SEARCH · Search NASA

Results for “relative cooling power”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 109 records · Page 6

All sources NASA NTRS DOE OSTI

NASA NTRS1989

Spinoff from a Moonsuit

Hypohidrotic ectodermal dysplasia refers to the absence of sweat glands which allow body heat to escape. Children with the disease become overheated quickly and suffer from a number of related afflictions. Several have been assisted by Life Support Systems, Inc., a NASA spinoff company which manufactures a garment cooled by a heat exchanger powered by a minipump through a network of fluid-filled tubes. The suits are used by firefighters, crop dusting pilots, workers in hazardous industries, etc. The company was founded by a former NASA contractor employee. When Sara Moody, whose nephew Stevie Roper has HED, contacted Langley Research Center, she was referred to LSSI. With help from PoFolks Restaurant Corporation and others, she raised $5,000 for a suit for Stevie. LSSI agreed to manufacture the suit at cost. After receiving the suit, Stevie's life improved dramatically, and Sara Moody established the HED Foundation. Through the foundation, other children have also received cool suits.

Source record↗

DOE OSTI2021

Cost-Optimized Cold Climate Heat Pump Development and Field Test

Cold climate heat pumps (CCHPs) expand the heat pump market to climates where heating demand is dominant. They can achieve more than 70% energy savings compared with electric resistance heating and operate at lower cost than using tank-stored propane to fuel a furnace. A high-efficiency heat pump with a heating seasonal performance factor (HSPF)—as defined by the Air-Conditioning, Heating, and Refrigeration Institute (AHRI 2008)—greater than 10.0 would be more efficient than gas heating in terms of source energy. However, developing a cost-effective CCHP involves some challenges. A typical single-speed, air-source heat pump (ASHP) with an HSPF of 7.7 Btu/Wh does not work well under cold outdoor temperature conditions typical of cold climate locations for four major reasons: 1. Discharge temperature is too high—The low suction pressure and high compression pressure ratio at low ambient temperatures causes high compressor discharge temperatures in excess of the maximum limit for many of the compressors on the market. Furthermore, system charge of a heat pump is usually optimized in the cooling mode, which leads to overcharge conditions in the heating mode, further increasing the discharge temperature. 2. Heating capacity is insufficient if sized to meet the building design cooling load— Heating capacity of a single-speed heat pump decreases with ambient temperature. The heating capacity at -13°F (-25°C) typically decreases to 20%–40% of the rated heating capacity at 47°F (8.3°C) (~equivalent to the rated cooling capacity at 95°F [35°C]). Therefore, a single-speed heat pump, typically sized to match the building design cooling load, cannot provide adequate heating capacity to match the building heating load at low ambient temperatures. The capacity deficit is filled by inefficient resistance heat, thus lowering the system efficiency and significantly increasing power demand. 3. Cyclic loss is significant if sized to meet the building design heating load—If a single-speed heat pump is sized to meet the heating load, it will be significantly oversized relative to the cooling load in many cold climates. This will cause excessive on/off cyclic loss during the cooling and heating operations at moderately low ambient temperatures. Thus, capacity modulation capability (e.g., using a variable-speed or multi-stage compressor) is necessary for a CCHP, which uses its full capacity to meet the peak heating load and partial capacity to meet the cooling and part-load heating loads. 4. Coefficient of performance (COP) is low—Heating COP degrades significantly at low ambient temperatures owing to the large temperature difference between the heat source and sink. A target CCHP should be sized to meet the building design heating load while minimizing the cyclic loss for the cooling and heating operations at moderate ambient temperatures.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2012

The Cosmic History of Hot Gas Cooling and Radio AGN Activity in Massive Early-Type Galaxies

We study the X-ray properties of 393 optically selected early-type galaxies (ETGs) over the redshift range of z approx equals 0.0-1.2 in the Chandra Deep Fields. To measure the average X-ray properties of the ETG population, we use X-ray stacking analyses with a subset of 158 passive ETGs (148 of which were individually undetected in X-ray). This ETG subset was constructed to span the redshift ranges of z = 0.1-1.2 in the approx equals 4 Ms CDF-S and approx equals 2 Ms CDF-N and z = 0.1-0.6 in the approx equals 250 ks E-CDF-S where the contribution from individually undetected AGNs is expected to be negligible in our stacking. We find that 55 of the ETGs are detected individually in the X-rays, and 12 of these galaxies have properties consistent with being passive hot-gas dominated systems (i.e., systems not dominated by an X-ray bright Active Galactic Nucleus; AGN). On the basis of our analyses, we find little evolution in the mean 0.5-2 keY to B-band luminosity ratio (L(sub x) /L(sub Beta) varies as [1 +z]) since z approx equals 1.2, implying that some heating mechanism prevents the gas from cooling in these systems. We consider that feedback from radio-mode AGN activity could be responsible for heating the gas. We select radio AGNs in the ETG population using their far-infrared/radio flux ratio. Our radio observations allow us to constrain the duty cycle history of radio AGN activity in our ETG sample. We estimate that if scaling relations between radio and mechanical power hold out to z approx equals 1.2 for the ETG population being studied here, the average mechanical power from AGN activity is a factor of approx equals1.4 -- 2.6 times larger than the average radiative cooling power from hot gas over the redshift range z approx equals 0-1.2. The excess of inferred AGN mechanical power from these ETGs is consistent with that found in the local Universe for similar types of galaxies.

Danielson, A. L. R.↗

DOE OSTI2020

The Gaia–Kepler Stellar Properties Catalog. II. Planet Radius Demographics as a Function of Stellar Mass and Age

Studies of exoplanet demographics require large samples and precise constraints on exoplanet host stars. Using the homogeneous Kepler stellar properties derived using the Gaia Data Release 2 by Berger et al., we recompute Kepler planet radii and incident fluxes and investigate their distributions with stellar mass and age. We measure the stellar mass dependence of the planet radius valley to be dlogR{sub p}/dlogM{sub ⋆} = 0.26{sub −0.16}{sup +0.21}, consistent with the slope predicted by a planet mass dependence on stellar mass (0.24–0.35) and core-powered mass loss (0.33). We also find the first evidence of a stellar age dependence of the planet populations straddling the radius valley. Specifically, we determine that the fraction of super-Earths (1–1.8 R{sub ⊕}) to sub-Neptunes (1.8–3.5 R{sub ⊕}) increases from 0.61 ± 0.09 at young ages (<1 Gyr) to 1.00 ± 0.10 at old ages (>1 Gyr), consistent with the prediction by core-powered mass loss that the mechanism shaping the radius valley operates over Gyr timescales. Additionally, we find a tentative decrease in the radii of relatively cool (F {sub p} < 150 F{sub ⊕}) sub-Neptunes over Gyr timescales, which suggests that these planets may possess H/He envelopes instead of higher mean molecular weight atmospheres. We confirm the existence of planets within the hot sub-Neptunian “desert” (2.2 R {sub ⊕} < R {sub p} < 3.8 R{sub ⊕}, F {sub p} > 650 F{sub ⊕}) and show that these planets are preferentially orbiting more evolved stars compared to other planets at similar incident fluxes. In addition, we identify candidates for cool (F {sub p} < 20 F{sub ⊕}) inflated Jupiters, present a revised list of habitable zone candidates, and find that the ages of single and multiple transiting planet systems are statistically indistinguishable.

79 ASTRONOMY AND ASTROPHYSICS↗

NASA NTRS1989

Radio emission and the hot interstellar medium of early-type galaxies

The results of an analysis of a sample of 84 elliptical and S0 galaxies, observed in X-rays with the Einstein Observatory and in radio continuum at 5 GHz, are reported. Radio flux densities result in some of the lowest radio powers yet reported for early-type galaxies. Radio structures extending beyond the optical radius are found only in galaxies with 5 GHz radio power greater than about 10 exp 29.5 ergs/s/Hz. Radio and X-ray luminosities are correlated, although with large intrinsic scatter, suggesting that more than one mechanism may be involved. A correlation between core radio power and the X-ray-to-optical ratio suggests a connection between the hot ISM and nuclear radio sources and points to accreting cooling flows as the fuel for the radio sources. For the same radio core power, extended radio lobes tend to be associated with galaxies with relatively smaller X-ray-to-optical ratios, pointing to the importance of the hot ISM in disrupting the radio jets and confining extended radio structures.

Fabbiano, G.↗

NASA NTRS2007

Amplified Thermionic Cooling Using Arrays of Nanowires

A class of proposed thermionic cooling devices would incorporate precise arrays of metal nanowires as electron emitters. The proposed devices could be highly miniaturized, enabling removal of heat from locations, very close to electronic devices, that have previously been inaccessible for heat-removal purposes. The resulting enhancement of removal of heat would enable operation of the devices at higher power levels and higher clock speeds. Moreover, the mass, complexity, and bulk of electronic circuitry incorporating these highly miniaturized cooling devices could be considerably reduced, relative to otherwise equivalent circuitry cooled by conventional electromechanical, thermoelectric, and fluidic means. In thermionic cooling, one exploits the fact that because only the highest-energy electrons are thermionically emitted, collecting those electrons to prevent their return to the emitting electrode results in the net removal of heat from that electrode. Collection is effected by applying an appropriate positive bias potential to another electrode placed near the emitting electrode. The concept underlying the proposal is that the thermionic-emission current and, hence, the cooling effect attainable by use of an array of nanowires could be significantly greater than that attainable by use of a single emitting electrode or other electron- emitting surface. The wires in an array according to the proposal would protrude perpendicularly from a planar surface and their heights would be made uniform to within a sub-nanometer level of precision

Yang, Eui-Hyeok↗

NASA NTRS2004

A Continuous Adiabatic Demagnetization Refrigerator for Far-IR/Sub-mm Astronomy

We report on recent progress in the development of a continuous adiabatic demagnetization refrigerator (CADR). Continuous operation avoids the constraints of long hold times and short recycle times that lead to the generally large mass of single-shot ADRs, allowing us to achieve an order of magnitude larger cooling power per unit mass. Our current design goal is 10 microW of cooling at 50 mK using a 6-10 K heat sink. The estimated mass is less than 10 kg, including magnetic shielding of each stage. The relatively high heat rejection capability allows it to operate with a mechanical cryocooler as part of a cryogen-free, low temperature cooling system. This has the advantages of long mission life and reduced complexity and cost. We have assembled a three-stage CADR and have demonstrated continuous cooling using a superfluid helium bath as the heat sink. The temperature stability is 8 microK rms or better over the entire cycle, and the cooling power is 2.5 microW at 60 mK rising to 10 microW at 100 mK.

Shirron, Peter↗

DOE OSTI1992

Nuclear Safety [Vol. 33, No. 4, October-December 1992]

Nuclear Safety is a review journal that covers significant developments in the field of nuclear safety. Its scope includes the analysis and control of hazards associated with nuclear energy, operations involving fissionable materials, and the products of nuclear fission and their effects on the environment. Primary emphasis is on safety in reactor design, construction, and operation; however, the safety aspects of the entire fuel cycle, including fuel fabrication, spent-fuel processing, nuclear waste disposal, handling of radioisotopes, and environmental effects of these operations, are also treated. Table of Contents for this issue follows. GENERAL SAFETY CONSIDERATIONS: 499 Technical Note: Nuclear Regulatory Commission’s Examination Question Bank System, C. L Jensen and N. L. Skinner; 506 Report on the Specialists’ Meeting on Passive and Active Safety Features of Liquid-Metal Fast Breeder Reactors Organized by the International Atomic Energy Agency at Oarai Engineering Centre of Power Reactor and Nuclear Development Corporation, Japan, November 5-7,1991, S. R. Paranjpe; ACCIDENT ANALYSIS: 514 A Review of Hydrogen Production During Melt/Water Interaction in LWRs, D. F. Fletcher, B. D. Turland, and S. P. A. Lawrence; 535 A Review of the U 3 0 8 -Al Reaction as a Potential Heat Source in Research and Test Reactor Accidents, J. L. Snelgrove; CONTROL AND INSTRUMENTATION: 543 Multilevel Interfaces for Power Plant Control Rooms II: A Preliminary Design Space, K. J. Vicente; DESIGN FEATURES: 549 Twenty-Second DOE/NRC Nuclear Air Cleaning and Treatment Conference, R. R. Bellamy, D. W. Moeller, and M. W. First; 562 Book Review: Safety Assessment of Unit 5 (WWER-440/W-213) of the Greifswald Nuclear Power Station, M. H. Fontana; WASTE AND SPENT FUEL MANAGEMENT: 576 Activities Related to Waste and Spent Fuel Management, M. D. Muhlheim and E. G. Silver; OPERATING EXPERIENCES: 586 Analysis of Corrective Actions Applied to Nuclear Power Plant Operations, A. E. Cross; 593 Reactor Shutdown Experience, Compiled by J. W. Cletcher; 596 Operating U.S. Power Reactors, Compiled by M. D. Muhlheim and E. G. Silver; 609 Non-Commercial Power Operating Experience; 614 World Nuclear Performance, Compiled by M. D. Muhlheim; RECENT DEVELOPMENTS: 623 General Administrative Activities, Compiled by M. D. Muhlheim and E. G. Silver; 635 Reports, Standards, and Safety Guides, D. S. Queener; 639 Proposed Rule Changes as of June 30, 1992; ANNOUNCEMENTS: 513 Fourth International Conference on Nuclear Fuel Reprocessing and Waste Management RECOD '94; 585 International Topical Meeting on Advanced Reactors Safety; 622 International Workshop on Implementation of ALARA at Nuclear Power Plants; 648 Short Course on Nuclear Criticality Safety; 648 8th Topical Meeting on Problems in Reactor Physics MEPhi-VOLGA-93; 643 The Authors; 646 Reviewers of Nuclear Safety, Vol. 33

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2008

Development and Testing of Space Fission Technology at NASA-MSFC

The Early Flight Fission Test Facility (EFF-TF) at NASA-Marshall Space Flight Center (MSFC) provides a capability to perform hardware-directed activities to support multiple inspace nuclear reactor concepts by using a non-nuclear test methodology. This includes fabrication and testing at both the module/component level and near prototypic reactor configurations allowing for realistic thermal-hydraulic evaluations of systems. The EFF-TF is currently performing non-nuclear testing of hardware to support a technology development effort related to an affordable fission surface power (AFSP) system that could be deployed on the Lunar surface. The AFSP system is presently based on a pumped liquid metal-cooled reactor design, which builds on US and Russian space reactor technology as well as extensive US and international terrestrial liquid metal reactor experience. An important aspect of the current hardware development effort is the information and insight that can be gained from experiments performed in a relevant environment using realistic materials. This testing can often deliver valuable data and insights with a confidence that is not otherwise available or attainable. While the project is currently focused on potential fission surface power for the lunar surface, many of the present advances, testing capabilities, and lessons learned can be applied to the future development of a low-cost in-space fission power system. The potential development of such systems would be useful in fulfilling the power requirements for certain electric propulsion systems (magnetoplasmadynamic thruster, high-power Hall and ion thrusters). In addition, inspace fission power could be applied towards meeting spacecraft and propulsion needs on missions further from the Sun, where the usefulness of solar power is diminished. The affordable nature of the fission surface power system that NASA may decide to develop in the future might make derived systems generally attractive for powering spacecraft and propulsion systems in space. This presentation will discuss work on space nuclear systems that has been performed at MSFC's EFF-TF over the past 10 years. Emphasis will be place on both ongoing work related to FSP and historical work related to in-space systems potentially useful for powering electric propulsion systems.

Polzin, Kurt↗

NASA NTRS2002

Progress in the Development of a Continuous Adiabatic Demagnetization Refrigerator

We report on recent progress in the development of a continuous adiabatic demagnetization refrigerator (CADR). Continuous operation avoids the constraints of long hold times and short recycle times that lead to the generally large mass of single-shot ADRs, allowing us to achieve an order of magnitude larger cooling power per unit mass. Our current design goal is 10 micro W of cooling at 50 mK using a 6-10 K heat sink. The estimated mass is less than 10 kg, including magnetic shielding of each stage. The relatively high heat rejection capability allows it to operate with a mechanical cryocooler as part of a cryogen-free, low temperature cooling system. This has the advantages of long mission life and reduced complexity and cost. We have assembled a three-stage CADR and have demonstrated continuous cooling using a superfluid helium bath as the heat sink. The temperature stability is 8 micro K rms or better over the entire cycle, and the cooling power is 2.5 micro W at 60 mK rising to 10 micro W at 100 mK.

Shirron, Peter↗

NASA NTRS1992

Low energy CMOS for space applications

The current focus of NASA's space flight programs reflects a new thrust towards smaller, less costly, and more frequent space missions, when compared to missions such as Galileo, Magellan, or Cassini. Recently, the concept of a microspacecraft was proposed. In this concept, a small, compact spacecraft that weighs tens of kilograms performs focused scientific objectives such as imaging. Similarly, a Mars Lander micro-rover project is under study that will allow miniature robots weighing less than seven kilograms to explore the Martian surface. To bring the microspacecraft and microrover ideas to fruition, one will have to leverage compact 3D multi-chip module-based multiprocessors (MCM) technologies. Low energy CMOS will become increasingly important because of the thermodynamic considerations in cooling compact 3D MCM implementations and also from considerations of the power budget for space applications. In this paper, we show how the operating voltage is related to the threshold voltage of the CMOS transistors for accomplishing a task in VLSI with minimal energy. We also derive expressions for the noise margins at the optimal operating point. We then look at a low voltage CMOS (LVCMOS) technology developed at Stanford University which improves the power consumption over conventional CMOS by a couple of orders of magnitude and consider the suitability of the technology for space applications by characterizing its SEU immunity.

Panwar, Ramesh↗

NASA NTRS2009

OP09O-OP404-9 Wide Field Camera 3 CCD Quantum Efficiency Hysteresis

The HST/Wide Field Camera (WFC) 3 UV/visible channel CCD detectors have exhibited an unanticipated quantum efficiency hysteresis (QEH) behavior. At the nominal operating temperature of -83C, the QEH feature contrast was typically 0.1-0.2% or less. The behavior was replicated using flight spare detectors. A visible light flat-field (540nm) with a several times full-well signal level can pin the detectors at both optical (600nm) and near-UV (230nm) wavelengths, suppressing the QEH behavior. We are characterizing the timescale for the detectors to become unpinned and developing a protocol for flashing the WFC3 CCDs with the instrument's internal calibration system in flight. The HST/Wide Field Camera 3 UV/visible channel CCD detectors have exhibited an unanticipated quantum efficiency hysteresis (QEH) behavior. The first observed manifestation of QEH was the presence in a small percentage of flat-field images of a bowtie-shaped contrast that spanned the width of each chip. At the nominal operating temperature of -83C, the contrast observed for this feature was typically 0.1-0.2% or less, though at warmer temperatures contrasts up to 5% (at -50C) have been observed. The bowtie morphology was replicated using flight spare detectors in tests at the GSFC Detector Characterization Laboratory by power cycling the detector while cold. Continued investigation revealed that a clearly-related global QE suppression at the approximately 5% level can be produced by cooling the detector in the dark; subsequent flat-field exposures at a constant illumination show asymptotically increasing response. This QE "pinning" can be achieved with a single high signal flat-field or a series of lower signal flats; a visible light (500-580nm) flat-field with a signal level of several hundred thousand electrons per pixel is sufficient for QE pinning at both optical (600nm) and near-UV (230nm) wavelengths. We are characterizing the timescale for the detectors to become unpinned and developing a protocol for flashing the WFC3 CCDs with the instrument's internal calibration system in flight. A preliminary estimate of the decay timescale for one detector is that a drop of 0.1-0.2% occurs over a ten day period, indicating that relatively infrequent cal lamp exposures can mitigate the behavior to extremely low levels.

Collins, Nick↗

NASA NTRSDate not supplied

Comparison of Recent Solar Minima Using SABER Data and the Thermosphere Climate Index

The solar minimum at the end of Solar Cycle (SC) 23 was surprisingly long and deep, and it is predicted that the SC 24 minimum will be similar. We present results from analysis of the two most recent solar minima in terms of their duration in time and the degree of cooling that occurs, along with comparisons to the minima of five preceding solar cycles. Measurements of infrared emissions from NO and CO2 made by the Sounding of the Atmosphere Using Broadband Emission Radiometry (SABER) instrument on the NASA Thermosphere-Ionosphere-Mesosphere Energetics and Dynamics (TIMED) satellite for nearly 19 years allow us to see the effects of solar minima in the thermosphere. These data,and products derived from them, including the Thermosphere Climate Index (TCI), provide direct, quantitative information on the state of the upper atmosphere and enable comparisons of different SCs. The TCI extends the SABER record of nitric oxide infrared emission at 5.3 ìm using a linear multiple regression fit of solar and geomagnetic indices to the daily cooling power derived from SABER NO. Thus the TCI provides a 73-year measure of solar variability in Earth’s atmosphere and permits determination of the relative contribution of solar irradiance and geomagnetic processes at solar minimum and throughout the solar cycle. Results of these calculations will be presented to compare solar minima for the six solar cycles included in the TCI time series.

thermosphere↗

DOE OSTI2022

Advanced Airfoil Cooling Schemes to Increase Efficiency in Gas Turbines for Combined Heat and Power Applications

This report describes a three-year interdisciplinary effort funded by the U.S. Department of Energy’s (DOE) Energy Efficiency and Renewable Energy/Advanced Manufacturing Office (EERE/AMO) to promote market penetration of combined heat and power (CHP) technologies. Prior studies have shown the technical potential for CHP in the United States is much larger than the current deployment of CHP systems. A large portion of the technical potential CHP market aligns with small (<20 MWe) gas turbines. CHP systems are an attractive alternative to reduce greenhouse gas (GHG) emissions. For example, CHP systems can reduce GHG emissions by 30–40% relative to a conventional boiler and power configuration. These GHG emission reductions are “avoided emissions” which means no CO 2 separation or sequestration is required. This report describes an effort to use additive manufacturing (AM) technologies and advanced airfoil cooling designs to increase the turbine inlet temperature by 100 °C for small gas turbines typically used in CHP systems. At the beginning of this effort, baseline performance data for small gas turbines was not available, and the potential benefits of cooling system improvements were not quantified in the available literature.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

An Assessment of Persistent Acoustic Monitoring of a Nuclear Reactor during Full Power Generation

Persistent low-frequency (<180 Hz) acoustic detection took place within the boundaries of Oak Ridge National Laboratory to monitor full power operations of the High Flux Isotope Reactor. Three acoustic sensors were installed at distances of 69, 101, and 914 m from the northeast corner of the cooling towers to monitor and assess four reactor power generation cycles. Features were extracted from power spectral density calculations where data were collected during reactor on and off operations. Diverse spectral features were present during full reactor power, including a 21.4 Hz fundamental frequency and ascending harmonics. Using bandpass filters, these related frequencies were isolated and summed, and the root mean square energy was calculated. The method of isolating and summing characteristic features provided a significant improvement in identifying acoustic behavior related to reactor power when the raw signals were obscured by noise.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2003

Ultrasound in space

Physiology of the human body in space has been a major concern for space-faring nations since the beginning of the space era. Ultrasound (US) is one of the most cost effective and versatile forms of medical imaging. As such, its use in characterizing microgravity-induced changes in physiology is being realized. In addition to the use of US in related ground-based studies, equipment has also been modified to fly in space. This involves alteration to handle the stresses of launch and different power and cooling requirements. Study protocols also have been altered to accommodate the microgravity environment. Ultrasound studies to date have shown a pattern of adaptation to microgravity that includes changes in cardiac chamber sizes and vertebral spacing. Ultrasound has been and will continue to be an important component in the investigation of physiological and, possibly, pathologic changes occurring in space or as a result of spaceflight.

Review, Tutorial↗

NASA NTRSDate not supplied

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel cells (air supply and thermal management), electric batteries (thermal management), evaporators and recuperators of waste-heat-to-power systems, and rocket engines. Even if the results are more generally applicable, the heat exchangers applications to which this study is more closely related are regeneratively cooled rocket nozzles and chambers, and repressurization systems for the launch vehicles. These components are often thin-walled and contain pressurized fluids, like propellants at cryogenic or elevated temperatures. Given that the environments that these propulsion components must endure are challenging, the manufacturing to meet these specifications often require long lead times due to specialty processes and unique tooling associated with the combined thin-wall integral channel and large-scale structures. Additive manufacturing (AM) offers programmatic advantages for reduction in processing time and cost in addition to various technical advantages, including the possibility to achieve enhanced hardware complexity targeted to superior performance, part consolidation, and the capability of processing of novel alloys. While AM is already being utilized for heat exchanger components in propulsion applications, almost all these AM components are made by means of Laser Powder Bed Fusion (L-PBF). L-PBF allows for fine features but is rather limited with respect to the overall size of the components that can be manufactured. Recent developments are maturing the Laser Powder Directed Energy Deposition (LP-DED) process which may be used, for example, to make integral channel thin-wall regeneratively-cooled rocket nozzles with diameters greater than 1 m. This paper highlights some integral channel heat exchanger demonstrator hardware applications of LP-DED, as well as the characterization of this process in combination with the use of the NASA HR-1 alloy. To properly utilize LP-DED for heat exchanger manufacturing, various aspects are being characterized such as geometry limitations, measurement of surface texture and geometric angled surfaces, surface enhancements for internal channels, and material evaluation. NASA HR-1 (FeNi-Cr) is a high strength hydrogen resistant superalloy developed for use in aerospace applications, such as heat exchangers. Some aspects and considerations about the design of heat exchangers are summarized together with data relevant to LP-DED manufacturing in combination with the NASA HR-1 alloy. Microchannels were successful deposited down to 2.54 mm and 1 mm wall thickness, wall angles of 30°, both with high reproducibility. It was also found that the areal surface roughness is highly dependent on the size of the powder feedstock used for deposition. The characterization of these LP-DED features is critical for fluid flow and heat transfer predictions as it can be exploited to enhance heat transfer at the cost of increased pressure drop.

Additive Manufacturing↗

NASA NTRSDate not supplied

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

additive manufacturing↗