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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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DOE OSTI2024

Design and Manufacturing of High Performance, Reduced Charge Heat Exchangers

Air-to-fluid heat exchangers (HXs) play a critical role as the main heat transfer component in Heating, Ventilation, Air-Conditioning, and Refrigeration (HVAC&R) systems. However, their airside thermal resistance significantly inhibits their overall performance. Furthermore, these HXs must be continually more compact to meet the latest refrigerant charge limits to reduce emissions. Recent literature suggests that traditional HX geometries (e.g., round or flat tubes with fins), have reached their limits, and more sophisticated shape- and topology-optimized designs are required to achieve the next jump in performance. This research sheds light on the next generation of air-to-refrigerant HXs and aims to address several practical issues to commercialization such as novelty challenges (improved performance for significant charge reduction; modeling expertise & time investment), manufacturing challenges (non-round tube manufacturing; tube-header integration; product qualification, e.g., burst pressure testing, extreme operational environment, etc.), and operational challenges (flow maldistribution, fouling & wetting, noise & vibration). For example, a >20% improvement on one (or more) HX-level performance metrics (e.g., envelope volume, airside pressure drop, face area, capacity, refrigerant charge, weight, cost, etc.) must be achieved before a HX design is considered for commercialization. We present a new, comprehensive and experimentally validated air-to-refrigerant HX optimization framework with simultaneous thermal-hydraulic performance and mechanical strength considerations for novel, non-round, shape- and topology-optimized tubes capable of optimizing single and two-phase HX designs for any refrigerant choice and performance requirement with significant engineering time savings compared to conventional design practices. The framework was exercised for a wide range of applications and refrigerants, resulting in HXs which achieved greater than 20% improved performance, 20% reductions in size, and 25% reductions in refrigerant charge. To enable non-round tube bundle use in next generation HVAC&R equipment, novel manufacturing techniques were investigated, including the development of conventional manufacturing methods for small diameter, non-round tubes and novel tube-header integration strategies. In total, ten HX prototypes were manufactured, nine using conventional methods directly attributed to this project and one using advanced additive manufacturing methods. The five-year manufacturing feasibility of the proposed HXs was found to have a good outlook. The non-round tube HX simulated performance was validated through comprehensive experimental testing, including nine in-house component-level tests, one independent component-level test at an industry partner laboratory, and in-house system-level tests of using a commercially-available, residential packaged A/C unit which was retrofitted with a non-round tube prototype HX. It was found that HX designs proposed by the new framework can successfully predict experimental thermal-hydraulic performance within ±10-20% the first time with no manual design changes, eliminating the need for time-consuming and expensive prototyping efforts. This work will accelerate design and time to market for next generation HXs while simultaneously facilitating industry transition to new refrigerants at lower charge.

42 ENGINEERING↗
NASA NTRS2014

An Evaluation of a Passively Cooled Cylindrical Spectrometer Array in Lunar Orbit

This thesis will evaluate a passively cooled cylindrical spectrometer array in lunar orbit characterizing the thermal response in order to provide context for decision-making to scientists and engineers. To provide perspective on thermal issues and controls of space science instruments, a background search of historical lunar missions is provided. Next, a trial science mission is designed and analyzed which brings together the elements of the background search, lunar orbit environment and passive cooling. Finally, the trial science mission analysis results are provided along with the conclusions drawn. Scintillators are materials that when struck by particle radiation, absorb the particle energy which is then reemitted as light in or near the visible range. Nuclear astrophysics utilizes scintillating materials for observation of high-energy photons which are generated by sources such as solar flares, supernovae and neutron stars. SPMs are paired with inorganic scintillators to detect the light emitted which is converted into electronic signals. The signals are captured and analyzed in order to map the number and location of the high-energy sources. The SPM is utilized as it has single photon sensitivity, low voltage requirements and a fast response. SPMs are also compact, relatively inexpensive and allow the usage of lower-cost scintillating materials within the spectrometer. These characteristics permit large-area arrays while lowering cost and power requirements. The ability of a spectrometer to record and identify the interaction of high-energy photons for scientific return is not a trivial matter. Background noise is generated when particles that have not originated from the desired distant source impact the spectrometer. Additionally, thermally induced electrical signals are randomly generated within the SPM even in the absence of light which is referred to as dark current. Overcoming these obstacles requires greater light emittance and energy resolution with reduced dark current. Strong scintillation photon emittance ensures that low energy impacts will produce enough visible photons to be detected by the SPM. Higher energy resolution will ensure that single photon impacts can be distinguished from others of similar wavelength and energy; reduced dark current decreases the generation of random signals not associated with a photon impact. Increasing efficiency in each of these properties in a spectrometer comprised of inorganic scintillators and SPMs requires low temperatures. Low temperature maintenance in a lunar environment presents many unique challenges of its own. Even with the accumulated successes of past missions, the lunar environment remains a thermal challenge for engineers. The lunar orbit thermal environment is driven by radiation from three sources, direct solar radiation, reflected solar radiation from the lunar surface (albedo) and lunar radiation (Clawson 2002). Direct solar radiation values are consistent with those seen in Earth orbit (1325 W/m2) (Clawson 2002). The percentage of solar radiation reflected from the moon is consistently very low with the moon's dark regolith covered surface absorbing nearly 90% of the incident light (Clawson 2002). Yet, it is this absorption that gives the lunar orbit environment one of its most difficult thermal attributes as the absorbed solar radiation is released from the lunar surface as infrared radiation (IR). IR is of a wavelength that is readily absorbed by surfaces designed to function as radiation emitters. It is practical to therefore "choose radiator locations and spacecraft attitude to minimize radiator views to the lunar surface, when possible...pointing the radiator towards the sun to some extent, to minimize its view to the lunar surface, is frequently preferable. (Clawson 2002)" Additionally, the amount of direct solar radiation, lunar IR and albedo an orbiting satellite receives varies from one side of the moon to the other as the moon blocks the sun from view. This environment produces large temperature variations in a satellite's instrumentation, control electronics and propulsion systems which must be understood to characterize operating temperature envelopes.

Waggoner, Jason↗
NASA NTRS1991

Laboratory studies of the newly discovered infrared band at 4705.2 cm-1 (2.1253 micrometers) in the spectrum of Io: the tentative identification of CO2

We discuss over 120 laboratory experiments pertaining to the identification of the new absorption band discovered by Trafton et al. (1991) at 4705.2 cm-1 (2.1253 micrometers) in the spectrum of Io. It is shown that this band is not due to overtones or combinations of the fundamental bands associated with the molecules (or their chemical complexes) already identified on Io, namely, SO2, H2S, and H2O. Thus, this band is due to a new, previously unidentified, component of Io. Experiments also demonstrate that the band is not due to molecular H2 frozen in SO2 frosts. Since the frequency of this band is very close to the first overtone of the nu 3 asymmetric stretching mode of CO2, we have investigated the spectral behavior of CO2 under a variety of conditions appropriate for Io. The profile of the Io band is not consistent with the rotational envelope expected for single, freely rotating, gaseous CO2 under Io-like conditions. It was found that pure, solid CO2 and CO2 intimately mixed in a matrix of solid SO2 and H2S produce bands with similar widths (5-10 cm-1), but that these bands consistently fall at frequencies about 10-20 cm-1 (approximately 0.007 micrometer) lower than the Io band. CO2 in SO2 : H2S ices also produces several additional bands that are not in the Io spectra. The spectral fit improves, however, as the CO2 concentration in SO2 increases, suggesting that CO2-CO2 interactions might be involved. A series of Ar : CO2 and Kr : CO2 matrix isolation experiments, as well as laboratory work done elsewhere, show that CO2 clustering shifts the band position to higher frequencies and provides a better fit to the Io band. Various laboratory experiments have shown that gaseous CO2 molecules have a propensity to cluster between 80 and 100 K, temperatures similar to those found on the colder regions of Io. We thus tentatively identify the newly discovered Io band at 4705.2 cm-1 (2.1253 micrometers) with CO2 multimers or "clusters" on Io. Whether these clusters are buried within an SO2 frost, reside on the surface, or are in a residual, steady-state "atmospheric aerosol" population over local coldtraps is not entirely clear, although we presently favor the latter possibility. The size of these clusters is not well defined, but evidence suggests groups of more than four molecules are required. The absorption strength of the 2 nu 3 CO2 cluster overtone determined in the laboratory, in conjunction with the observed strength of the Io band, suggests that the disk-integrated abundance of CO2 is less than 1% that of the SO2. Studies of the sublimation behavior of CO2 indicate that it probably resides predominantly in the cooler areas (< 100 K) of Io. The relative constancy of the Io feature over a variety of orbital phases suggests that the polar regions may contain much of the material. Some consequences of the physical properties of CO2 under conditions pertinent to Io are discussed. The presence of CO2 clusters on Io could be verified by the detection of any one of several other infrared bands associated with the CO2 molecule, of which the strongest are the nu 3 12CO2 asymmetric stretch fundamental near 2350 cm-1 (4.25 micrometers) and the nu 2 bending mode fundamental near 660 cm-1 (15.1 micrometers). Weaker bands that may also be detectable include the nu 3 13CO2 asymmetric stretch fundamental near 2280 cm-1 (4.39 micrometers), the 2 nu 2 + nu 3 combination/overtone band near 3600 cm-1 (2.78 micrometers), and the nu 1 + nu 3 combination band near 3705 cm-1 (2.70 micrometers).

NASA Center ARC↗