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The development of electric aircraft poses significant gains for the environment; however, the integration of high-power systems increases the number of heat sources that need to be managed in-flight. This 30-minute session discusses the importance of robust thermal management systems and reviews new design concepts to improve overall aircraft efficiency.
The 2017 Electrical and Electronics Technical Team Roadmap [1] proposes aggressive research and development targets aimed at improving power electronics technology to enable the mass-market penetration of electric-drive vehicles. Achieving these aggressive targets will require a decrease in cost (year 2025 cost target: $2.70/kW) and an increase in power density (year 2025 power density target: 100 kW/L) as compared with current on-road technology. Replacing traditional silicon device-based components with more efficient and higher-temperature wide-bandgap (WBG) semiconductor device-based components will enable increased power density. However, meeting the power density target will also require innovative thermal management solutions to increase the heat fluxes dissipated and allow for compact electronics packaging.
Provided are embodiments for a feeder cooling tube, a system and method for performing thermal management. Embodiments include a feeder cooling tube having an inner tube arranged to define a path to flow a fluid through a length of the inner tube, wherein the fluid is provided to remove heat, and an outer tube arranged to enclose the inner tube which defines an area. Embodiments also include one or more feeder cables arranged between the inner tube and the outer tube, and a plurality of cooling struts, wherein each cooling strut of the plurality of cooling struts extends from a surface of the inner tube to a surface of the outer tube.
Solid oxide fuel cell (SOFC) is an efficient and clean electrical power generation system compared to conventional combustion based technologies with energy efficiency reaching as high as 85-90% in co-generation mode (electricity and heat). Other advantages of SOFCs are hybridization, modularity of construction, small CO 2 foot print per kWh of generated electricity and fuel flexibility. Hydrocarbons present in the gaseous fuel is utilized in SOFCs by internal or external reforming. There are two different internal reforming concepts: Direct Internal Reforming (DIR) and Indirect Internal Reforming (IIR). For DIR operation, the endothermic reforming reaction and the exothermic reaction from the oxidation reaction are operated together in the single unit eliminating the requirement for a separate fuel reformer. This configuration also simplifies the overall system design, making SOFC more attractive and efficient means of producing electrical power. The main advantage of the DIR type of operation is that the H 2 or CO consumption by the electrochemical reaction could directly promote the conversion of methane at the anode side of the fuel cell resulting in high conversion and high efficiency. The DIR operation, however, requires an anode material that has desired dual catalytic (hetero and electro) properties for reforming reaction and electrochemical reactions. The anode materials also need to remain resistant to carbon formation at the operating temperature and atmosphere with stable cell performance. Another requirement is to match the reforming reactions and electrochemical reactions to avoid local cooling or overheating, which can result in mechanical failure due to thermally induced stresses. Direct internal reforming (DIR) of hydrocarbon fuels simplifies the overall SOFC system design making it more attractive and efficient for producing electrical power. Low cost alloy anodes for distributed internal reforming of methane and other hydrocarbon fuels offer increased fuel-flexibility, reliability, and long term performance stability of solid oxide fuel cells (SOFC). The research program examined modification of the chemical compositions and microstructure of high entropy alloy (HEA) anode materials using thermochemical calculations and process simulation and modeling to achieve distributed reforming over the entire anode to eliminate hot zones. Cell fabrication and testing of the HEA anodes using button cell configuration has been performed to demonstrate the advantages of new anode over traditional Ni-YSZ anodes for distributed reforming and carbon free operation. Technical accomplishments include identification and synthesis of HEA carbon-resistant anode, demonstration of reduction in reforming rate confirmed by GC and modelling data validating effectiveness for thermal management in cell/stacks, electrochemical testing of HEA anode in single cell (HEA-GDC||YSZ||LSM-YSZ) and Characterization of pretest and posttest anode materials by TEM and SEM-EDS confirming carbon-free operation.
Probes to penetrate the thick ice shells of our solar system’s Ocean Worlds have been studied for nearly 20 years, since scientific evidence strongly suggested a subsurface ocean on the Jupiter moon called Europa. There is keen scientific interest in exploring four significant themes on such proposed missions: 1) Geodynamics, 2) Geochemistry, 3) Habitability, and 4) Life Detection. The ice shells of Ocean Worlds are predicted to be up to 40 km thick; they exhibit extreme thermal environments, with ice temperatures from 100 K to 270 K, and extreme pressure environments from vacuum to 53 MPa. Jet Propulsion Laboratory has conducted a broad-look investigation of proposed mission concepts to Europa to identify the significant technology and operational challenges of Europa ice-penetration. The thermal-mechanical system (TMS) of an ice penetration probe (IPP) designed to access the ocean of an icy moon using radioisotope thermoelectric generators for heat and power faces technological hurdles exacerbated by severe thermal and volume constraints. This study identified thermal management and control (TMC) challenges that are strongly linked to: ice penetration start-up, mobility and navigation in the ice, communications while in the ice sheet, and detecting and avoiding in-ice hazards. The major objectives of the TMC system are: 1) Absorb internal thermal energy from the IPP radioisotope power source, 2) Maintain liquid water conditions around the IPP at all times, 3) Manage and control thermal flows from probe nose to tail, and 4) Provide pressure containment for all internal probe components. This work discusses the baseline TMC system architecture and design developed to accomplish these objectives, and survive and transit the extreme ice thicknesses in pursuit of Icy/Ocean Worlds science goals. The proposed TMC system consisting of an internal pumped two-phase fluid loop “thermal bus” for thermal energy capture, variable conductance heat pipe system for passively adaptive thermal energy transport around the probe, and water jetting system for ice cutting is described and discussed. Critical testing performed to date is described.
Due to the combined increase in circuit integration and chip power dissipation, there is a rapidly growing demand for solving the thermal management issues of power microelectronics.
Single-phase cooling using microchannel heat sinks (MCHS) has become a popular approach for overcoming the thermal challenges associated with high-powered microelectronic devices. Thermal management is one of the largest barriers to higher power densities in electronics and frequently limits overall device performance. The implementation of forced convective cooling via single-phase liquid cooling in MCHS reduces the thermal resistance resulting in lower device temperatures at high-power conditions, which can decrease the package size and extend the lifespan of devices. The goal of the work described in this article was to investigate practical cooling solutions for laser diode bars. This study examined the effectiveness of a copper tungsten (CuW) microchannel heat sink paired with a dielectric coolant (FC3283) for dissipating both discrete and uniform heat fluxes up to 600 W/cm2 across a 0.25-cm2 surface area through a numerical and experimental study. CuW was chosen as the MCHS material because it is thermal expansion matched to GaAs, which is a common laser diode substrate. FC3283 serves as a dielectric coolant that is compatible with power electronics cooling. The microchannels utilized in this work were approximately $365$ $μ$ m deep and $100$ $μ$ m wide resulting in a hydraulic diameter of $160$ $μ$ m. The study investigated the cooling performance across a variety of applied power loads and flow rates to determine optimal effectiveness. The resulting thermal resistance ranged from 0.15 cm2 K/W at the highest flow rate to 0.26 cm2 K/W at the lowest flow rate. Further, the resulting thermal performance from this study demonstrates the importance of considering discrete heat sources separately from uniform heat sources and proved that the unique combination of CuW microchannels with FC3283 can be a promising cooling option toward future advancements of laser diode bars and other high-power microelectronics.
This paper presents the results obtained to date in a program to develop a high heat flux condenser for use in two-phase spacecraft thermal management loops. The objective is to obtain a several fold increase in condensation heat transfer coefficient over those which can be achieved with shear-controlled or capillary-wick condensers. The internally drained condenser relies on shaped fins to develop a capillary pressure gradient over the surface of the fins and drive the condensate toward narrow drainage grooves separating the fins. The condensate then flows through a drainage network embedded in the condenser walls. Heat transfer coefficients of up to 8 W/sq cm C were measured in steam, providing a heat transfer enhancement ratio greater than a factor of 8. In the paper the proof-of-concept experiments are described and simplified models to predict the performance of the internally drained condenser are presented.
Thermal barrier coatings applied to the heated side of engine components such as seals, combustor, and blades of a gas turbine offer a potential increase in efficiency through the use of higher gas temperatures or less cooling air or benefits arising from extended component life by reducing component metal temperatures. The considered investigation has the objective to show that while a thermal barrier coated (TBC) specimen can be brought to a fixed temperature using various fuel-air ratio (F/A) values, lower calculated stresses are associated with lower (F/A) values. This implies that control of (F/A) values (i.e., rates of heat input) during the starting transient and to a lesser extent during shutdown and operation, offers a potential method of improving TBC lifetime through thermal cycle management.
Two- and three-dimensional carbon-carbon composites with either resin-derived matrix or CVI matrix were joined to Cu-clad-Mo using active Ag-Cu braze alloys for thermal management applications. The joint microstructure and composition were examined using Field-Emission Scanning Electron Microscopy and Energy-Dispersive Spectroscopy, and the joint hardness was characterized using the Knoop microhardness testing. Observations on the infiltration of the composite with molten braze, dissolution of metal substrate, and solute segregation at the C-C surface have been discussed. The thermal response of the integrated assembly is also briefly discussed.
A computational method for predicting the two-phase transient fluid flow and heat transfer characteristics within a reservoir of the capillary-pumped-loop, intended to be used for spacecraft thermal management, has been developed. The model is based on the enthalpy formulation in an axisymmetric configuration. The reservoir operates under a constant thermodynamic pressure by allowing mass exchange between the reservoir and the outside loop. Both 1 g and 0 g environments have been considered to assess the effects of gravity on the reservoir performance. Depending on the gravity level, the power input and the reservoir orientation, three different convection modes have been identified, namely, the thermocapillary mode, the buoyancy mode, and the rapid-expansion mode (caused by interface movement). The impact of these modes on the performance of the reservoir and the associated physical phenomena have been discussed.
We report on the growth of monoclinic β- and orthorhombic κ-phase Ga2O3 thin films using liquid-injection metal-organic chemical vapor deposition on highly thermally conductive 4H-SiC substrates using gallium (III) acetylacetonate or tris(2,2,6,6-tetramethyl-3,5-heptanedionato) gallium (III). Both gallium precursors produced the β phase, while only the use of the latter led to growth of κ-Ga2O3. Regardless of the used precursor, best results for β-Ga2O3 were achieved at a growth temperature of 700 °C and O2 flows in the range of 600–800 SCCM. A relatively narrow growth window was found for κ-Ga2O3, and best results were achieved for growth temperatures of 600 °C and the O2 flow of 800 SCCM. While phase-pure β-Ga2O3 was prepared, κ-Ga2O3 showed various degrees of parasitic β phase inclusions. X-ray diffraction and transmission electron microscopy confirmed a highly textured structure of β- and κ-Ga2O3 layers resulting from the presence of multiple in-plane domain orientations. Thermal conductivities of 53 nm-thick β-Ga2O3 (2.13 + 0.29/−0.51 W/m K) and 45 nm-thick κ-Ga2O3 (1.23 + 0.22/−0.26 W/m K) were determined by transient thermoreflectance and implications for device applications were assessed. Presented results suggest great potential of heterointegration of Ga2O3 and SiC for improved thermal management and reliability of future Ga2O3-based high power devices.
Advanced carbon carbon composites were joined to copper-clad molybdenum (Cu/Mo) using four active metal brazes containing Ti (Cu ABA, Cusin-1 ABA, Ticuni, and Ticusil) for potential use in thermal management applications. The brazed joints were characterized using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS) and Knoop microhardness measurements across the joint region. Metallurgically sound C-C/Cu/Mo joints, devoid of interfacial cracks formed in all cases. The joint interfaces were preferentially enriched in Ti, with Cu ABA joints exhibiting the largest interfacial Ti concentrations. The microhardness measurements revealed hardness gradients across the joint region, with a peak hardness of 300-350 KHN in Cusin-1 ABA and Ticusil joints and 200-250 KHN in Cu ABA and Ticuni joints, respectively.
Experiments were performed aboard the NASA-JSC KC-135 aircraft to study the effect of reduced gravity on two-phase (liquid/vapor) flow and condensation. A prototype two-phase thermal management system for a large spacecraft was tested. Both visual observation and photography of the flow regimes were made. Ground test simulations of the KC-135 flight tests were conducted for comparison purposes. Two-phase pressure drops were predictable by the Heat Transfer Research Institute (HTRI) method, or the Friedel correlation.
The objective is to provide turbine-cooling technologies to meet Propulsion 21 goals related to engine fuel burn, emissions, safety, and reliability. Specifically, the GE Aviation (GEA) Advanced Turbine Cooling and Thermal Management program seeks to develop advanced cooling and flow distribution methods for HP turbines, while achieving a substantial reduction in total cooling flow and assuring acceptable turbine component safety and reliability. Enhanced cooling techniques, such as fluidic devices, controlled-vortex cooling, and directed impingement jets, offer the opportunity to incorporate both active and passive schemes. Coolant heat transfer enhancement also can be achieved from advanced designs that incorporate multi-disciplinary optimization of external film and internal cooling passage geometry.
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Development of multifunctional and thermally switchable systems to address reduced mass and components, and tailored for both structural and transient thermal applications. Active, passive, and novel combinations of the two functional approaches are being developed along two lines of research investigation: switchable systems and transient heat spreading. The approach is to build in thermal functionality to structural elements to lay the foundation for a revolution in the way high energy space systems are designed.
Phase change materials (PCMs) are attractive solutions for thermal energy storage (TES) applications by absorbing and releasing large amounts of latent heat during solid–liquid phase transitions. However, their relatively low thermal conductivity requires novel heat exchanger–based solutions to improve the power density and overall energy storage efficiency of the TES system. This work presents the design and experimental results of a finned tube heat exchanger to store collected natural thermal energy from a building envelope in a latent-based TES and to release it later for building heating/cooling applications. We experimentally evaluate the finned tube heat exchanger and evaluate the performance of TES in reducing building heating and cooling loads over 3–4 h of desired time of operation (e.g., peak load). The optimized design allows for maximum energy density by minimizing the heat exchanger volume, and the system is evaluated experimentally using commercially available heat exchanger materials and an organic PCM. Here, the experimental results reveal that the TES system is able to charge and discharge stored latent energy within 3–4 h, matching peak building electricity demand duration under an average fluid flow rate of 0.136 kg/s and temperature difference of 5.55 °C. Importantly, such optimized designs illuminate a path toward TES designs that are low-cost, scalable, and optimized for thermal energy and power availability under the desired time of operation.