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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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NASA’s PACE Ocean Color Instrument Thermal Design Evolution: from Goddard’s Instrument Design Lab through Flight Development

NASA’s Plankton, Aerosol, Cloud, ocean Ecosystem (PACE) mission, set to launch in 2024, seeks to provide data continuity for the ocean color, aerosol and cloud measurements acquired by NASA’s on-orbit Earth Science observatories since the 1990s. It will accomplish this through its Ocean Color Instrument (OCI), an optical spectrometer being developed for hyper-spectral measurements in the ultraviolet-to-near-infrared band between 340 nm and 2260 nm. Although OCI’s instrument architecture will provide greater insight and resolution than its predecessors in this wavelength range, the engineering required to achieve this also poses a greater challenge. In thermal engineering, this translates to a more complex thermal control approach to address high heat dissipations, stringent stabilities, the volume of heat that requires transport, and changing thermal environments due to tilting of the entire instrument ±20° twice per orbit. This current work explores how the PACE OCI instrument design has evolved from its initial conception in NASA Goddard’s Instrument Design Laboratory (IDL) to the current iteration of its flight design. The IDL studies explored three separate instrument configurations and two spatial resolutions per configuration, which were then down selected to a single instrument type and spatial resolution for flight instrument development. OCI subsequently went through major project milestones, including Preliminary Design Review (PDR), Critical Design Review (CDR), Pre-Environmental Review (PER) and Pre-Ship Review (PSR), with significant design updates along the way. This paper aims to provide a comprehensive account of OCI’s thermal control architecture evolution and the engineering drivers that have shaped it, with the goal of identifying trends spanning the full instrument development timeline to inform and advance future instrument thermal designs.

PACE↗
DOE OSTI2020

Failure analysis of field-failed bypass diodes

Defective bypass diodes are often found as the largest factor leading to power loss in solar modules. Here, we report on failure mechanisms by investigating shunted bypass diodes from a rooftop installation, using a combination of multiple characterizations including current–voltage analysis, thermal-runaway testing, X-ray computed tomography, lock-in thermography, focused ion-beam cross-section imaging, chemical decapsulation, optical microscopy, and scanning electron microscopy with energy-dispersive X-ray spectroscopy. Differing from static discharge typically associated with lightning strikes on modules, we found diode failure by the mechanism of thermal damage under continuous, long-term overstress in forward bias. Our conclusion is based on evidence of energy dissipated—the small to medium extent of melt-through on the Schottky diode face. The diode failure shows distortions or roughening of the Schottky diode metal-semiconductor interface with the die attach, and some failures are accompanied by die-attach solder melting. We propose that nonuniform irradiance on the modules caused diode shunting due to extended periods of heat dissipation in the modules, because modules in this string were placed in two different orientations. In contrast, a second parallel module string of the same module type on the same rooftop with a unique plane of array did not show any diode failures. The thermal damage failure of melt-through was caused by the long-term current generated by overstressing of diodes that may have had crystalline and impurity defects.

14 SOLAR ENERGY↗
NASA NTRS1984

Arc-driven rail gun research

The equations describing the performance of an inductively-driven rail gun are analyzed numerically. Friction between the projectile and rails is included through an empirical formulation. The equations are applied to the experiment of Rashleigh and Marshall to obtain an estimate of energy distribution in rail guns as a function of time. The effect of frictional heat dissipation on the bore of the gun is calculated. The mechanism of plasma and projectile acceleration in a dc rail gun is described from a microscopic point of view through the establishment of the Hall field. The plasma conductivity is shown to be a tensor indicating that there is a small component of current parallel to the direction of acceleration. The plasma characteristics are evaluated as a function of plasma mass through a simple fluid mechanical analysis of the plasma. By equating the energy dissipated in the plasma with the radiation heat loss, the properties of the plasma are determined.

Ray, P. K.↗
NASA NTRS2004

Thermal characteristics of Lithium-ion batteries

Lithium-ion batteries have a very promising future for space applications. Currently they are being used on a few GEO satellites, and were used on the two recent Mars rovers Spirit and Opportunity. There are still problem that exist that need to be addressed before these batteries can fully take flight. One of the problems is that the cycle life of these batteries needs to be increased. battery. Research is being focused on the chemistry of the materials inside the battery. This includes the anode, cathode, and the cell electrolyte solution. These components can undergo unwanted chemical reactions inside the cell that deteriorate the materials of the battery. During discharge/ charge cycles there is heat dissipated in the cell, and the battery heats up and its temperature increases. An increase in temperature can speed up any unwanted reactions in the cell. Exothermic reactions cause the temperature to increase; therefore increasing the reaction rate will cause the increase of the temperature inside the cell to occur at a faster rate. If the temperature gets too high thermal runaway will occur, and the cell can explode. The material that separates the electrode from the electrolyte is a non-conducting polymer. At high temperatures the separator will melt and the battery will be destroyed. The separator also contains small pores that allow lithium ions to diffuse through during charge and discharge. High temperatures can cause these pores to close up, permanently damaging the cell. My job at NASA Glenn research center this summer will be to perform thermal characterization tests on an 18650 type lithium-ion battery. High temperatures cause the chemicals inside lithium ion batteries to spontaneously react with each other. My task is to conduct experiments to determine the temperature that the reaction takes place at, what components in the cell are reacting and the mechanism of the reaction. The experiments will be conducted using an accelerating rate calorimeter (ARC), which uses a heat-wait-search mode until an exothermic reaction is detected. After an exotherm is found the calorimeter maintains an adiabatic environment around a bomb which holds the test sample. The ARC will help identify important reactions and what temperature these exothermic reactions take place at. In order fully understand the battery, we are first going to take apart the battery and test the individual components of the battery using the ARC. I will first conduct a test on the electrolyte solution by itself. We will then test the electrolyte solution with the anode. We would like to see how the electrolyte solution reacts with the anode and its binder material. The next would be the same test using the cathode instead of the anode. By comparing the results of the electrolyte, electrolyte with anode, and the electrolyte with the cathode we can determine the reactions that are taking place due to each component. Using the heat capacity of the each individual sample and the temperature by which the sample increases, kinetic and thermo-dynamical information can then be found. A Gas chromatograph could be used to help with the task of identifying the by-products at the end of each test. One way of increasing the cycle life is to increase the stability of the materials inside the

Hauser, Dan↗
NASA NTRS2019

Operation of a Heat Pipe with Multiple Heat Loads Under Reflux Mode

"Heat pipes are being used on many spacecraft to acquire heat dissipated by the payload and transport the heat to a remote radiator. In instrument-level or spacecraft-level ground testing, many heat pipes are placed in a gravity-driven reflux mode where the condenser is well above the evaporator, resulting in the formation of a liquid pool at the bottom of the heat pipe. If a head load is applied to a site that is in contact with the liquid pool, the generated vapor will flow upward to the condenser and the condensate will fall back to the evaporator due the influence of gravity. Hence, the heat pipe can operate steadily under reflux mode because the heated site always has sufficient liquid supply to sustain the fluid flow. In contrast, when a heat load is applied to a site remote from the liquid pool, the heat pipe will be unable to transfer heat through liquid evaporation unless the heated site has a chance to be in contact with liquid. This can be accomplished by applying an additional heat load to the liquid pool to establish a reflux flow so that the remote site can capture the falling condensate. An experimental investigation was conducted to study the effect of gravity on the thermal performance of a heat pipe under reflux mode with multiple heat loads. An aluminum ammonia heat pipe with internal axial grooves was placed in a vertical position. Cooling was provided to the top of the heat pipe, and heat was applied to three sites below the condenser with various heat distributions. One of the heated sites was above the liquid pool, and two were in direct contact with the liquid pool. Test results showed that when a heat load was applied to either one or both of the lower sites, the heat pipe could run steadily under reflux mode. After a reflux flow had been established, a heat load could be applied to the upper site. If the upper site could capture sufficient liquid falling from the condenser to handle its heat load solely by liquid evaporation, the heat pipe could reach steady operation. Otherwise, the temperature of the upper site would oscillate due to its intermittent contact with the falling liquid. For a given heat load to the upper site, the amplitude of temperature oscillation decreased with an increasing heat load to the lower sites because there was more falling condensate available for the upper site to capture. Moreover, the temperature oscillation disappeared completely when the total heat loads to lower sites exceeded a threshold power, and the threshold power increased with an increasing heat load to the upper site."

Ku, Jentung↗
NASA NTRS2019

Electrical and Thermal Characterization of 3D Printed Thermoplastic Parts with Embedded Wires for High Current-Carrying Applications

Fabrication of parts exhibiting multi-functionality has recently been complemented by hybrid polymer extrusion additive manufacturing in combination with wire embedding technology. While much mechanical characterization has been performed on parts produced with fused deposition modeling, limited characterization has been performed when combined electrical and thermal loads are applied to 3D printed multi-material parts. As such, this work describes the design, fabrication, and testing of 3D printed thermoplastic coupons containing embedded copper wires that carried current. An automated fabrication process was used employing a hybrid additive manufacturing machine that dispensed polycarbonate thermoplastic and embedded bare copper wires. Testing included AC and DC hipot testing as well as thermal testing on as-fabricated and heat treated coupons to determine the effect of porosity in the substrate. The heat-treated parts contained reduced amounts of porosity, as corroborated through scanning electron microscopy, which led to 50 % increased breakdown strength and 30 to 40 % increased heat dissipation capabilities. The results of this research are describing a set of design protocol that can be used as a guideline for 3D printed embedded electronics to predict the electrical and thermal behavior.

Hipot testing↗
DOE OSTI2025

Using leaf and stomatal traits to predict biomass production and water use efficiency in Populus

Climate change is reshaping ecosystems, driving plants to adapt through leaf-trait plasticity that reflects strategies for growth and water use. Predicting biomass production and intrinsic water use efficiency (iWUE) remains challenging because of genetic, taxonomic, and environmental variability. Here, we used eastern cottonwood and Populus hybrids as a model system to test whether easily measurable leaf traits can serve as reliable predictors of performance, and whether adding stomatal and biochemical traits improves predictive power. Across two field sites in Mississippi, leaf mass per area (LMA), biomass production, iWUE, leaf area, and foliar nitrogen ( N %) differed significantly among taxa and sites, while other traits were conserved. Factorial analysis of mixed data (FAMD) revealed distinct clustering of taxa and sites, indicating coordinated variation among leaf and stomatal traits. Pairwise correlations highlighted fundamental trade-offs, with biomass positively related to LMA and petiole length but negatively associated with iWUE, N %, and carbon isotopic ratios (δ 13 C). Leaf temperature and leaf angle varied among taxa and were significantly correlated with LMA and petiole length, suggesting mechanisms of heat dissipation and leaf movability that link simple traits to gas exchange and productivity. Weighted multiple linear regression models explained 80%–91% of variation in biomass production and iWUE. Models using only LMA, petiole length, and stomatal metrics performed nearly as well as those incorporating N %, and δ 13 C, with complex traits adding approximately 10% explanatory power. These results demonstrate that simple morphological traits capture integrated functional trade-offs, while complex traits refine predictions. This tiered approach provides an efficient framework for selecting high-yielding, water-efficient genotypes of Populus and other hardwood species, offering practical pathways to enhance carbon uptake and iWUE under climate change.

biomass production↗
DOE OSTI2023

Surface Merging Technique to Design GA-Optimized Heat Sinks

High-power density inverters require efficient and small heat dissipation systems. For liquid cooling systems, an effective heat sink design is important to enable higher heat transfer and keep the pressure drop within reasonable limits. A heat sink geometry generated from an extruded, 1D fast Fourier transform can achieve more even temperature distribution and improved heat transfer than a conventional heat sink. Building on this concept, this paper proposes a new heat sink geometry creation algorithm. Instead of one plane profile being extruded, multiple plane profiles, each created from the fast Fourier transform method, are subsequently merged by smooth surfaces along the flow direction of the heat sink. Thus, a 3D heat sink geometry is created that enables 3D coolant flow and efficient heat transfer. The volume of this design was reduced by 50% compared with pin fin heat sinks. Compared with extruded 1D fast Fourier transform heat sinks, the proposed design showed an approximately 5% device temperature reduction and a 20% pressure drop reduction.

Barua, Himel↗
NASA NTRS1948

Investigation of Effectiveness of Air-Heating a Hollow Steel Propeller for Protection Against Icing. 2: 50% Impartitioned Blades

The icing protection afforded an internal air-heated propeller blade by radial partitioning at 50-percent chord to confine the heated air to the forward half of the blade was determined in the NACA Cleveland icing research tunnel. A modified production-model hollow steel propeller, was used for the investigation. Temperatures of the blade surfaces for several heating rates were measured under various tunnel Icing' conditions. Photographic observations of ice formations on blade surfaces and blade heat-exchanger effectiveness were obtained. With 50-percent partitioning of the blades, adequate icing protection at 1050 rpm was obtained with a heating rate of 26,000 Btu per hour per blade at the blade shank using an air temperature of 400 F with a flow rate of 280 pounds per hour per blade, which is one-third less heat than was found necessary for similar Ice protection with unpartitioned blades. The chordwise distribution of the applied heat, as determined by surface temperature measurements, was considered unsatisfactory with much of the heat dissipated well back of the leading edge. Heat-exchanger effectiveness of approximately 56 percent also Indicated poor utilization of available heat. This effectiveness was, however, 9 percent greater than that obtained from unpartitioned blades.

Perkins, Porter J.↗
NASA NTRS2004

GRABER: The Duct Tape of Space and JIMO Heat Conducting Foam

Crack formation in the space shuttle's heat shield during flight poses a major safety concern to everyone on board. Cracking weakens the structure of the shield and lessens the protection it offers against the high temperatures and forces encountered during re-entry. Astronauts need a way to mend these cracks while in space. This is GRABER s function; it can be spackled into the cracks by an astronaut. The material then hardens, or cures, due to being in a vacuum and the heat encountered when it faces the sun. A great deal of work and testing is necessary to create a material that will be workable in a vacuum over a wide range of temperatures, will cure without cracking, will adhere to the sides of the crack, and that can withstand the extreme temperatures of re-entry. A Brookfield PVS Rheometer is being used to characterize GRABER's viscosity at various temperatures and stirring rates. Various compositions of GRABER are being heat treated in a vacuum to determine probably curing times in space. The microstructures of cured samples of each composition are being examined using both optical and electron microscopy. Jupiter s Icy Moon Orbiter (JIMO) will be lifting off sometime around 2013. JIMO will have more power than its predecessor, Galileo, allowing it to change orbits to circle three of Jupiter s moons. Both of the engine types being considered require large heat dissipation systems. These systems will be comprised of heat conductive tubing and plates with a liquid flowing through them. In order to maximize the speed of heat transfer between the tubes and the panels, the in-between areas will be filled with heat conductive silicon carbide foam. Two different foam systems are being considered for this foam. Currently, experimentation is underway with adding Sic, carbon, and carbon fibers to a two part fuel retardant foam. The foam is them pyrolized and its mass and dimensional changes are measured. The structure of the foam will be examined using optical and electron microscopy as well. Work is also planned with a foam system developed by an Italian team.

Gamble, Eleanor A.↗
NASA NTRS2019

Interface Conductance Under a Real Electronics Box

Electronics Boxes with high heat dissipations use a thermal interface material to increase heat transfer to the radiator in a vacuum/space environment. There are lots of materials to choose from, but for Spacecraft applications, there are more than high heat transfer metrics which must be met. Contamination (both particle generation and outgassing), ease of cutting, and removal are just as important metrics in material selection. However, vendor data of material thermal conductance is usually based on a 1" X 1" piece of material under high uniform pressures. Large Electronics boxes almost never have optimal pressures, as they are bolted along the perimeter and leave gaps in the center regions. In order to characterize the relative thermal conductance for large Electronics boxes, an 8" X 8" plate was fabricated to simulate an electronics box bottom and bolted around the perimeter to a cold plate. Various thermal interface materials were inserted between the box and cold plate, and overall thermal conductance's were calculated. A table was generated which compares the full gamut of thermal interface materials for large boxes, from a dry joint to a wet joint. Materials were placed in order of high to low conductance's, so an engineer can compare the benefit of each material in a real-world scenario.

Thermal Interface Conductance↗
DOE OSTI2024

Transient Optimization of the Cryogenic Moderator System Controller at the Spallation Neutron Source for Improved Performance

The high-energy neutron beam generated at the Spallation Neutron Source (SNS) at Oak Ridge National Laboratory is moderated to use cold (slow) neutrons for scientific discoveries. The Cryogenic Moderator System (CMS) removes heat from the neutron beam using cryogenic hydrogen (H 2 ) moderators connected via heat exchangers to a helium (He) refrigeration loop that dissipates heat using a compressor-brake system. However, the CMS is affected by sporadic losses in beam power, referred to as "beam trips," as these events generate significant disturbances in cooling requirements. To accommodate the heat load transients during beam trips, the CMS uses a decentralized control strategy consisting of four flow valves and one electric heater adjusted by independent proportional-integral (PI) controllers. During the CMS’s initial commissioning, the PI gains were calibrated based only on tracking performance, overlooking their effectiveness in disturbance rejection. A data-driven, control-oriented closed-loop model was developed to recalibrate the PI gains and minimize the transient disturbances caused by beam trips. The model consists of three main components: (1) a physics-based model of the He refrigeration loop, (2) a machine-learning model of the cryogenic H 2 cooling trains, and (3) the control logic used for feedback set-point tracking. Experimental results showed that the recalibrated gains obtained in this study improved the CMS’s transient response during beam trips.

Maldonado Puente, Bryan↗
NASA NTRS1997

Transpiring Cooling of a Scram-Jet Engine Combustion Chamber

The peak cold-wall heating rate generated in a combustion chamber of a scram-jet engine can exceed 2000 Btu/sq ft sec (approx. 2344 W/sq cm). Therefore, a very effective heat dissipation mechanism is required to sustain such a high heating load. This research focused on the transpiration cooling mechanism that appears to be a promising approach to remove a large amount of heat from the engine wall. The transpiration cooling mechanism has two aspects. First, initial computations suggest that there is a reduction, as much as 75%, in the heat flux incident on the combustion chamber wall due to the transpirant modifying the combustor boundary layer. Secondly, the heat reaching the combustor wall is removed from the structure in a very effective manner by the transpirant. It is the second of these two mechanisms that is investigated experimentally in the subject paper. A transpiration cooling experiment using a radiant heating method, that provided a heat flux as high as 200 Btu/sq ft sec ( approx. 234 W/sq cm) on the surface of a specimen, was performed. The experiment utilized an arc-lamp facility (60-kW radiant power output) to provide a uniform heat flux to a test specimen. For safety reasons, helium gas was used as the transpirant in the experiments. The specimens were 1.9-cm diameter sintered, powdered-stainless-steel tubes of various porosities and a 2.54cm square tube with perforated multi-layered walls. A 15-cm portion of each specimen was heated. The cooling effectivenes and efficiencies by transpiration for each specimen were obtained using the experimental results. During the testing, various test specimens displayed a choking phenomenon in which the transpirant flow was limited as the heat flux was increased. The paper includes a preliminary analysis of the transpiration cooling mechanism and a scaling conversion study that translates the results from helium tests into the case when a hydrogen medium is used.

Choi, Sang H.↗
DOE OSTI2021

Prediction of Probabilistic Shock Initiation Thresholds of Energetic Materials Through Evolution of Thermal-Mechanical Dissipation and Reactive Heating

The ignition threshold of an energetic material (EM) quantifies the macroscopic conditions for the onset of self-sustaining chemical reactions. The threshold is an important theoretical and practical measure of material attributes that relate to safety and reliability. Historically, the thresholds are measured experimentally. In this work, we present a new Lagrangian computational framework for establishing the probabilistic ignition thresholds of heterogeneous EM out of the evolutions of coupled mechanical-thermal-chemical processes using mesoscale simulations. Furthermore, the simulations explicitly account for microstructural heterogeneities, constituent properties, and interfacial processes and capture processes responsible for the development of material damage and the formation of hotspots in which chemical reactions initiate. The specific mechanisms tracked include viscoelasticity, viscoplasticity, fracture, post-fracture contact, frictional heating, heat conduction, reactive chemical heating, gaseous product generation, and convective heat transfer. To determine the ignition threshold, the minimum macroscopic loading required to achieve self-sustaining chemical reactions with a rate of reactive heat generation exceeding the rate of heat loss due to conduction and other dissipative mechanisms is determined. Probabilistic quantification of the processes and the thresholds are obtained via the use of statistically equivalent microstructure sample sets (SEMSS). The predictions are in agreement with available experimental data.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Heat sink for luminaire and luminaire arrangements having a heat sink

A heat sink for a luminaire includes a central portion having a top surface and a bottom surface. The bottom surface is adapted to receive a lighting arrangement. The heat sink further includes a plurality of arms configured to dissipate heat generated by the lighting arrangement. The plurality of arms extend radially outward from the central portion. Each one of the plurality of arms is substantially arcuate between a proximal end and a distal end.

Trublowski, John↗
DOE OSTI2022

Numerical Modeling of Atmospheric Rime Ice Accretion on an Airfoil Using an Eulerian Approach

This paper presents an approach to numerically simulate the inherently unsteady rime ice accretion problem on a two-dimensional airfoil and elucidate the associated variations under different icing conditions. The airflow field and the water impingement on the airfoil are obtained based on an Eulerian two-phase model. A dynamic mesh strategy is employed to unsteadily account for the changes in the ice profile and its impact on the air and droplet flow by continuously reconstructing the computational grid at each time-step through smoothing and layering mechanisms. All main icing modules including the airflow field, droplet trajectory, icing thickness profile, and mesh management are fully coupled within the same computational framework without resorting to any external tools. Classical icing theory is employed to model the rime ice roughness, and it is assumed that the ice accretes in a direction normal to the airfoil surface. The governing Reynolds-averaged Navier–Stokes (RANS) conservation equations along with the energy and continuity equations are solved to produce the velocity and temperature fields. A convective film heat transfer coefficient is computed based on the surface heat flux and a recovery temperature which takes into account the dissipative heat release in the boundary layer in the vicinity of the airfoil surface. With the implemented strategy and calculating the convective heat transfer coefficient, the water film thickness is also calculated along with the ice shape. Furthermore, the model is validated by comparing the local collection efficiency distribution and ice shape with experimental data, and the results show that the implemented approach provides acceptable predictions of ice accretion profiles and rates.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗