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At least 145 records · Page 8

Heat transfer to throat tubes in a square-chambered rocket engine at the NASA Lewis Research Center

A gaseous H2/O2 rocket engine was constructed at the NASA-Lewis to provide a high heat flux source representative of the heat flux to the blades in the high pressure fuel turbopump (HPFTP) during startup of the space shuttle main engines. The high heat flux source was required to evaluate the durability of thermal barrier coatings being investigated for use on these blades. The heat transfer, and specifically, the heat flux to tubes located at the throat of the test rocket engine was evaluated and compared to the heat flux to the blades in the HPFTP during engine startup. Gas temperatures, pressures and heat transfer coefficients in the test rocket engine were measured. Near surface metal temperatures below thin thermal barrier coatings were also measured at various angular orientations around the throat tube to indicate the angular dependence of the heat transfer coefficients. A finite difference model for a throat tube was developed and a thermal analysis was performed using the measured gas temperatures and the derived heat transfer coefficients to predict metal temperatures in the tube. Near surface metal temperatures of an uncoated throat tube were measured at the stagnation point and showed good agreement with temperatures predicted by the thermal model. The maximum heat flux to the throat tube was calculated and compared to that predicted for the leading edge of an HPFTP blade. It is shown that the heat flux to an uncooled throat tube is slightly greater than the heat flux to an HPFTP blade during engine startup.

Nesbitt, James A.↗

The NASA, Marshall Space Flight Center drop tube user's manual

A comprehensive description of the structural and instrumentation hardware and the experimental capabilities of the 105-meter Marshall Space Flight Center Drop Tube Facility is given. This document is to serve as a guide to the investigator who wishes to perform materials processing experiments in the Drop Tube. Particular attention is given to the Tube's hardware to which an investigator must interface to perform experiments. This hardware consists of the permanent structural hardware (with such items as vacuum flanges), and the experimental hardware (with the furnaces and the sample insertion devices). Two furnaces, an electron-beam and an electromagnetic levitator, are currently used to melt metallic samples in a process environment that can range from 10(exp -6) Torr to 1 atmosphere. Details of these furnaces, the processing environment gases/vacuum, the electrical power, and data acquisition capabilities are specified to allow an investigator to design his/her experiment to maximize successful results and to reduce experimental setup time on the Tube. Various devices used to catch samples while inflicting minimum damage and to enhance turnaround time between experiments are described. Enough information is provided to allow an investigator who wishes to build his/her own furnace or sample catch devices to easily interface it to the Tube. The experimental instrumentation and data acquisition systems used to perform pre-drop and in-flight measurements of the melting and solidification process are also detailed. Typical experimental results are presented as an indicator of the type of data that is provided by the Drop Tube Facility. A summary bibliography of past Drop Tube experiments is provided, and an appendix explaining the noncontact temperature determination of free-falling drops is provided. This document is to be revised occasionally as improvements to the Facility are made and as the summary bibliography grows.

Rathz, Thomas J.↗

Heat tube device

The present invention discloses a heat tube device through which a working fluid can be circulated to transfer heat to air in a conventional air conditioning system. The heat tube device is disposable about a conventional cooling coil of the air conditioning system and includes a plurality of substantially U-shaped tubes connected to a support structure. The support structure includes members for allowing the heat tube device to be readily positioned about the cooling coil. An actuatable adjustment device is connected to the U-shaped tubes for allowing, upon actuation thereof, for the heat tubes to be simultaneously rotated relative to the cooling coil for allowing the heat transfer from the heat tube device to air in the air conditioning system to be selectively varied.

Khattar, Mukesh K.↗

Electrically heated tube investigation of cooling channel geometry effects

The results of an experimental investigation on the combined effects of cooling channel aspect ratio and curvature for rocket engines are presented. Symmetrically heated tubes with average heat fluxes up to 1.7 MW/m(exp 2) were used. The coolant was gaseous nitrogen at an inlet temperature of 280 K (500 R) and inlet pressures up to 1.0 x 10(exp 7) N/m(exp 2) (1500 psia). Two different tube geometries were tested: a straight, circular cross-section tube, and an aspect-ratio 10 cross-section tube with a 45 deg bend. The circular tube results are compared to classical models from the literature as validation of the system. The curvature effect data from the curved aspect-ratio 10 tube compare favorably to the empirical equations available in the literature for low aspect ratio tubes. This latter results suggest that thermal stratification of the coolant due to diminished curvature effect mixing may not be an issue for high aspect-ratio cooling channels.

Meyer, Michael L.↗

Implications of Depleted flux Tubes in the Jovian Magnetosphere

A rare but persistent phenomenon in the jovian magnetosphere is the occurrence of apparently depleted flux tubes, whose magnetic pressures are significantly above ambient levels. These flux tubes occur about 0.25% of the observing time in the region of the Io torus in the Galileo high resolution data. The importance of these tubes is that they can return to the inner magnetosphere the magnetic flux that has been convected radially outward with the iogenic plasma to the tail. The paucity of these tubes is consistent with the expected flux return rates if the tubes are moving inward at an average rate of about 5-10 km/s in the torus. Depleted flux tubes have yet to be observed inside of the lo orbit where the plasma beta is lower than in the hot torus. Estimates of the plasma density outside the tube from plasma wave measurements enable the average perpendicular temperature to be obtained from the magnetic field change. Extrapolating this temperature back to lo, we obtain an average ion temperature of approximately 60 eV. These values are generally consistent with earlier Voyager observations but on the low side of their range of uncertainty, and agree quite well with contemporaneous Galileo measurements where these are available.

Russell, C. T.↗

Lunar Lava Tubes - The Promise of New Orbital Data

The basaltic plains of the Moon contain lava channels on scales of tens of meters to hundreds of kilometers. Many of these channels are segmented, strongly suggesting that some portions include covered lava tubes. Lunar lava tubes are expected to provide unique environments below the harsh lunar surface, maintaining near-isothermal conditions and substantial shielding from solar and galactic radiation. A lava tube has often been suggested as natural shelter for a future human outpost. Previous searches for lunar lava tubes have been limited by a combination of image resolution and completeness of coverage. The five robotic Lunar Orbiter spacecraft combined to photograph essentially the entire lunar surface with a resolution of 60 m, and covered selected sites with resolutions as high as 2 m. The highest-resolution Apollo images, from the mapping and panoramic cameras, covered swaths totaling 16% of the lunar surface, at resolutions of approximately 5 m. The Lunar Reconnaissance Orbiter -- launched in June 2009 to a polar orbit -- carries a suite of instruments that will revolutionize lunar remote sensing, including the identification and characterization of lava tubes. The Lunar Reconnaissance Orbiter Camera (LROC) system includes a multi-spectral wide-angle camera with a resolution of 70 m, allowing a comprehensive survey of the entire lunar surface. The LROC narrow-angle camera is providing targeted images at resolutions of 0.5 - 2 m, including stereo coverage, which should allow detection of tube entrances and breakdown structures. The Lunar Orbiter Laser Altimeter is producing a global topographic map with a vertical resolution of 1 m and a horizontal resolution of 50 m. These data will be critical to understanding lava dynamics and tube emplacement.

Allen, Carlton C.↗

Recirculating 1-K-Pot for Pulse-Tube Cryostats

A paper describes a 1-K-pot that works with a commercial pulse tube cooler for astrophysics instrumentation testbeds that require temperatures <1.7 K. Pumped liquid helium-4 cryostats were commonly used to achieve this temperature. However, liquid helium-4 cryostats are being replaced with cryostats using pulse tube coolers. The closed-cycle 1K-pot system for the pulse tube cooler requires a heat exchanger on the pulse tube, a flow restriction, pump-out line, and pump system that recirculates helium-4. The heat exchanger precools and liquefies helium- 4 gas at the 2.5 to 3.5 K pulse tube cold head. This closed-cycle 1-K-pot system was designed to work with commercially available laboratory pulse tube coolers. It was built using common laboratory equipment such as stainless steel tubing and a mechanical pump. The system is self-contained and requires only common wall power to operate. The lift of 15 mW at 1.1 K and base temperature of 0.97 K are provided continuously. The system can be scaled to higher heat lifts of .30 to 50 mW if desired. Ground-based telescopes could use this innovation to improve the efficiency of existing cryo

Paine, Christopher T.↗

Thermal Design, Analysis, and Sensitivity of a Sample Tube on the Martian Surface

NASA will launch a rover to Mars in 2020 to collect and cache samples of Martian rocks and regolith for potential return to Earth on a future mission. The collected samples will be placed in tubes, hermetically sealed, and deposited on the surface of Mars for a period of up to 10 years. Preventing the deposited samples from overheating is an important consideration in order to ensure their scientific integrity. The samples are required to remain below 60 °C, however there is a goal to keep them below 40 °C. This temperature requirement is challenging, considering that the maximum surface temperature of Mars is 38 °C and the tube must be thermally controlled through only passive means. As a result, a significant effort has been made to design a tube to contain the samples and investigate innovative tube surface treatments that maintain proper sample temperatures without significant adverse effects of sample contamination. The tube uses a specialized aluminum oxide coating to prevent overheating on the Martian surface. The maximum predicted tube temperature is relatively insensitive to local thermal inertia, ground contact, and ground slope, but is very sensitive to landing site latitude and dust deposition. The maximum predicted sample temperature in the +/- 30° landing latitude range with worst case assumptions is 54 °C, but many of the potential landing sites have significantly cooler maximum predicted sample temperatures. This paper describes the thermal design, analysis, and sensitivity studies performed on the sample tubes and also discusses operational considerations.

Novak, Keith↗

Using X-Ray Computed Tomography to Catalog Rock Fragments in Apollo Drive Tube 73002

Overview: The Apollo missions collected 382 kg of rock, regolith, and core samples from six locations on the nearside of the Moon. Approximately 84% by mass of the Apollo collection remains in pristine condition within the curation facility at Johnson Space Center (i.e., never allocated, continuously stored in dry-N2 purged cabinets, exposure history restricted to Teflon, stainless steel, and Al-metal). Although most Apollo samples have been well characterized, there are several types of samples that have remained wholly or largely unstudied since their return, and/or that have been cu-rated under special conditions, e.g., frozen samples, samples stored in He-purged environment, and previously unopened drive tubes. NASA solicited proposals for the Apollo Next Generation Sample Analysis Pro-gram (ANGSA), and 9 teams were selected to study a subset of the unopened and frozen samples [1]. The first sample opened as part of the ANGSA pro-gram was drive tube 73002. This was originally a ~30 cm long, 4 cm diameter drive tube collected on a land-slide deposit near Lara Crater at the Apollo 17 landing site. It was part of a ~60 cm long double drive tube collected, and the bottom half of the tube (73001) was sealed under vacuum on the Moon [2]. Prior to opening sample 73002, the sample was imaged with a high resolution X-ray Computed Tomography (XCT) scan of the entire tube [3], which provided invaluable information during the dissection process [4]. In addition to the pre-dissection XCT scans, individual >4 mm particles were separated from the 73002 regolith during processing and scanned at high resolution by XCT. Here we pre-sent the initial lithologic classification of 134 individual >4 mm rock fragments separated from the 73002 core during the dissection process. Methodology: Drive tube 73002 was manually dissected in 0.5 cm depth intervals in three passes (Fig. 1) [4,5]. Each interval from pass 1 and 2 was sieved to <1 mm and >1 mm size fractions, and >1 mm particles were further manually subdivided into 1-2, 2-4, 4-10, and >10 mm size fractions. Pass 3 was not sieved, but >10 mm clasts were separated manually. Each 4-10 mm and >10 mm fragment was individually weighed, triply bagged in Teflon, and scanned by XCT. There are 60 rock fragments in Pass 1, 64 rock fragments in Pass 2 (from the 4-10 mm and >10 mm size fractions), and 8 rock fragments from Pass 3 (>10 mm size fraction). Each individually bagged rock fragment was scanned using the 180 kV nano-focus transmission source on the Nikon XTH 320 XCT system at NASA Johnson Space Center [6]. Scanning conditions varied considerably for individual particles, in large part be-cause of the large variation in size (0.008-19.623 g). All scans fell within the following range of scan conditions: 2.8-20.6 um voxel size; 90-155 kV voltage; 18-39 uA current; 1891-3141 projections; and 902-2000 slices. Results and Discussion: The 132 rock fragments from sample 73002 fall into the following general cat-gories: agglutinates (n = 6); basalts (13); impact melts (5); impact melt breccias (IMB; 42); regolith breccias (62); and soil breccias (4); see Figure 2 for representative examples of each lithology. Within most of these broad lithologic groups are recognizable subgroups. For example, a significant portion of regolith breccia fragments contain some agglutinate-like glass (n = 9) or are dilithologic (7) because they contain a single large clast (~50% or more by volume). Subgroups can be based on similarities to previously identified lunar lithologies, such as high-Ti basalts (9) and VLT basalts (4; Fig. 3), or based on commonly seen features within the fragments, such as poikilitic ilmenite IMB (10), ilmenite-lath IMB (12), or vesicular IMB (11) “groups”. Particles in the same “group” are not necessarily intended to be genetically related, but rather identify particles that are similar and that follow-up studies can classify in more detail [7]. Conclusion: Identification of lithologies based on XCT is a powerful tool, but a more absolute classification will sometimes require additional textural information from thin sections (e.g., glassy-matrix regolith vs. impact-melt vs. granulitic breccia) or quantitative mineral compositions (e.g., basalt vs. monomict breccia).

R A Zeigler↗

Numerical study of heat transfer enhancement in laminar and turbulent flow in enhanced tubes with uniform and non-uniform thermal boundary conditions

Various types of tube enhancements have been proposed in order to increase heat transfer while minimizing any associated increases in pressure drop. This paper presents a numerical study of two different types of enhanced tubes: the relatively common twisted tape insert tube, and a novel tube with airfoil shaped pins on the inner surface. Each tube is studied in both the laminar and turbulent flow regime. In addition to the typical constant temperature and constant flux boundary conditions, a non-constant heat flux boundary condition is applied on one half of the tube, a situation which may be encountered when absorbing solar radiation. In general, each type of enhanced tube offers a thermal performance factor greater than unity at certain Re. In addition, the non-uniform heat flux boundary condition appears to function similarly as the uniform heat flux boundary condition.

Sandlin, Matthew J.↗

Numerical study of heat transfer enhancement in laminar and turbulent flow in enhanced tubes with uniform and non-uniform thermal boundary conditions

Various types of tube enhancements have been proposed in order to increase heat transfer while minimizing any associated increases in pressure drop. This paper presents a numerical study of two different types of enhanced tubes: the relatively common twisted tape insert tube, and a novel tube with airfoil shaped pins on the inner surface. Each tube is studied in both the laminar and turbulent flow regime. In addition to the typical constant temperature and constant flux boundary conditions, a non-constant heat flux boundary condition is applied on one half of the tube, a situation which may be encountered when absorbing solar radiation. In general, each type of enhanced tube offers a thermal performance factor greater than unity at certain Re. In addition, the non-uniform heat flux boundary condition appears to function similarly as the uniform heat flux boundary condition.

Sandlin, M↗

Investigating microstructural evolution in SolidStir™ extruded oxide dispersion strengthened 14YWT alloy fuel cladding tube

Structural components for extreme environments require advanced materials and manufacturing processes. One such advanced material is oxide dispersion strengthened (ODS) Fe–14 wt.%Cr–3W–0.4Ti–0.3Y 2 O 3 (14YWT), which is developed for components to be used in Gen IV and fusion nuclear reactors. However, the conventional manufacturing processes to produce components, such as fuel cladding tubes, either do not retain the desired microstructural attributes or are costly and less efficient. As a result, a more attractive option is a novel manufacturing process developed on the principle of friction stir welding or processing (FSW/P) and commercially referred to as SolidStir™ Extrusion (SSE). Here this study used the SSE technique to study the manufacturing and microstructural evolution of a fuel cladding tube made of ODS 14YWT alloy. The cladding extrusion by the SSE technique involved the use of ball-milled 14YWT powders with Y, Ti, and O in the solid solution and the use of a specially designed W-25Re-Hf tool for consolidation and extrusion of the powders. A scanning electron microscope (SEM), electron backscattered diffraction (EBSD), and transmission electron microscope (TEM) were utilized for microstructural characterization. A Keyence microscope captured macrostructural photographs of the extruded tube. EBSD examination of the extruded tube on both transverse and longitudinal cross-sections showed the presence of dynamically recrystallized grains and revealed that the average grain size of the transverse cross-section was smaller than that of the longitudinal cross-section. The texture was weak and consisted of some amount of shear texture. The presence of nano-oxide clusters or precipitates of Y, Ti, and O (pyrochlores) in the extruded tube was determined by TEM. Aging heat treatment caused the average precipitate size to decrease and the density to increase compared to the as-processed condition. The results indicated that SSE is a viable tool for manufacturing fuel cladding tubes with the desired microstructural attributes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

An Experimental Investigation of Flow Across Tube Banks

Flow across tube banks was investigated by surveys of total dynamic and static pressure by visualization of the flow through the use of titanium tetrachloride smoke, by thermocouple surveys of heated tubes, and by hot-wire surveys of both heated and unheated tubes. It was found that turbulence increased as the depth of the bank increased and that the broad wake behind each tube affected flow over the succeeding tubes.

AIR FLOW, TURBULENT-MEASUREMENT, HOT-WIRE↗

Anisotropic thermal diffusivity and conductivity in SiC/SiC tubes studied by infrared imaging and X-ray computed tomography

Traditional flash diffusivity evaluation of thermal diffusivity/conductivity of composite tubes require machining of specimens. For a thin-wall tube, this method can only be used to obtain through-thickness transport property. A novel method to evaluate anisotropic thermal diffusivity in a composite tube has been developed. Braided SiC/SiC composite tubes were subjected to a xenon flash heating pulse. A high-speed, high-sensitivity infrared camera was used to measure surface temperature changes as a function of time and nondestructively detect subsurface defects/damages, such as macroscopic pores. Standard reference material (Pyroceram 9606) and curved SiC/SiC composite tube specimens were used to validate thermal diffusivity obtained from infrared imaging. Unlike the traditional method, there is no need prepare special specimens, and thermal diffusivity values in three orientations are obtained after a single flash. A finite element analysis model based on x-ray computed tomography scans was developed to simulate the heat transfer. In conclusion, this technique is significant in assessing thermal conductivity and inspecting the health of ceramic tubes during and after service.

36 MATERIALS SCIENCE↗

Fabrication of thin-walled tubes from alloy 602 CA using shear assisted processing and extrusion

Thin-walled tube is usually produced seamlessly via an expensive multi-step process or via welding of thin sheets but at reduced performance. To overcome the current process and performance inefficiencies, advanced manufacturing methods need to be investigated. In this investigation, shear assisted processing and extrusion (ShAPE) was used to fabricate thin-walled Inconel 602 tube in a single-step. Tubes measuring 0.83 m length with a 12 mm outer diameter and 1 mm wall thickness were fabricated with an average surface roughness, Ra of 1.6 µm and Rz of 15 µm. Tensile testing of tubes in the as-fabricated condition showed strength increases of 4-35% over current offerings while maintaining or improving elongation. Electron microscopy analysis revealed the recrystallized microstructure with refined inter- and intra-granular carbides. Preliminary results obtained in this investigation shows the feasibility of producing thin-wall high temperature tube in single-step via ShAPE. This achievement marks a significant step towards manufacturing larger diameter nickel alloy tubes for the U.S. Department of Energy’s Waste Treatment and Immobilization Plant.

36 MATERIALS SCIENCE↗

Surface roughness and dimensional evaluation of laser powder bed fusion additively manufactured shell and tube heat exchangers

The growing interest in additively manufactured (AM) heat exchangers drove the need to understand how this construction technique impacts heat exchanger performance. Two primary factors driven by AM that influence heat exchanger performance are surface roughness and geometry. To better understand these parameters, a range of shell and tube heat exchangers constructed using laser powder bed fusion were evaluated. Of those evaluated, the surface roughness throughout a fourteen-tube, zero-baffle heat exchanger was measured using computed tomography. Between the inner and outer tubes, the inner tube surfaces had a greater surface roughness than the outer by 8.07 μm, while the surfaces at the top of the build volume had higher surface roughness values than the bottom. Dimensionally, the inner tube diameters of this heat exchanger were 0.15% different from the design value, while the outer diameters were within a 0.84 % difference. Manual measurements across seven other heat exchangers yielded a maximum 1.15% difference between the design and measured diameters. Across the build volume for all heat exchangers studied, the tube diameters at the top were larger than at the bottom by a maximum of 1.24% difference. Inconsistent melting throughout the individual parts and the build volume, as well as particle splatter and thermal gradient variation were attributed to the surface roughness and dimensional changes seen. These results strengthen the knowledge of dimensional and surface roughness considerations when designing AM heat exchangers.

36 MATERIALS SCIENCE↗

Shear assisted processing and extrusion of enhanced strength aluminum alloy tubing

Hollow extrusions are used in many industries to make strong, lightweight, and affordable structures. Shear Assisted Processing and Extrusion (ShAPE) enables the extrusion of many alloys, often with noteworthy properties. In this investigation, ShAPE was used to extrude 1 and 2 mm wall tubes of aluminum alloy 6063 measuring 12 mm in diameter at extrusion speeds up to 3.8 m/min. This speed is 10 and 15 times faster than has been reported for any alloy using ShAPE and friction stir back extrusion, respectively. Increasing the extrusion speed from 0.7 to 3.8 m/s resulted in using 68% less process energy at steady state. Microstructural analysis and tensile testing were performed on as-extruded tubes and tubes with a direct T5 heat treatment. Grain refinement from 65 µm to below 20 µm was observed. Growth of macroscale Mg 2 Si strengthening precipitates was not observed. ShAPE processing resulted in recrystallization, and extrusion speed was shown to influence final extrudate texture. Here, transmission electron microscopy analysis revealed that the as-extruded microstructure was free of nanoscale ß" strengthening precipitates. Nanoscale ß" was prominent in direct-aged (T5) ShAPE tubes, similar to a slightly over-aged conventional T6 microstructure. As-extruded tubes had ultimate tensile strengths on par with conventional T5 extrusions and approximately double the total elongation. Tubes that underwent a T5 heat treatment had yield and ultimate strengths averaging 198 and 234 MPa, respectively, with an average total elongation of 11%. The tensile test results are comparable to a conventional T6 heat treatment, but without the solutionization heat treatment step. Mechanical properties either remained flat or improved with increased extrusion speed, which suggests that ShAPE can be scaled up to an industrial process to create energy- and economically efficient high-strength extrusions.

36 MATERIALS SCIENCE↗

Manufacture aluminum alloy tube from powder with a single-step extrusion via ShAPE

Mechanical performance of aluminum in terms of strength, wear and corrosion resistance, especially high-temperature strength has been shown to improve with the addition of transition metal (TM) elements of Fe, Cr, and Ti. However, these feedstock materials occur as powders. As such, the traditional fabrication process is complex and expensive because it requires multiple procedures and consumes considerable energy. This study developed Shear Assisted Processing and Extrusion (ShAPE) as a single-step process that manufactures tubes directly from Al-TM powders obtained via gas atomization. Meter-long Al-TM alloy tubes are extruded from powders with different processing conditions. The ShAPE tubes have very low porosity and the average density is 2.94 kg/cm 3 , which is equal to or higher than parts fabricated by hot extrusion and sintering. The powder-to-tube fabrication process was revealed and discussed by examining the microstructural evolution. The Vickers hardness of ShAPE tubes ranges from 110 to 140 HV through wall thickness and at different extrusion speeds. The variation in hardness was correlated with the extent of refinement of intermetallics and attributed to the shear deformation per unit extrusion length. Energy cost analysis shows that ShAPE save ~60% energy compared to the conventional sintering and extrusion processes. Results indicate ShAPE is a low-cost, high-efficiency manufacturing process for producing tubes from metallic powders.

36 MATERIALS SCIENCE↗