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All sourcesNASA NTRSDOE OSTI
NASA NTRS2013

Development of Flow Boiling and Condensation Experiment on the International Space Station- Normal and Low Gravity Flow Boiling Experiment Development and Test Results

Flow boiling and condensation have been identified as two key mechanisms for heat transport that are vital for achieving weight and volume reduction as well as performance enhancement in future space systems. Since inertia driven flows are demanding on power usage, lower flows are desirable. However, in microgravity, lower flows are dominated by forces other than inertia (like the capillary force). It is of paramount interest to investigate limits of low flows beyond which the flow is inertial enough to be gravity independent. One of the objectives of the Flow Boiling and Condensation Flight Experiment sets to investigate these limits for flow boiling and condensation. A two-phase flow loop consisting of a Flow Boiling Module and two Condensation Modules has been developed to experimentally study flow boiling condensation heat transfer in the reduced gravity environment provided by the reduced gravity platform. This effort supports the development of a flow boiling and condensation facility for the International Space Station (ISS). The closed loop test facility is designed to deliver the test fluid, FC-72 to the inlet of any one of the test modules at specified thermodynamic and flow conditions. The zero-g-aircraft tests will provide subcooled and saturated flow boiling critical heat flux and flow condensation heat transfer data over wide range of flow velocities. Additionally, these tests will verify the performance of all gravity sensitive components, such as evaporator, condenser and accumulator associated with the two-phase flow loop. We will present in this paper the breadboard development and testing results which consist of detailed performance evaluation of the heater and condenser combination in reduced and normal gravity. We will also present the design of the reduced gravity aircraft rack and the results of the ground flow boiling heat transfer testing performed with the Flow Boiling Module that is designed to investigate flow boiling heat transfer and Critical Heat Flux (CHF) phenomena.

microgravity↗
NASA NTRS2016

Flow Boiling and Condensation Experiment (FBCE) for the International Space Station

An effective means to reducing the size and weight of future space vehicles is to replace present mostly single-phase thermal management systems with two-phase counterparts. By capitalizing upon both latent and sensible heat of the coolant rather than sensible heat alone, two-phase thermal management systems can yield orders of magnitude enhancement in flow boiling and condensation heat transfer coefficients. Because the understanding of the influence of microgravity on two-phase flow and heat transfer is quite limited, there is an urgent need for a new experimental microgravity facility to enable investigators to perform long-duration flow boiling and condensation experiments in pursuit of reliable databases, correlations and models. This presentation will discuss recent progress in the development of the Flow Boiling and Condensation Experiment (FBCE) for the International Space Station (ISS) in collaboration between Purdue University and NASA Glenn Research Center. Emphasis will be placed on the design of the flow boiling module and on new flow boiling data that were measured in parabolic flight, along with extensive flow visualization of interfacial features at heat fluxes up to critical heat flux (CHF). Also discussed a theoretical model that will be shown to predict CHF with high accuracy.

flow boiling↗
NASA NTRSDate not supplied

Flow Boiling and Condensation Experiment (FBCE): Latest Findings from the Summary ISS Experiments

Since 2011, researchers from Purdue University and NASA Glenn Research Center (GRC) have been collaborating to investigate the effects of gravity on several aspects of flow boiling and flow condensation. This massive research endeavor, termed the Flow Boiling and Condensation Experiment (FBCE), has culminated in development of NASA’s largest and most complex facility for investigation of two-phase fluid physics onboard the ISS. FBCE consists of two separate studies: flow boiling, using the Flow Boiling Module (FBM), and flow condensation, using the Condensation Module for Heat Transfer Measurements (CM-HT); the FBM experiments have already been completed while the condensation experiments began in 2024. This presentation will summarize mostly new results from the flow boiling experiments, with a focus on analysis of pressure drop and two-phase flow instabilities in microgravity using both experimental data and video records from the ISS experiments, as well as development of machine learning models. These new predictive tools are part of the arsenal of predictive methods developed by the Purdue-Glenn team for design of future space systems.

Microgravity↗
NASA NTRSDate not supplied

Flow Boiling and Condensation Experiment (FBCE): Summary of Findings for Flow Boiling based on Completed ISS Experiments

Since 2011, researchers from Purdue University and NASA Glenn Research Center (GRC) have been collaborating to investigate the effects of gravity on several aspects of flow boiling and flow condensation. This massive research endeavor, termed the Flow Boiling and Condensation Experiment (FBCE), has culminated in development of NASA’s largest and most complex facility for investigation of two-phase fluid physics onboard the ISS. FBCE consists of two separate studies: flow boiling, using the Flow Boiling Module (FBM), and flow condensation, using the Condensation Module for Heat Transfer Measurements (CM-HT); this presentation concerns the FBM portion of FBCE. Fitted with FBM, FBCE was launched to the ISS in August 2021 and experiments were successfully performed starting in February 2022 to amass a large microgravity-flow-boiling database supported by extensive visualization of interfacial behavior using high-speed video. Based on FBCE experiments performed previously in Earth gravity and parabolic flight, along with the new ISS data, several empirical correlations, theoretical models, and CFD models have been developed, enabling the prediction of crucial flow boiling parameters, including heat transfer coefficient and critical heat flux (CHF). These predictive tools, which will be summarized in this presentation, are expected to serve as foundation for design of future space systems involving flow boiling.

Two-phase flow and phase transition↗
NASA NTRSDate not supplied

Mini-Channel Flow Boiling in 1g and μg

Subcooled flow boiling combines complex processes governed by a strong coupling of heat and mass transfer, hydrodynamics, and liquid-vapor transitions. The gravitational body force plays an important role in these processes. By exploiting the latent heat of vaporization, subcooled flow boiling can transfer up to several orders-of-magnitude more heat compared to forced liquid flow. It is widely used in Earth-based thermal equipment to reduce the cost, size, and power required to move heat. Subcooled flow boiling is now considered a promising technology for space applications since it offers a means to control the motion of bubbles near the heated surface and thereby enhance nucleate boiling. However, a lack of data and predictive models on the role that gravity plays in these phenomena hinders the use of flow boiling in a microgravity environment. We will present results of experiments on transients in nucleate boiling that were carried out in the Flow Boiling Module (FBM) on the International Space Station (ISS). The unique ISS FBM ability is to couple large heat loads with flow visualization in testing flow boiling under strict control of experimental conditions in long-duration microgravity. Comparison of results of microgravity experiments with data obtained in a similar setup on the NASA GRC demonstrates the role of gravity in nucleate boiling. The work is supported by the NASA Flight Opportunities program (grant 80NSSC21K0501) and NSF/CASIS program (NSF CBET grants 1832260, 2126461, 2126462).

Two-phase flow and phase transition↗
NASA NTRS2023

Heat Transfer and Interfacial Flow Physics of Microgravity Flow Boiling in Single-Side-Heated Rectangular Channel with Subcooled Inlet Conditions – Experiments Onboard the International Space Station

This study is the culmination of a long-term collaborative effort between researchers from the Purdue University Boiling and Two-Phase Flow Laboratory (PU-BTPFL) and the NASA Glenn Research Center to investigate gravitational effects on flow boiling and flow condensation. The science and design concepts for this large-scale effort were initiated in 2011 and included several studies detailing various aspects of two-phase fluid physics in both Earth gravity and microgravity, culminating in construction of the large-scale experimental facility named “Flow Boiling and Condensation Experiment (FBCE)”. The experiment was launched to the International Space Station (ISS) in August 2021. Following the successful installation of FBCE, equipped with the Flow Boiling Module (FBM), onboard the ISS and completion of several safety checks, flow boiling experiments were performed for five months from February 2022 until July 2022. This resulted in a large flow boiling database covering broad ranges of operating parameters and heating configurations spanning several research objectives. This study investigates microgravity flow boiling of n-perfluorohexane with subcooled inlet in a single-side-heated rectangular channel of dimensions 114.6-mm heated length, 2.5-mm heated width, and 5.0-mm height. Key operating parameters investigated are mass velocity (199.90 – 3200.13 kg/m 2 s), inlet subcooling (0.10 – 45.76°C), and inlet pressure (113.30 – 164.29 kPa). Images and image sequences acquired via high-speed-video are presented to elucidate the interfacial flow physics. To analyze and explain the effects of various parameters in microgravity, heat transfer results are presented as flow boiling curves, streamwise profiles of wall temperature and heat transfer coefficient, and parametric trends of local and averaged heat transfer coefficient. Mass velocity and inlet subcooling significantly influenced most of the aforementioned aspects of flow boiling, whereas effects of inlet pressure were comparatively insignificant. Although the data and observed flow physics might be different, the parametric effects and trends in microgravity are similar to vertical upflow in Earth gravity. Some cases, especially low mass velocities, high heat fluxes, and large degrees of inlet subcooling, experienced temporally anomalous flow behaviors caused by two-phase flow instabilities manifesting as flow reversals and resulted in deviations in overall trends. Severe thermodynamic non-equilibrium is observed throughout the channel. Overall, FBCE’s ISS experiments were successful for subcooled inlet with single-sided heating of rectangular channel, and the collected data well established the various effects on flow boiling physics in highly controlled long-term microgravity conditions.

flow boiling↗
NASA NTRS2024

Microgravity Flow Boiling Experiments With Liquid-Vapor Mixture Inlet Onboard the International Space Station

This article is part of a series of studies culminating from the multi-objective Flow Boiling and Condensation Experiment (FBCE) onboard the International Space Station, which utilized the Flow Boiling Module (FBM) for experiments between February and July 2022. This study investigates microgravity flow boiling of n-Perfluorohexane with liquid-vapor mixture (two-phase) inlet conditions to the FBM with either one or two opposite walls heated. The FBM’s channel has a rectangular cross-sectional area of 5.0 × 2.5 mm 2 and a heated length of 114.6 mm. Key parameters of interest include mass velocity (180 – 2400 kg/m 2 s), inlet quality (-0.01 – 0.87), inlet pressure (120 – 200 kPa), and heat flux (1.8 W/cm 2 to critical heat flux), and a large database is amassed. The flow is visualized via a high-speed video camera and photographs are recorded at each heating increment to assess the periodic flow patterns within the channel and the near-wall interfacial behavior. Flow patterns are complex and mainly characterized by high- and low-density fronts alternately traversing the channel to yield high- and low-density-dominant periods of boiling. At all operating conditions, high-density fronts are faster during high-density-dominant periods. At low inlet qualities, the flow is annular near the channel inlet with a central vapor core surrounded by an annular liquid layer. Each high-density front having a high liquid fraction leaves a thin liquid layer sheared onto the heated walls. Boiling occurs within the liquid layer and a vapor layer is formed next to the heated wall. Inlet quality and mass velocity most dictate the overall flow patterns followed by heating configuration, and to a much lesser extent, heat flux and inlet pressure. Heat transfer characteristics are assessed via averaged boiling curves, streamwise profiles of wall temperature and heat transfer coefficient, and parametric curves of local and averaged heat transfer coefficients. Inlet pressure has an insignificant effect on heat transfer. At similar operating conditions, both the heating configurations yield similar trends and values of heat transfer coefficient and critical heat flux (CHF, slightly higher for single-sided) even though double-sided heating adds twice the heat to the fluid and doubly raises local quality. The heat fluxes required for both onset of nucleate boiling degradation and CHF are larger at high mass velocities and low inlet qualities. For a fixed inlet quality, high mass velocities yield higher average heat transfer coefficients at both lower and higher heat fluxes, while the nucleate boiling regime at intermediate heat fluxes is unaffected. For a fixed mass velocity, higher inlet qualities yield higher and lower average heat transfer coefficients at lower and higher heat fluxes, respectively.

Microgravity↗
NASA NTRS2023

Effects of Heating Configuration and Operating Parameters on Heat Transfer and Interfacial Physics of Microgravity Flow Boiling With Subcooled Inlet Conditions –Experiments Onboard the International Space Station

This study is part of the Flow Boiling and Condensation Experiment (FBCE), a collaborative effort between the Purdue University Boiling and Two-Phase Flow Laboratory (PU-BTPFL) and the NASA Glenn Research Center. The FBCE fitted with the Flow Boiling Module (FBM) was launched to the International Space Station (ISS) in August 2021 and experiments were successfully performed from February to July 2022 to amass a large microgravity-flow-boiling database. This study is focused on heat transfer and flow visualization of microgravity flow boiling of n-Perfluorohexane in a rectangular channel of 5.0 mm height, 2.5 mm width (heated), and 114.6 mm length, with subcooled inlet conditions. High-speed-video photography is utilized to present flow patterns and temporal interfacial behavior. Heat transfer results are presented in the form of flow boiling curves and both parametric curves and streamwise profiles of wall temperature and heat transfer coefficient. Firstly, the parametric effects of mass velocity (199.4 – 3200.0 kg/m 2 s), inlet subcooling (0.2 – 46.0°C), and inlet pressure (124.2 – 176.7 kPa), on the aforementioned aspects are assessed for double-sided heating to establish them for a microgravity environment. Of these three parameters, mass velocity and inlet subcooling mostly determine the microgravity flow boiling behavior, while inlet pressure plays an insignificant role. Flow patterns for double-sided heating are more complex than those for single-sided heating due to interaction between the two vapor layers. Vapor interaction is minimized at high subcoolings and high mass velocities due to strong condensation offered by the subcooled bulk liquid layer separating them. Despite the different flow patterns, both single- and double-sided heating generally result in similar parametric trends and local heat transfer coefficients for similar operating conditions. Flow instabilities manifest as temporal flow anomalies and temperature oscillations, and their severity increases with increasing boiling number. Secondly, the effects of heating configuration are analyzed by comparing and contrasting several aspects of single- and double-sided heating data. The heat fluxes at which onset of nucleate boiling degradation (ONBD) and critical heat flux (CHF) occur are distinctly different for single- and double-sided heating. There exists a threshold inlet subcooling demarcating the dominance of flow acceleration and condensation effects in vapor removal from the near-wall region and replenishment of fresh liquid for boiling. Above the threshold, condensation from the near-wall region is dominant and single-sided heating yields higher heat fluxes, and below it, acceleration is dominant and double-sided yields higher heat fluxes. At mass velocity in the range of 200 – 2400 kg/m 2 s, the threshold inlet subcooling lies in the approximate range of 20 – 30°C (corresponding inlet quality of roughly -0.40 – -0.20).

Microgravity↗
NASA NTRSDate not supplied

Flow Boiling & Condensation Experiment (FBCE): Flow Boiling in Earth Gravity and Onboard the International Space Station

Two phase thermal management systems that capitalize on both latent and sensible heats of the working fluid can yield orders of magnitude enhancements in flow boiling and condensation heat transfer coefficients and reduce size and weight of future space systems. Because the understanding of microgravity influences on two-phase flow and heat transfer is quite limited, there is presently an urgent need for a new experimental microgravity facility to enable investigators to perform long-duration flow boiling and condensation experiments in pursuit of reliable databases. This presentation will discuss results from the Flow Boiling and Condensation Experiment (FBCE), a collaborative effort between Purdue University and NASA Glenn Research Center. Experiments have been performed using the final system with the Flow Boiling Module (FBM) in vertical orientation in Earth gravity (Mission Sequence Tests, MST) and in microgravity onboard the International Space Station (ISS). High-speed-video flow visualization, heat transfer, and critical heat flux (CHF) results from the MST are presented for both subcooled liquid and saturated liquid-vapor inlet conditions. CHF predictions made using the Interfacial Lift-off Model are compared with a consolidated database made by compiling FBM datasets obtained in prior years for different orientations in Earth gravity and on parabolic flights. New explicit correlations for CHF and subcooled flow boiling heat transfer coefficient are developed and shown to be excellent in their predictive accuracies against consolidated experimental databases. Computations are performed for flows in microgravity and horizontal flows in Earth gravity, the results of which show a good predictive accuracy for both void fraction and wall temperature. Finally, similar preliminary results from the recent ISS experiments are presented.

Issam Mudawar↗
NASA NTRSDate not supplied

Experimental, Computational, Theoretical and Analytical Investigation of Flow Boiling in Reduced Gravity

Two-phase thermal management systems are far superior to their single-phase counterparts because of their ability to capitalize on the coolant’s both sensible and latent heats, thereby yielding orders of magnitude higher heat transfer coefficients and smaller system footprints. A vital knowledge necessary for their implementation in future space systems is performance in microgravity. Long-duration microgravity experiments are necessary to obtain reliable databases, which would then be used to build reliable predictive tools. To achieve this goal, investigators at the Purdue University Boiling and Two-Phase Flow Laboratory (PU-BTPFL) and the NASA Glenn Research Center (NASA-GRC) have been collaborating towards the development of the Flow Boiling and Condensation Experiment (FBCE) and eventual execution onboard the International Space Station (ISS). FBCE has now matured to a point where it is ready for transport to the ISS, where first tests will be conducted using the Flow Boiling Module (FBM). In preparation for the ISS tests, a series of pre-launch Mission Sequence Tests (MSTs) was performed at GRC in Earth gravity with FBM mounted in a vertical upflow orientation using n-perfluorohexane as working fluid. The pre-launch tests included variations of flow rate, surface heat flux, inlet conditions, and both single-sided and double-sided wall heating. This presentation will summarize experimental results from these tests as well as both analytic and theoretical tools for prediction of two-phase heat transfer coefficient and critical heat flux (CHF). Also discussed will be an assessment of predictive accuracy of these tools against the experimental data.

Mission Sequence tests↗
NASA NTRS2022

Flow Visualization, Heat Transfer, and Critical Heat Flux of Flow Boiling in Earth Gravity with Saturated Liquid-Vapor Mixture Inlet Conditions – In Preparation for Experiments Onboard the International Space Station

This study investigates flow boiling of n-Perfluorohexane with saturated two-phase mixture inlet in a rectangular channel of dimensions 114.6-mm heated length, 2.5-mm width, and 5 mm-height. The experiments were performed as part of the Mission Sequence Testing of the Flow Boiling and Condensation Experiment’s (FBCE) Flow Boiling Module (FBM) in the vertical upflow configuration in Earth gravity using the same experimental system that was launched to the International Space Station (ISS) in August 2021. The operating parameters varied are heating configuration (single- and double-sided), mass velocity (380 – 2400 kg/m2s), inlet quality (0.011 – 0.519), and inlet pressure (120 – 179 kPa). High-speed video photographs are presented to explain the two-phase flow patterns within the channel’s heated length. Flow patterns are constituted by low-density and high-density fronts moving along the channel, with the high-density fronts gradually reducing in length due to evaporation. Heat transfer results in terms of flow boiling curves, streamwise wall temperature profiles, streamwise heat transfer coefficient profiles, and average heat transfer coefficients are presented and trends discussed. CHF data from the present experiments are combined with prior databases to compile a consolidated FBCE-CHF database for saturated inlet to expand the ranges of operating conditions and include other flow orientations in Earth gravity. Experimental CHF trends are also discussed. The interfacial lift-off model shows a good CHF predictive accuracy evidenced by a mean absolute error of 11.97% for this consolidated database after constraining it to mass velocities greater than or equal to 500 kg/m2s. Finally, this study confirmed reliability of the upcoming ISS experiments for saturated inlet conditions and the collected Earth-gravity data will be compared to ISS microgravity data.

Flow boiling↗
NASA NTRSDate not supplied

Flow Boiling and Condensation Experiment: Flow Boiling in a Rectangular Channel with Subcooled Inlet Conditions in Microgravity

Two-phase thermal management subsystems that take advantage of both the sensible and latent heat of a working fluid can potentially yield significant enhancements in overall performance by adopting heat transfer processes that are based on phase transition like boiling and condensation. Performance of terrestrial two-phase flow systems may be predictable because the hydrodynamic and body forces are understood, however, in microgravity, which is predominant during planetary space travel, forces that are masked by the strong body force on Earth (gravitational or buoyancy force) reappear with different magnitude and influence. The need arose for a facility that provides for two-phase flow with phase transition testing in microgravity. The Flow Boiling and Condensation Experiment (FBCE) is a facility that was launched to the International Space Station in August of 2021 and is in operation since February of 2022. This facility enables investigators to perform two-phase flow and phase transition research in flow boiling and condensation. Along with the test module that is experiment specific, the FBCE system consists of the fluid, avionics, and software subsystems. Currently two test modules, namely, the Flow Boiling Module (FBM) and the Condensation Module for Heat Transfer (CM-HT) are available. A third module, the Transfer Line test Module (TL) is being developed. The fluid subsystem conditions and delivers the fluid at the desired thermodynamic state to the test module. It consists of two fluid modules and a heater module that are connected by flex hoses for fluid circulation and by data and electrical cables for control and data acquisition. Two avionics modules acquire pressure and temperature data from various sensors in the flow loop. For FBM, a high-speed camera is available to acquire images of the boiling process. Experiments are operated autonomously by software and are based on an Experiment Parameters Master Table (EPMT) that is uploaded to ISS and is executed by the FBCE flight software. This presentation briefly introduces the objectives of FBCE and provides a system description of the experiment onboard of the ISS/Fluid Integrated Rack (FIR). Results of the test campaign carried out using the FBM are presented. Specifically, microgravity flow boiling of n-perfluorohexane (test fluid) is discussed with subcooled inlet conditions in a single-side-heated rectangular channel of dimensions 114.6-mm heated length, 2.5-mm heated width, and 5.0-mm height. Key operating parameters investigated are mass velocity (199.90 – 3200.13 kg/m2s), inlet subcooling (0.10 – 45.76°C), and inlet pressure (113.30 – 164.29 kPa). Image sequences acquired via high-speed-video are shown to elucidate the interfacial flow physics. The effects of various parameters on flow boiling heat transfer in microgravity, from the onset of boiling to the critical heat flux are discussed. Heat transfer results are presented in terms of flow boiling curves, streamwise profiles of wall temperature and heat transfer coefficient, and parametric trends of local and averaged heat transfer coefficient, and the critical heat flux.

Two-phase flow and phase transition↗
NASA NTRS2019

Flow Boiling and Condensation Experiment Flight Hardware Development

The Flow Boiling and Condensation Experiment (FBCE) to be manifested on the International Space Station (ISS) consists of a fluid system and the associated electronics to provide for conditioning the test fluid (normal-PerFluorohexane or nPFH-C6F14) to the proper thermodynamic state prior to entering a test module, which can be interchangeable based on the science objectives. Two separate test modules have been manufactured for the FBCE, the Flow Boiling Module (FBM), which investigates flow boiling for a subcooled liquid, saturated liquid, or two phase mixture, and the Condensation Module Heat Transfer (CM-HT), which investigates condensation of a flowing saturated or superheated vapor. The test fluid heating is accomplished using the Bulk Heater Module (BHM), which heats the fluid to various states based on the demands of the currently installed test module. ISS Internal Thermal Control System (ITCS) water is utilized to cool the test fluid prior to entering the circulation pump, and is also utilized for cooling for condensation in CM-HT, for cooling of a camera in FBM. An adjustable pressure bellows-type accumulator is used to set the pressure at the inlet of the test section, but does not provide active pressure control during testing. The flow of the test fluid is achieved using a gear pump controlled by a coriolis flow meter, which also provides the flow rate measurement. Flow rates for the ITCS water loops are measured and controlled using coriolis flow meters with directly controlled proportional valves. During execution of FBCE operations, the FBM is scheduled to collect data for three months before being exchanged with CM-HT for another three month data collection run. In this work, we present the development of the flight hardware, the associated challenges experienced during the development such as packaging flight system hardware, and the lessons learned in overcoming the encountered challenges.

Guzik, Monica C.↗
NASA NTRSDate not supplied

Recent Ground-based Test Results for the Closed Loop Two-Phase Flow Chilldown Test Module for Future Integration with the Flow Boiling and Condensation Experiment onboard International Space Station

Effective cryogenic fluid management is important to the success of future manned and unmanned NASA missions, and the transfer line chilldown process is recognized as a key technological challenge. To address this challenge, the Two-phase Flow and Thermal Management Lab (TFTML) at Case Western Reserve University is collaborating with NASA Glenn Research Center to develop, test and deploy a closed loop two-phase flow chilldown test section onboard the International Space Station to be integrated with the current Flow Boiling and Condensation Experiment (FBCE) module. The final results of this project will create the first chilldown process database under pure and sustained microgravity conditions and will significantly advance the understanding of the chilldown process for cryogenic fluid management. In the present work, the ground-based test results of the closed loop SS-316 chilldown test section in a horizontal configuration at varying inlet mass flow rates (3-40 g/s) and inlet liquid subcooling (5-35 0C) are presented. The working fluid is PF-5060 and the chilldown curves captured the entire quenching curve involving the different boiling regimes and temperature transition points viz., film boiling, Leidenfrost/re-wetting point, transition boiling, critical heat flux (CHF), nucleate boiling, onset of nucleate boiling (ONB) and single-phase liquid flow regions, when the test section is pre-heated to around 250 0C. The major findings of the present study are, (i) the bottom part of the test section sees a lower re-wetting temperature due to the horizontal flow configuration, (ii) the re-wetting temperatures are relatively unaffected by inlet liquid mass flow rates though the increase in mass flow rates reduce the chilldown time, and (iii) the re-wetting temperatures decrease with decrease in inlet liquid subcooling. Further, preliminary flow visualization studies in a transparent pyrex test section will also be presented to understand the intricate flow boiling regime transitions during the chilldown process.

ISS↗
NASA NTRS2015

Development and Capabilities of ISS Flow Boiling and Condensation Experiment

An experimental facility to perform flow boiling and condensation experiments in long duration microgravity environment is being designed for operation on the International Space Station (ISS). This work describes the design of the subsystems of the FBCE including the Fluid subsystem modules, data acquisition, controls, and diagnostics. Subsystems and components are designed within the constraints of the ISS Fluid Integrated Rack in terms of power availability, cooling capability, mass and volume, and most importantly the safety requirements. In this work we present the results of ground-based performance testing of the FBCE subsystem modules and test module which consist of the two condensation modules and the flow boiling module. During this testing, we evaluated the pressure drop profile across different components of the fluid subsystem, heater performance, on-orbit degassing subsystem, heat loss from different modules and components, and performance of the test modules. These results will be used in the refinement of the flight system design and build-up of the FBCE which is manifested for flight in late 2017-early 2018.

microgravity↗
NASA NTRSDate not supplied

Visible and Infrared Imaging of Various Flow Regimes in the Flow Boiling and Condensation Experiment Transfer Line

The Flow Boiling and Condensation Experiment (FBCE) Transfer Line (TL) test module is being developed to study fluid physics of cryogenic transfer lines in microgravity. The TL module will reside in the FBCE facility located within the Fluids Integration Rack (FIR) aboard the International Space Station (ISS). TL will use the same normal perfluoro hexane (nPFH) used in the previous FBCE test sections. To simulate cryogenic line transfer in the visualization section, a sapphire tube coated with indium tin oxide (ITO) is heated via Joule heated while a bypass line is used to flow liquid nPFH at the desired inlet conditions. Once the visualization line reaches steady-state temperature and pressure conditions, flow is diverted through the heated line and chilldown begins. All flow regimes observed within a cryogenic TL are created and studied using visible imaging with diffuse backlighting to image inverted annular flow, transition, and nucleate boiling. A visible laser light sheet provided by FIR will provide a means to observe and track droplets in the dispersed flow regime. IR imaging of the visualization tube outer surface with the emissivity of the ITO coating provides the surface chilldown temperature profile. Preliminary imaging system development includes some of the components used in the Flow Boiling Module (FBM) and some new components that are easily integrated into the PC-based system but will require some refinement to operate properly on the FIR PCIe/104 imaging system. Optical design and packaging within the limited volume of the module enclosure is also presented. This paper presents FBCE-TL visible and infrared laboratory-based imaging studies and anticipated visualization capabilities of the TL module under preliminary breadboard development and under the utilization constraints within the FBCE/FIR host facility.

transfer line↗
NASA NTRSDate not supplied

Designing the Imaging and Breadboard System for FBCE-TL Project

This presentation outlines the support work done on designing the imaging and breadboard system of the Transfer Line (TL) project, which is the third module for the Flow Boiling and Condensation Experiment (FBCE) operating in the Fluids Integrated Rack on-board the International Space Station (ISS). The goal of the FBCE is to serve as a facility for flow boiling and condensation investigating two-phase flow and heat transfer data in microgravity. The TL module aims use existing FBCE hardware to study cryogenic chilldown, a large component of cryogenic propellant tank transfer research. The TL test module will perform chilldown studies with normal-perfluorohexane (nPFH), a cryogenic simulant, flowing through a super-heated line, which is heated through the process of Joule-heating. SolidWorks and Creo were used to create electrically conductive pipe junctions that connect and seal several Indium Tin Oxide (ITO) coated sapphire tube sections together to allow for low leak probability fluid flow and circumferentially uniform electrical current density. It is necessary to understand and calculate the thermal expansion of the tubing sections such that the junctions would not leak at anticipated operating temperatures and pressures, would maintain electrical contact, and not crack the crystalline tubes. Optical imaging techniques were used to build an experimentally validated image remapping process for flight-like setups of cylindrical tubes. Then MATLAB was used to create an algorithm that distorts an image based on the refraction of light passing through the mediums we were imaging through to accurately visualize the cryogenic chilldown that is of scientific interest. This research will assist NASA to move forward with long-duration spaceflight missions where knowledge of efficient heat transfer processes becomes more critical.

imaging system↗
NASA NTRSDate not supplied

Conceptual Design of a Test Section for a Cryogenic Transfer Line Experiment

This project presents the development of a comprehensive computer-aided design (CAD) model for the Transfer Line test section, which is an upcoming test module for the Flow Boiling and Condensation Experiment (FBCE) aboard the International Space Station. The FBCE aims to serve as the primary platform to study two-phase flow in microgravity, and the Transfer Line module aims to utilize its existing hardware to study cryogenic chilldown; a critical component of cryogenic propellant transfer in space. The CAD model was created using SolidWorks software and includes the test section’s main components: a heat transfer line, a flow visualization line, insulation, high-speed visible imaging, and infrared imaging. The heat transfer line primarily consists of a stainless steel tube that will be heated via Joule heating. The flow visualization line consists of segmented Indium-Titanium-Oxide coated sapphire tubes, which allow for visualization of flow regimes by high-speed and infrared cameras, similar thermal properties as the stainless steel tube, and Joule heating via the ITO coating resistance. Polyether Ether Ketone was used to insulate and encapsulate the two sections. High-speed visible imaging and infrared imaging were also incorporated to view the propagation of fluid during inverted annular flow and map out the thermal profile of the ITO-coated sapphire tube. This model serves as the guiding concept design for the Transfer Line project and will assist the project team during future safety reviews and concept design reviews. Overall, this work is significant in two-phase flow research and offers a promising path towards an established facility for cryogenic transfer line research in microgravity.

Flow boiling↗