-version finite elements. The work was motivated by a thermal analysis of a HSCT wing structure which showed the importance of radiation heat transfer throughout the structure. The analysis also showed that refining a traditional finite element mesh to accurately capture the temperature distribution on the internal structure led to very large meshes with unacceptably long execution times. Further study indicated using p-version finite elements might improve computation performance for this class of problem. Methods for determining internal radiation heat transfer were then developed and demonstrated on test problems representative of the geometry found in an aircraft wing structure. This paper presents the results of the application of these new methods to the analysis of a high speed aircraft wing. Results for both a wing box model as well as a full wing model are presented. 'Me reduced wing box model allows for a comparison of the traditional finite element method with mesh refinement (h-refinement) to the new p-version finite elements while the full wing model demonstrates the applicability and efficiency of p-version finite elements for large models.

Gould, Dana C.↗

Guidelines for the Selection of Near-Earth Thermal Environment Parameters for Spacecraft Design

Thermal analysis and design of Earth orbiting systems requires specification of three environmental thermal parameters: the direct solar irradiance, Earth's local albedo, and outgoing longwave radiance (OLR). In the early 1990s data sets from the Earth Radiation Budget Experiment were analyzed on behalf of the Space Station Program to provide an accurate description of these parameters as a function of averaging time along the orbital path. This information, documented in SSP 30425 and, in more generic form in NASA/TM-4527, enabled the specification of the proper thermal parameters for systems of various thermal response time constants. However, working with the engineering community and SSP-30425 and TM-4527 products over a number of years revealed difficulties in interpretation and application of this material. For this reason it was decided to develop this guidelines document to help resolve these issues of practical application. In the process, the data were extensively reprocessed and a new computer code, the Simple Thermal Environment Model (STEM) was developed to simplify the process of selecting the parameters for input into extreme hot and cold thermal analyses and design specifications. In the process, greatly improved values for the cold case OLR values for high inclination orbits were derived. Thermal parameters for satellites in low, medium, and high inclination low-Earth orbit and with various system thermal time constraints are recommended for analysis of extreme hot and cold conditions. Practical information as to the interpretation and application of the information and an introduction to the STEM are included. Complete documentation for STEM is found in the user's manual, in preparation.

Anderson, B. J.↗