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At least 19 records

High-temperature ceramic heat exchanger element for a solar thermal receiver

A study has been completed on the development of a high-temperature ceramic heat exchanger element to be integrated into a solar reciver producing heated air. A number of conceptual designs were developed for heat exchanger elements of differing configuration. These were evaluated with respect to thermal performance, pressure drop, structural integrity, and fabricability. The final design selection identified a finned ceramic shell as the most favorable concept. The ceramic shell is surrounded by a larger metallic shell. The flanges of the two shells are sealed to provide a leak-tight pressure vessel. The ceramic shell is fabricated by an innovative combination of slip casting the receiver walls and precision casting the heat transfer finned plates. The fins are bonded to the shell during firing. Fabrication of a one-half scale demonstrator ceramic receiver has been completed.

Strumpf, H. J.↗

High-temperature ceramic heat exchanger element for a solar thermal receiver

A study was performed by AiResearch Manufacturing Company, a division of The Garrett Corporation, on the development a high-temperature ceramic heat exchanger element to be integrated into a solar receiver producing heated air. A number of conceptual designs were developed for heat exchanger elements of differing configuration. These were evaluated with respect to thermal performance, pressure drop, structural integrity, and fabricability. The final design selection identified a finned ceramic shell as the most favorable concept. The shell is surrounded by a larger metallic shell. The flanges of the two shells are sealed to provide a leak-tight pressure vessel. The ceramic shell is to be fabricated by an innovative combination of slip casting the receiver walls and precision casting the heat transfer finned plates. The fins are bonded to the shell during firing. The unit is sized to produce 2150 F ar at 2.7 atm pressure, with a pressure drop of about 2 percent of the inlet pressure. This size is compatible with a solar collector providing a receiver input of 85 kw(th). Fabrication of a one-half scale demonstrator ceramic receiver has been completed.

Strumpf, H. J.↗

A high temperature ceramic heat exchanger element for a solar thermal receiver

The development of a high-temperature ceramic heat exchanger element to be integrated into a solar receiver producing heated air was studied. A number of conceptual designs were developed for heat exchanger elements of differing configuration. These were evaluated with respect to thermal performance, pressure drop, structural integrity, and fabricability. The final design selection identified a finned ceramic shell as the most favorable concept. The shell is surrounded by a larger metallic shell. The flanges of the two shells are sealed to provide a leak-tight pressure vessel. The ceramic shell is to be fabricated by a innovative combination of slip casting the receiver walls and precision casting the heat transfer finned plates. The fins are bonded to the shell during firing. The unit is sized to produce 2150 F air at 2.7 atm pressure, with a pressure drop of about 2 percent of the inlet pressure. This size is compatible with a solar collector providing a receiver input of 85 kw(th). Fabrication of a one-half scale demonstrator ceramic receiver was completed.

Strumpf, H. J.↗

Characteristics of heat exchange in the region of injection into a supersonic high-temperature flow

An experimental investigation of the local heat transfer coefficient distribution during gas injection into the supersonic-flow portion of a Laval nozzle is discussed. The controlling dimensionless parameters of the investigated process are presented in terms of a generalized relation for the maximum value of the heat transfer coefficient in the nozzle cross section behind the injection hole. Data on the heat transfer coefficient variation along the nozzle length as a function of gas injection rate are also presented, along with the heat transfer coefficient distribution over a cross section of the nozzle.

Bakirov, F. G.↗

A Ceramic Heat Exchanger for Solar Receivers

Design intended for high-temperature service. Proposed ceramic-tube and header heat exchangers used for solar-concentrating collector operating in 25- to 150-KW power range at temperatures between 2,000 degrees and 3,000 degrees F (1,095 degrees and 1,650 degrees C).

Robertson Jr., C.↗

Stirling Space Engine Program: Appendixes A, B, C and D - Volume 2

The objective of this program was to develop the technology necessary for operating Stirling power converters in a space environment and to demonstrate this technology in full-scale engine tests. Volume 2 of the report includes the following appendices: Appendix A: Heater Head Development (Starfish Heater Head Program, 1/10th Segment and Full-Scale Heat Pipes, and Sodium Filling and Processing); Appendix B: Component Test Power Converter (CTPC) Component Development (High-temperature Organic Materials, Heat Exchanger Fabrication, Beryllium Issues, Sodium Issues, Wear Couple Tests, Pressure Boundary Penetrations, Heating System Heaters, and Cooler Flow Test); Appendix C: Udimet Testing (Selection of the Reference Material for the Space Stirling Engine Heater Head, Udimet 720LI Creep Test Result Update, Final Summary of Space Stirling Endurance Engine Udimet 720L1 Fatigue Testing Results, Udimet 720l1 Weld Development Summary, and Udimet 720L1 Creep Test Final Results Summary), and Appendix D: CTPC Component Development Photos.

Dhar, Manmohan↗

Heat-Transfer Coefficients for a Full-Scale Pebble-Bed Heater

Large quantities of high-temperature air are needed for work with hypersonic flight problems. At temperatures above 2500 degrees Reamur, where conventional heat exchangers have exceeded their material limits, regenerative pebble-bed exchangers may be used with high-temperature refractories. The design of such a heat exchanger requires the use of reliable heat-transfer coefficients for a packed bed. Considerable data are available on the subject, but they spread over two orders of magnitude at any one Reynolds number value. The facility from which the present data were obtained is used at the Lewis Research Center (NASA) for testing air-breathing engine components. The purpose of this work was to obtain heat-transfer data during the initial operation of the bed as a guide to the design of similar equipment. The facility was designed with a conservative estimate of the heat-transfer coefficient, and is shown schematically. Temperatures throughout the packing were measured continuously so that point values of the coefficient might be obtained.

Lancashire, R. B.↗

High-Temperature, Flexible, Pressure-Assisted Brush Seal

Ceramic-fibers brush and integral spring clip block hot, engine flows. High-temperature, pressure-assisted brush seal installed in movable panel in advanced hypersonic engine. Seal prevents flow of hot engine gas from penetrating gap between movable panel and adjacent stationary panel. Potential applications include sealing gaps in variable-geometry two-dimensional turbojet exhaust nozzles or sealing control surface gaps of hypersonic vehicles. Ceramic brush seals also used as structural seals in high-temperature furnaces or advanced ceramic heat exchangers.

Steinetz, Bruce M.↗

In-Situ Heat Rejection to the Martian Atmosphere

In order to provide in-situ heat rejection to the thin Martian atmosphere, approaches relying on forced convection and buoyancy flow are conceptualized. A convective radiator concept utilizing a fan to draw local atmosphere through an expanded metal foam heat exchanger panel is developed. To provide a pumped fluid loop interface, flow tubes are embedded in the heat exchanger panel and heat is transferred from the tubes to the foam via conduction and subsequently convectively to the environment. To forgo the use of a specialized high throughput fan, a concept utilizing a buoyant chimney tower to draw atmospheric flow through a low pressure drop heat exchanger is also considered. Both concepts may best align with moderate- to high-temperature heat loads that provide a significant delta temperature relative to the ambient atmosphere temperature. While eliminating dust accumulation on radiator surfaces, some type of serviceable filtration or screening may be required to prevent accumulation of dust inside the expanded metal foam heat exchanger for both concepts.

Heat Rejection↗

Copper Alloy For High-Temperature Uses

Alloy of Cu/8Cr/4Nb (numbers indicate parts by atom percent) improved over older high-temperature copper-based alloys in that it offers enhanced high temperature strength, resistance to creep, and ductility while retaining most of thermal conductivity of pure copper; in addition, alloy does not become embrittled upon exposure to hydrogen at temperatures as high as 705 degrees C. Designed for use in presence of high heat fluxes and active cooling; for example, in heat exchangers in advanced aircraft and spacecraft engines, and other high-temperature applications in which there is need for such material. High conductivity and hardness of alloy exploited in welding electrodes and in high-voltage and high-current switches and other applications in which wear poses design problem.

Dreshfield, Robert L.↗

Computational chemistry and aeroassisted orbital transfer vehicles

An analysis of the radiative heating phenomena encountered during a typical aeroassisted orbital transfer vehicle (AOTV) trajectory was made to determine the potential impact of computational chemistry on AOTV design technology. Both equilibrium and nonequilibrium radiation mechanisms were considered. This analysis showed that computational chemistry can be used to predict (1) radiative intensity factors and spectroscopic data; (2) the excitation rates of both atoms and molecules; (3) high-temperature reaction rate constants for metathesis and charge exchange reactions; (4) particle ionization and neutralization rates and cross sections; and (5) spectral line widths.

Cooper, D. M.↗

Graphitic heat shields for solar probe missions

The feasibility of using a graphitic heat-shield system on a solar probe going to within 4 solar radii of the center of the sun is investigated. An analysis of graphite vaporization, with commonly used vaporization coefficients, indicates that the maximum mass-loss rate from a conical shield as large as 4 m in diameter can be kept low enough to avoid interference with measurements of the solar environment. In addition to the mass-loss problem, the problem of protecting the payload from the high-temperature (up to 2300 K) primary shield must be solved. An analysis of radiation exchange between concentric disks provides a technique for designing the intermediate shielding. The technique is applied to the design of a system for the Starprobe spacecraft, and it is found that a system with 10 shields and a payload surface temperature of 600 K will have a payload diameter of 2.45 m. Since this is 61% of the 4-m diameter of the primary shield, it is concluded that a graphitic heat-shield system is feasible for the Starprobe mission.

Lundell, J. H.↗

Data Base for CFD Validation

The flow behind the shock wave formed around objects which fly at hypervelocity behaves differently from that of a perfect gas. Molecules become vibrationally excited, dissociated, and ionized. The hot gas may emit or absorb radiation. When the atoms produced by dissociation reach the wall surface, chemical reactions, including recombination, may occur. The thermochemical phenomena of vibration, dissociation, ionization, surface chemical reaction, and radiation are referred to commonly as high-temperature real-gas phenomena. The phenomena cause changes in the dynamic behavior of the flow and the surface pressure and heat transfer distribution around the object. The character of a real gas is described by the internal degrees of freedom and state of constituent molecules; nitrogen and oxygen for air. The internal energy states, rotation, vibration and electronic, of the molecules are excited and, in the limit, the molecular bonds are exceeded and the gas dissociated into atomic and, possibly, ionic constituents. The process of energy transfer causing excitation, dissociation and recombination is a rate process controlled by particle collisions. Binary, two-body, collisions are sufficient to cause internal excitation, dissociation and ionization while three-body collisions are required to recombine the particles into molecular constituents. If the rates of energy transfer are fast with respect to the local fluid dynamic time scale the gas is in, or nearly in, equilibrium. If the energy transfer rates are very slow the gas can be described as frozen. In all other instances, wherein any of the energy exchange rates are comparable to the local fluid time scale, the gas will be thermally or chemically reacting and out of equilibrium. Real gas thermochemical nonequilibrium processes are important in the determination of aerodynamic heating; both convective (including wall catalytic effects) and radiative heating. To illustrate this we consider the hypervelocity flow over a bluff body typical of an atmospheric entry vehicle or an aerospace transfer vehicle (ASTV). The qualitative aspects of a hypersonic flow field over a bluff body are discussed in two parts, forebody and afterbody, with attention to which particular physical effects must be included in an analysis. This will indicate what type of numerical modeling will be adequate in each region of the flow. A bluff forebody flow field is dominated by the presence of the strong bow shock wave and the consequent heating, and chemical reaction of the gas. At high altitude hypersonic flight conditions the thermal excitation and chemical reaction of the gas occur slowly enough that a significant portion of the flow field is in a state of thermochemical nonequilibrium. A second important effect is the presence of the thick boundary layer along the forebody surface. In this region there are large thermal and chemical species gradients due to the interaction of the gas with the wall. Also at high altitudes the shock wave and the boundary layer may become so thick that they merge; in this case the entire shock layer is dominated by viscous effects.

Deiwert, George S.↗

The GA sulfur-iodine water-splitting process - A status report

The development of a sulfur-iodine thermal water splitting cycle is described. The process features a 50% thermal efficiency, plus all liquid and gas handling. Basic chemical investigations comprised the development of multitemperature and multistage sulfuric acid boost reactors, defining the phase behavior of the HI/I2/H2O/H3PO4 mixtures, and development of a decomposition process for hydrogen iodide in the liquid phase. Initial process engineering studies have led to a 47% efficiency, improvements of 2% projected, followed by coupling high-temperature solar concentrators to the splitting processes to reduce power requirements. Conceptual flowsheets developed from bench models are provided; materials investigations have concentrated on candidates which can withstand corrosive mixtures at temperatures up to 400 deg K, with Hastelloy C-276 exhibiting the best properties for containment and heat exchange to I2.

Besenbruch, G. E.↗

Rate constants for chemical reactions in high-temperature nonequilibrium air

In the nonequilibrium atmospheric chemistry regime that will be encountered by the proposed Aeroassisted Orbital Transfer Vehicle in the upper atmosphere, where air density is too low for thermal and chemical equilibrium to be maintained, the detailed high temperature air chemistry plays a critical role in defining radiative and convective heating loads. Although vibrational and electronic temperatures remain low (less than 15,000 K), rotational and translational temperatures may reach 50,000 K. Attention is presently given to the effects of multiple temperatures on the magnitudes of various chemical reaction rate constants, for the cases of both bimolecular exchange reactions and collisional excitation and dissociation reactions.

Jaffe, R. L.↗

Creep Testing of High-Temperature Cu-8 Cr-4 Nb Alloy Completed

A Cu-8 at.% Cr-4 at.% Nb (Cu-8 Cr-4 Nb) alloy is under development for high-temperature, high heatflux applications, such as actively cooled, hypersonic vehicle heat exchangers and rocket engine combustion chambers. Cu-8 Cr-4 Nb offers a superior combination of strength and conductivity. It has also shown exceptional low-cycle fatigue properties. Following preliminary testing to determine the best processing route, a more detailed testing program was initiated to determine the creep lives and creep rates of Cu-8 Cr-4 Nb alloy specimens produced by extrusion. Testing was conducted at the NASA Lewis Research Center with constant-load vacuum creep units. Considering expected operating temperatures and mission lives, we developed a test matrix to accurately determine the creep properties of Cu-8 Cr-4 Nb between 500 and 800 C. Six bars of Cu-8 Cr-4 Nb were extruded. From these bars, 54 creep samples were machined and tested. The figure on the left shows the steady-state, or second-stage, creep rates for the samples. Comparison data for NARloy-Z (Cu-3 wt % Ag-0.5 wt % Zr), the alloy currently used in combustion chamber liners, were not unavailable. Therefore the steady-state creep rates for Cu at similar temperatures are presented. As expected, in comparison to pure Cu, the creep rates for Cu-8 Cr-4 Nb are much lower. The lives of the samples are presented in the figure on the right. As shown, Cu-8 Cr-4 Nb at 800 C is comparable to NARloy-Z at 648 C. At equivalent temperatures, Cu-8 Cr-4 Nb enjoys a 20 to 50 percent advantage in stress for a given life and 1 to 3 orders of magnitude greater life at a given stress. The improved properties allow for design tradeoffs and improvements in new and existing heat exchangers such as the next generation of combustion chamber liners. Average creep rates for Cu-8 Cr-4 Nb and pure Cu are shown. Average creep lives for Cu-8 Cr- 4 Nb and NARloy-Z are also shown. Currently, two companies are interested in the commercial usage of the Cu-8 Cr-4 Nb alloy. The Rocketdyne Division of Rockwell International is conducting independent testing to analyze the properties for their projected needs in advanced rocket engine applications. Metallamics, a company based in Traverse City, Michigan, is entering into a Space Act Agreement to evaluate and test Cu-Cr-Nb alloys as materials for welding electrodes that are used in robotic welding operations. Creep rate is one of the alloy properties that determines the degree to which a welding electrode will mushroom or expand at the tip. A material with a low creep rate will resist mushrooming and give the electrode a longer life, minimizing downtime. This application holds the potential for large-scale usage of the alloy in the automotive and other industries. Success here would dramatically decrease the cost of the alloy and increase availability for aerospace applications.

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