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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS1993

Plasma arc welding repair of space flight hardware

Repair and refurbishment of flight and test hardware can extend the useful life of very expensive components. A technique to weld repair the main combustion chamber of space shuttle main engines has been developed. The technique uses the plasma arc welding process and active cooling to seal cracks and pinholes in the hot-gas wall of the main combustion chamber liner. The liner hot-gas wall is made of NARloyZ, a copper alloy previously thought to be unweldable using conventional arc welding processes. The process must provide extensive heat input to melt the high conductivity NARloyZ while protecting the delicate structure of the surrounding material. The higher energy density of the plasma arc process provides the necessary heat input while active water cooling protects the surrounding structure. The welding process is precisely controlled using a computerized robotic welding system.

Hoffman, David S.↗
NASA NTRS1993

Plasma arc welding repair of space flight hardware

A technique to weld repair the main combustion chamber of Space Shuttle Main Engines has been developed. The technique uses the plasma arc welding process and active cooling to seal cracks and pinholes in the hot-gas wall of the main combustion chamber liner. The liner hot-gas wall is made of NARloy-Z, a copper alloy previously thought to be unweldable using conventional arc welding processes. The process must provide extensive heat input to melt the high conductivity NARloy-Z while protecting the delicate structure of the surrounding material. The higher energy density of the plasma arc process provides the necessary heat input while active water cooling protects the surrounding structure. The welding process is precisely controlled using a computerized robotic welding system.

Hoffman, David S.↗
NASA NTRS1983

Temperature-time distribution and thermal stresses on the RTG fins and shell during water cooling

Radioisotope thermoelectric generator (RTG) packages designed for space missions generally do not require active cooling. However, the heat they generate cannot remain inside of the launch vehicle bay and requires active removal. Therefore, before the Shuttle bay door is closed, the RTG coolant tubes attached to the heat rejection fins must be filled with water, which will circulate and remove most of the heat from the cargo bay. There is concern that charging a system at initial temperature around 200 C with water at 24 C can cause unacceptable thermal stresses in the RTG shell and fins. A computer model is developed to estimate the transient temperature distribution resulting from such charging. The thermal stresses resulting from the temperature gradients do not exceed the elastic deformation limit for the material. Since the simplified mathematical model for thermal stresses tends to overestimate stresses, it is concluded that the RTG can be cooled by introducing water at 24 C to the initially hot fin coolant tubes while the RTG is in the Shuttle cargo bay.

Turner, R. H.↗
NASA NTRS1997

Biomedical Application of Aerospace Personal Cooling Systems

Personal thermoregulatory systems which are used by astronauts to alleviate thermal stress during extravehicular activity have been applied to the therapeutic management of multiple sclerosis. However, little information is available regarding the physiologic and circulatory changes produced by routine operation of these systems. The objectives of this study were to compare the effectiveness of two passive and two active cooling vests and to measure the body temperature and circulatory changes produced by each cooling vest configuration. The MicroClimate Systems and the Life Enhancement Tech(LET) lightweight liquid cooling vests, the Steele Vest and LET's Zipper Front Garment were used to cool the chest region of 10 male and female subjects (25 to 55 yr.) in this study. Calf, forearm and finger blood flows were measured using a tetrapolar impedance rheograph. The subjects, seated in an upright position at normal room temperature (approx.22C), were tested for 60 min. with the cooling system operated at its maximum cooling capacity. Blood flows were recorded continuously using a computer data acquisition system with a sampling frequency of 250 Hz. Oral, right and left ear temperatures and cooling system parameters were logged manually every 5 min. Arm, leg, chest and rectal temperatures; heart rate; respiration; and an activity index were recorded continuously on a U.F.I., Inc. Biolog ambulatory monitor. In general, the male and female subjects' oral and ear temperature responses to cooling were similar for all vest configurations tested. Oral temperatures during the recovery period were significantly (P<0.05) lower than during the control period, approx. 0.2 - 0.5C, for both men and women wearing any of the four different garments. The corresponding ear temperatures were significantly (P<0.05) decreased approx.0.2 - 0.4C by the end of the recovery period. Compared to the control period, no significant differences were found in rectal temperatures during cooling and recovery periods.

Ku, Yu-Tsuan E.↗
NASA NTRS1977

Centaur propellant thermal conditioning system

An upgraded Centaur capability was studied by investigating three main areas: (1) Analytical and experimental investigation of promising capillary pumping concepts for passive cooling of cryogenic capillary acquisition devices resulted in selection, test, and empirical correlation of four wicking configurations. Only plate/screen-screen/plate and plate/screen-plate/screen configurations would function successfully under worst-case Centaur D-1S conditions. Weight estimates were developed for the passively cooled configurations and comparisons were made of passive and actively cooled capillary devices. (2) Thermal subcoolers for replacing pressurization and boost pump systems for three engine candidates and three Centaur D-1S missions were evaluated for several feed system configurations. Analysis included both transient and steady-state operation. Weight comparisons were made among feed system alternatives. (3) Existing experimental mixing studies to destroy thermal stratification were evaluated to determine the best mixing correlation to fit all available data. The correlation was then used to modify a computer program to size thermodynamic vent systems for Shuttle-based Centaur derivatives.

Blatt, M. H.↗
NASA NTRS2001

Design, Fabrication, and Testing of an Auxiliary Cooling System for Jet Engines

This report summarizes the technical effort of the Active Cooling for Enhanced Performance (ACEP) program sponsored by NASA. It covers the design, fabrication, and integrated systems testing of a jet engine auxiliary cooling system, or turbocooler, that significantly extends the use of conventional jet fuel as a heat sink. The turbocooler is designed to provide subcooled cooling air to the engine exhaust nozzle system or engine hot section. The turbocooler consists of three primary components: (1) a high-temperature air cycle machine driven by engine compressor discharge air, (2) a fuel/ air heat exchanger that transfers energy from the hot air to the fuel and uses a coating to mitigate fuel deposits, and (3) a high-temperature fuel injection system. The details of the turbocooler component designs and results of the integrated systems testing are documented. Industry Version-Data and information deemed subject to Limited Rights restrictions are omitted from this document.

Leamy, Kevin↗
NASA NTRS1992

Computation of Turbulent Recirculating Flow in Channels, and for Impingement Cooling

Fully elliptic forms of the transport equations have been solved numerically for two flow configurations. The first is turbulent flow in a channel with transverse rectangular ribs, and the second is impingement cooling of a plane surface. Both flows are relevant to proposed designs for active cooling of hypersonic vehicles using supercritical hydrogen as the coolant. Flow downstream of an abrupt pipe expansion and of a backward-facing step were also solved with various near-wall turbulence models as benchmark problems. A simple form of periodicity boundary condition was used for the channel flow with transverse rectangular ribs. The effects of various parameters on heat transfer in channel flow with transverse ribs and in impingement cooling were investigated using the Yap modified Jones and Launder low Reynolds number k-epsilon turbulence model. For the channel flow, predictions were in adequate agreement with experiment for constant property flow, with the results for friction superior to those for heat transfer. For impingement cooling, the agreement with experiment was generally good, but the results suggest that improved modelling of the dissipation rate of turbulence kinetic energy is required in order to obtain improved heat transfer prediction, especially near the stagnation point. The k-epsilon turbulence model was used to predict the mean flow and heat transfer for constant and variable property flows. The effect of variable properties for channel flow was investigated using the same turbulence model, but comparison with experiment yielded no clear conclusions. Also, the wall function method was modified for use in the variable properties flow with a non-adiabatic surface, and an empirical model is suggested to correctly account for the behavior of the viscous sublayer with heating.

Chang, Byong Hoon↗
NASA NTRS1998

Cool Star Binaries with ALEXIS

We proposed to search for high-temperature, flare-produced Fe XXIII line emission from active cool star binary systems using the ALEXIS all-sky survey. Previous X-ray transient searches with ARIEL V and HEAO-1, and subsequent shorter duration monitoring with the GINGA and EXOSAT satellites demonstrated that active binaries can produce large (EM approximately equals 10(exp 55-56/cu cm) X-ray flares lasting several hours or longer. Hot plasma from these flares at temperatures of 10(exp 7)K or more should produce Fe XXIII line emission at lambda = 132.8 A, very near the peak response of ALEXIS telescopes 1A and 2A. Our primary goals were to estimate flare frequency for the largest flares in the active binary systems, and, if the data permitted, to derive a distribution of flare energy vs. frequency for the sample as a whole. After a long delay due to the initial problems with the ALEXIS attitude control, the heroic efforts on the part of the ALEXIS satellite team enabled us to carry out this survey. However, the combination of the higher than expected and variable background in the ALEXIS detectors, and the lower throughput of the ALEXIS telescopes resulted in no convincing detections of large flares from the active binary systems. In addition, vignetting-corrected effective exposure times from the ALEXIS aspect solution were not available prior to the end of this contract; therefore, we were unable to convert upper limits measured in ALEXIS counts to the equivalent L(sub EUV).

Stern, Robert A.↗
NASA NTRS2005

Thermal System Verification and Model Validation for NASA's Cryogenic Passively Cooled James Webb Space Telescope (JWST)

A thorough and unique thermal verification and model validation plan has been developed for NASA s James Webb Space Telescope. The JWST observatory consists of a large deployed aperture optical telescope passively cooled to below 50 Kelvin along with a suite of several instruments passively and actively cooled to below 37 Kelvin and 7 Kelvin, respectively. Passive cooling to these extremely low temperatures is made feasible by the use of a large deployed high efficiency sunshield and an orbit location a! !he L2 Lagrange p~in!. Another enabling feature is the scale or size of the observatory that allows for large radiator sizes that are compatible with the expected power dissipation of the instruments and large format Mercury Cadmium Telluride (HgCdTe) detector arrays. This passive cooling concept is simple, reliable, and mission enabling when compared to the alternatives of mechanical coolers and stored cryogens. However, these same large scale observatory features, which make passive cooling viable, also prevent the typical flight configuration fully-deployed thermal balance test that is the keystone to most space missions thermal verification plan. JWST is simply too large in its deployed configuration to be properly thermal balance tested in the facilities that currently exist. This reality, when combined with a mission thermal concept with little to no flight heritage, has necessitated the need for a unique and alternative approach to thermal system verification and model validation. This paper describes the thermal verification and model validation plan that has been developed for JWST.

Parrish, Keith↗
NASA NTRS2005

Thermal System Verification and Model Validation for NASA's Cryogenic Passively Cooled James Webb Space Telescope

A thorough and unique thermal verification and model validation plan has been developed for NASA s James Webb Space Telescope. The JWST observatory consists of a large deployed aperture optical telescope passively cooled to below 50 Kelvin along with a suite of several instruments passively and actively cooled to below 37 Kelvin and 7 Kelvin, respectively. Passive cooling to these extremely low temperatures is made feasible by the use of a large deployed high efficiency sunshield and an orbit location at the L2 Lagrange point. Another enabling feature is the scale or size of the observatory that allows for large radiator sizes that are compatible with the expected power dissipation of the instruments and large format Mercury Cadmium Telluride (HgCdTe) detector arrays. This passive cooling concept is simple, reliable, and mission enabling when compared to the alternatives of mechanical coolers and stored cryogens. However, these same large scale observatory features, which make passive cooling viable, also prevent the typical flight configuration fully-deployed thermal balance test that is the keystone to most space missions thermal verification plan. JWST is simply too large in its deployed configuration to be properly thermal balance tested in the facilities that currently exist. This reality, when combined with a mission thermal concept with little to no flight heritage, has necessitated the need for a unique and alternative approach to thermal system verification and model validation. This paper describes the thermal verification and model validation plan that has been developed for JWST. The plan relies on judicious use of cryogenic and thermal design margin, a completely independent thermal modeling cross check utilizing different analysis teams and software packages, and finally, a comprehensive set of thermal tests that occur at different levels of JWST assembly. After a brief description of the JWST mission and thermal architecture, a detailed description of the three aspects of the thermal verification and model validation plan is presented.

Cleveland, Paul E.↗
NASA NTRS2002

Demonstration of Advanced C/SiC Cooled Ramp

Under a NASA contract, SPS is evaluating its C/SiC to metal brazing technique for the development of light, composite, actively cooled panels. The program first consisted of defining a system applicable to the X-33 nozzle ramp. SPS then performed evaluation tests for tube, composite, and braze material selection, and for the adaptation of braze process parameters to the parts geometry. SPS is presently manufacturing a 250x60 millimeter squared specimen, including 10 metallic tubes, which will be cycled in the NASA/GRC-CELL-22 test bed under engine representative conditions.

Bouquet, Clement↗
NASA NTRS2010

James Webb Space Telescope Integrated Science Instrument Module Thermal Balance/Thermal Vacuum Test Configuration and Test Planning at NASA's Goddard Space Flight Center

The James Webb Space Telescope (JWST) is the next of the great observatories , scheduled to be launched in 2014. Three of the four science instruments are passively cooled to their operational temperature range of 36K to 40K, and the fourth instrument is actively cooled to its operational temperature of approximately 6K. Thermal-vacuum testing of the flight science instruments at the Integrated Science Instrument Module (ISIM) element level will take place within a newly constructed shroud cooled by gaseous helium inside Goddard Space Flight Center s (GSFC) Space Environment Simulator (SES). The test enclosure surrounding the instruments during the integrated ISIM-level thermal balance testing is complex, and is designed to simulate as closely as possible the in-flight conductive and radiative thermal environment around the ISIM. Thermal control and measurement of parasitic sources of heat leak into the test volume is critical, as the dissipation plus known parasitics in the flight ISIM is approximately 454 mW, and additional parasitics attributed to the flight enclosure itself are nearly equal to this, resulting in the energy balance of the inflight ISIM being less than 1.0 W. Sources of test-induced parasitics must be carefully controlled and measured, and the ability to thermally control the test environment is critical to enable accurate thermal balance testing and thermal model correlation. This paper describes the test configuration and plans for the ISIM-level thermal vacuum/thermal balance testing at GSFC.

Glazer, Stuart↗
NASA NTRS2012

James Webb Space Telescope Integrated Science Instrument Module Calibration and Verification of High-Accuracy Instrumentation to Measure Heat Flow in Cryogenic Testing

The James Webb Space Telescope (JWST) is an upcoming flagship observatory mission scheduled to be launched in 2018, Three of the four science instruments are passively cooled to their operational temperature range of 36K to 40K, and the fourth instrument is actively cooled to its operational temperature of approximately 6K. The requirement for multiple thermal zones results in the instruments being thermally connected to five external radiators via individual high purity aluminum heat straps. Thermal-vacuum and thermal balance testing of the flight instruments at the Integrated Science Instrument Module (ISIM) element level will take place within a newly constructed shroud cooled by gaseous helium inside Goddard Space Flight Center's (GSFC) Space Environment Simulator (SES). The flight external radiators are not available during ISIM-Ievel thermal vacuum/thermal testing, so they will be replaced in test with stable and adjustable thermal boundaries with identical physical interfaces to the flight radiators. Those boundaries are provided on specially designed test hardware which measures the heat flow within each of the five heat straps to an accuracy of less than 2 m W, which is less than 5% of the minimum predicted heat flow values. This is essential to ISIM thermal model correlation, since thermal models are more accurately correlated when temperature data is supplemented by accurate knowledge of heat flows. Devices that measure heat flow in this manner have historically been referred to as "Q-meters". Perhaps the most important feature of the design of the Q-meters is that it does not depend on the absolute accuracy of its temperature sensors, but rather on a difference in heater power, for which a table is empirically developed during a calibration campaign in a small chamber at GSFC. This paper discusses the Q-meter calibration procedure including calibration chamber modifications and accommodations, the handling of differing conditions between calibration and usage, the calibration process itself, and the results of the tests used to determine if the calibration is successful.

Comber, Brian↗
NASA NTRS2012

James Webb Space Telescope Integrated Science Instrument Module Calibration and Verification of High-Accuracy Instrumentation to Measure Heat Flow in Cryogenic Testing

The James Webb Space Telescope (JWST) is an upcoming flagship observatory mission scheduled to be launched in 2018. Three of the four science instruments are passively cooled to their operational temperature range of 36K to 40K, and the fourth instrument is actively cooled to its operational temperature of approximately 6K. The requirement for multiple thermal zoned results in the instruments being thermally connected to five external radiators via individual high purity aluminum heat straps. Thermal-vacuum and thermal balance testing of the flight instruments at the Integrated Science Instrument Module (ISIM) element level will take place within a newly constructed shroud cooled by gaseous helium inside Goddard Space Flight Center's (GSFC) Space environment Simulator (SES). The flight external radiators are not available during ISIM-level thermal vacuum/thermal testing, so they will be replaced in test with stable and adjustable thermal boundaries with identical physical interfaces to the flight radiators. Those boundaries are provided by specially designed test hardware which also measures the heat flow within each of the five heat straps to an accuracy of less than 2 mW, which is less than 5% of the minimum predicted heat flow values. Measurement of the heat loads to this accuracy is essential to ISIM thermal model correlation, since thermal models are more accurately correlated when temperature data is supplemented by accurate knowledge of heat flows. It also provides direct verification by test of several high-level thermal requirements. Devices that measure heat flow in this manner have historically been referred to a "Q-meters". Perhaps the most important feature of the design of the JWST Q-meters is that it does not depend on the absolute accuracy of its temperature sensors, but rather on knowledge of precise heater power required to maintain a constant temperature difference between sensors on two stages, for which a table is empirically developed during a calibration campaign in a small chamber at GSFC. This paper provides a brief review of Q-meter design, and discusses the Q-meter calibration procedure including calibration chamber modifications and accommodations, handling of differing conditions between calibration and usage, the calibration process itself, and the results of the tests used to determine if the calibration is successful.

Comber, Brian↗
NASA NTRS2000

Physiologic Responses Produced by Active and Passive Personal Cooling Vests

Personal thermoregulatory systems which provide chest cooling are used in the industrial and aerospace environments to alleviate thermal stress. However, little information is available regarding the physiologic and circulatory changes produced by routine operation of these systems. The objectives of this study were to document and compare the subjects' response to three cooling vests in their recommended configurations. The Life Enhancement Tech (LET) lightweight active cooling vest with cap, the MicroClimate Systems Change of Phase garment (MCS), and the Steele Vest were each used to cool the chest regions of 12 male and 8 female Healthy subjects (21 to 69 yr.) in this study. The subjects, seated in an upright position at normal room temperature (approx. 22 C), were tested for 60 min. with one of the cooling garments. The LET active garment had an initial coolant fluid inlet temperature of 60 F, and was ramped down to 50 F. Oral, right and left ear canal temperatures were logged manually every 5 min. Arm, leg, chest and rectal temperatures; heart rate; and respiration were recorded continuously on a U.F.I., Inc. Biolog ambulatory monitor. For men, all three vests had similar, significant cooling effects. Decreases in the average rectal temperature, oral temperature, and ear canal temperatures were approximately 0.2 C, 0.2 C and 0.1 C, respectively. In contrast to the men, the female subjects wearing the MCS and Steel vests had similar cooling responses in which the core temperature remained elevated and oral and ear canal temperatures did not drop. The LET active garment cooled most of the female subjects in this study; rectal, oral and ear temperature decreased about 0.2 C, 0.3 C and 0.3 C, respectively. These results show that the garment configurations tested do not elicit a similar thermal response in all subjects. A gender difference is evident. The LET active garment configuration was most effective in decreasing temperatures of the female subjects; the MCS vest was least effective. For male subjects, the three vests appear to be more nearly equivalent. The active garment system under study included a cooling cap, which may account for some of the difference in response.

Ku, Yu-Tsuan E.↗
NASA NTRS2010

Enhancements to the NASA/Goddard Space Flight Center (GSFC) Space Environment Simulator (SES) Facility to Support Cryogenic Testing of the James Webb Space Telescope (JWST) Integrated Science Instrument Module (ISIM)

NASA is the mission lead for the James Webb Space Telescope (JWST), the next of the "Great Observatories", scheduled for launch in 2014. It is directly responsible for the integration and test of the Integrated Science Instrument Module (ISIM), which includes a composite truss structure provided by NASA, and four science instruments sponsored and provided by NASA, the European Space Agency (ESA), the Canadian Space Agency (CSA), and the European Consortium (EC). Three of the four instruments are passively cooled and designed to operate at temperatures in the 36K to 40K range, and the fourth instrument is actively cooled to approximately 6K. The ISIM will undergo several performance tests at various levels of integration in the NASA Goddard Space Flight Center's (GSFC) Space Environment Simulator (SES), GSFC's largest thermal vacuum chamber. These activities range from Cryo-cycling the bare flight composite structure to thermal balance and performance testing of the full ISIM module. This paper describes the enhancements made to the SES chamber in order to support all cryogenic thermal vacuum testing of the ISIM. Upgrades discussed include: design and fabrication of a very large, removable and reconfigurable helium shroud; a new valve box permitting independent flow control of gaseous helium (GHe) to up to ten zones; and development of in-situ 3-dimensional photogrammetry capability in a cryogenic environment. Also presented will be select results from several facility tests already conducted to verify the chamber capabilities and optimize operational procedures, including the Helium Shroud -03 Configuration Acceptance Test, and the Helium Shroud -01 Configuration Chamber Certification Test.

Cleveland, Paul↗
NASA NTRS2016

James Webb Space Telescope Integrated Science Instrument Module Thermal Vacuum Thermal Balance Test Campaign at NASA's Goddard Space Flight Center

The James Webb Space Telescope is a large infrared telescope with a 6.5-meter primary mirror, designed as a successor to the Hubble Space Telescope when launched in 2018. Three of the four science instruments contained within the Integrated Science Instrument Module (ISIM) are passively cooled to their operational temperature range of 36K to 40K with radiators, and the fourth instrument is actively cooled to its operational temperature of approximately 6K. Thermal-vacuum testing of the flight science instruments at the ISIM element level has taken place in three separate highly challenging and extremely complex thermal tests within a gaseous helium-cooled shroud inside Goddard Space Flight Centers Space Environment Simulator. Special data acquisition software was developed for these tests to monitor over 1700 flight and test sensor measurements, track over 50 gradients, component rates, and temperature limits in real time against defined constraints and limitations, and guide the complex transition from ambient to final cryogenic temperatures and back. This extremely flexible system has proven highly successful in safeguarding the nearly $2B science payload during the 3.5-month-long thermal tests. Heat flow measurement instrumentation, or Q-meters, were also specially developed for these tests. These devices provide thermal boundaries o the flight hardware while measuring instrument heat loads up to 600 mW with an estimated uncertainty of 2 mW in test, enabling accurate thermal model correlation, hardware design validation, and workmanship verification. The high accuracy heat load measurements provided first evidence of a potentially serious hardware design issue that was subsequently corrected. This paper provides an overview of the ISIM-level thermal-vacuum tests and thermal objectives; explains the thermal test configuration and thermal balances; describes special measurement instrumentation and monitoring and control software; presents key test thermal results; lists problems encountered during testing and lessons learned.

JWST ISIM Thermal↗
NASA NTRS2018

The James Webb Space Telescope: Observatory Status and Preparations for Launch

The James Webb Space Telescope (JWST) is a large (6.5 meter) segmented aperture telescope equipped with near- and mid-infrared instruments (0.6-28 microns), all of which are passively cooled to approximately 40 degrees Kelvin by a 5-layer sunshield while the mid-infrared instrument is actively cooled to 7 degrees Kelvin. The JWST telescope recently completed its cryogenic test program and the sunshield has been fully integrated and deployed. JWST is currently in the final stages of the test program at the Observatory level. The current estimated JWST performance metrics will be presented, such as the image quality, pointing stability, sensitivity, and stray light backgrounds. The JWST development status and future plans will be described for the final testing, launch, and commissioning.

McElwain, Michael↗