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Development in the design of leading heat pipes for the space shuttle are reported. The analysis, design, and integration of the heat pipes into the module structure are described along with the recommended tests. Results indicate the design goals were meet.
The construction of two test modules is presented for a feasibility demonstration of a concept for reusable space shuttle wing leading edge surfaces. In this leading edge concept high temperature heat pipes were incorporated into the structure to cool the stagnation region, allowing the use of super-alloys in place of refractory metal, ablator protected, or carbon-carbon structures. The program included the analysis and design of the heat pipes, their integration into the test module structure, heat pipe development testing, construction of the test modules and a facility adapter, and formulation of recommended testing conditions. The results of the heat pipe and leading edge module thermal analyses indicate the test modules will meet the design goal; reducing the leading edge temperature at the stagnation line from 1315 C (2400 F) to less than 1010 C (1850 F). The development tests demonstrated that the module assembly could be brazed with active heat pipes, as was borne out by the subsequent successful brazing of both modules with active heat pipes loaded with sodium.
Heat pipes can be used to effectively cool wing leading edges of hypersonic vehicles. . Heat-pipe leading edge development. Design validation heat pipe testing confirmed design. Three heat pipes embedded and tested in C/C. Single J-tube heat pipe fabricated and testing initiated. HPCLE work is currently underway at several locations.
A one-half scale heat-pipe-cooled leading edge model was designed and fabricated to verify feasibility and performance of a full-scale Phase B shuttle orbiter design. Model performance was investigated experimentally by radiant heating and aerothermal tests and analytically by using a simple technique which predicts heat pipe start-up from the frozen state and also predicts transient and steady-state thermal behavior. Analytical results agree well with experimental results for start-up and steady-state heat pipe operation. The results indicate that variations in angle of attack and roll orientation had a negligible effect on heat pipe performance. The heat pipes effectively isothermalized the leading edge, and reduced peak temperatures to levels compatible with the use temperatures of superalloys. Results of these tests demonstrated the durability of the heat-pipe-cooled leading edge in withstanding earth-entry thermal and mechanical loads and indicate that the use of heat pipes in leading edge structures is a reliable concept for fully reusable hypersonic cruise and space transportation systems.
A set of closed form equations for the preliminary evaluation and design of a heat-pipe-cooled leading edge is presented. The set of equations can provide a leading-edge designer with a quick evaluation of the feasibility of using heat-pipe cooling. The heat pipes can be embedded in a metallic or composite structure. The maximum heat flux, total integrated heat load, and thermal properties of the structure and heat-pipe container are required input. The heat-pipe operating temperature, maximum surface temperature, heat-pipe length, and heat pipe-spacing can be estimated. Results using the design equations compared well with those from a 3-D finite element analysis for both a large and small radius leading edge.
A theoretical study of the use of heat pipe structures for cooling the leading edges of hypersonic cruise aircraft was carried out over a Mach number range of 6 to 12. Preliminary design studies showed that a heat pipe cooling structure with a 33-in. chordwise length could maintain the maximum temperature of a 65 deg sweepback wing with a 0.5-in. leading edge radius below 1600 F during cruise at Mach 8. A few relatively minor changes in the steady-state design of the structure were found necessary to insure satisfactory cooling during the climb to cruise speed and altitude. It was concluded that heat pipe cooling is an attractive, feasible technique for limiting leading edge temperatures of hypersonic cruise aircraft.
Wing leading edge heat pipes were conceptually designed for three types of vehicle: an entry research vehicle, aero-space plane, and advanced shuttle. A full scale, internally instrumented sodium/Hastelloy X heat pipe was successfully designed and fabricated for the advanced shuttle application. The 69.4 inch long heat pipe reduces peak leading edge temperatures from 3500 F to 1800 F. It is internally instrumented with thermocouples and pressure transducers to measure sodium vapor qualities. Large thermal gradients and consequently large thermal stresses, which have the potential of limiting heat pipe life, were predicted to occur during startup. A test stand and test plan were developed for subsequent testing of this heat pipe. Heat pipe manufacturing technology was advanced during this program, including the development of an innovative technique for wick installation.
Heat pipes have been considered for use on wing leading edge for over 20 years. Early concepts envisioned metal heat pipes cooling a metallic leading edge. Several superalloy/sodium heat pipes were fabricated and successfully tested for wing leading edge cooling. Results of radiant heat and aerothermal testing indicate the feasibility of using heat pipes to cool the stagnation region of shuttle-type space transportation systems. The test model withstood a total seven radiant heating tests, eight aerothermal tests, and twenty-seven supplemental radiant heating tests. Cold-wall heating rates ranged from 21 to 57 Btu/sq ft-s and maximum operating temperatures ranged from 1090 to 1520 F. Follow-on studies investigated the application of heat pipes to cool the stagnation regions of single-stage-to-orbit and advanced shuttle vehicles. Results of those studies indicate that a 'D-shaped' structural design can reduce the mass of the heat-pipe concept by over 44 percent compared to a circular heat-pipe geometry. Simple analytical models for heat-pipe startup from the frozen state (working fluid initially frozen) were adequate to approximate transient, startup, and steady-state heat-pipe performance. Improvement in analysis methods has resulted in the development of a finite-element analysis technique to predict heat-pipe startup from the frozen state. However, current requirements of light-weight design and reliability suggest that metallic heat pipes embedded in a refractory composite material should be used. This concept is the concept presently being evaluated for NASP. A refractory-composite/heat-pipe-cooled wing leading edge is currently being considered for the National Aero-Space Plane (NASP). This concept uses high-temperature refractory-metal/lithium heat pipes embedded within a refractory-composite structure and is significantly lighter than an actively cooled wing leading edge because it eliminates the need for active cooling during ascent and descent. Since the NASP vehicle uses cryogenic hydrogen to cool structural components and then burns this fuel in the combustor, hydrogen necessary for descent cooling only, when the vehicle is unpowered, is considered to be a weight penalty. Details of the design of the refractory-composite/heat-pipe-cooled wing leading edge are currently being investigated. Issues such as thermal contact resistance and thermal stress are also being investigated.
Axially conducting gas controlled heat pipes leading to predictive capability for heat and mass transfer along heat pipe
This study presents preliminary thermal/structural analyses of a carbon-carbon/refractory-metal heat-pipe-cooled wing leading edge concept designed for an air breathing single-stage-to-orbit hypersonic vehicle. The concept features chordwise (i.e., normal to the leading edge) and spanwise (i.e., parallel to the leading edge) refractory-metal heat pipes which are completely embedded within a carbon-carbon primary structure. Studies of the leading edge were performed using nonlinear thermal and linear structural three-dimensional finite element analyses. The concept was shown to be thermally feasible within the limits of the assumptions made in the analyses when internal radiative cooling is present during ascent, and a three-dimensional carbon-carbon architecture is used. In addition, internal radiative cooling was found not to be necessary during descent. The linear stress analysis indicated excessively large thermal stresses in the rafractory metal walls of the heat pipes even though a soft layer of carbon was included between the heat pipe and the carbon-carbon structure in an attempt to reduce the thermal stresses. A nonlinear structural analysis may be necessary to properly model the response of the refractory-metal heat pipes.
A full-scale, internally instrumented, sodium/Hastelloy X heat pipe was designed and fabricated for the wing leading edge of an advanced reentry vehicle. A computer model was developed to predict the heat pipe startup. The heat pipe was tested, and the results were used to validate the startup methodologies. In addition, valuable fabrication and test procedure lessons were learned.
The development of a refractory-composite/heat-pipe-cooled leading edge has evolved from the design stage to the fabrication and testing of a full size, leading-edge-shaped heat pipe. The heat pipe had a 'D-shaped' cross section and was fabricated from arc cast Mo-4lRe. An artery was included in the wick. Several issues were resolved with the fabrication of the sharp leading edge radius heat pipe. The heat pipe was tested in a vacuum chamber at Los Alamos National Laboratory using induction heating and was started up from the frozen state several times. However, design temperatures and heat fluxes were not obtained due to premature failure of the heat pipe resulting from electrical discharge between the induction heating apparatus and the heat pipe. Though a testing anomaly caused premature failure of the heat pipe, successful startup and operation of the heat pipe was demonstrated.
Mathematical models and an associated computer program for heat pipe startup from the frozen state have been developed. Finite element formulations of the governing equations are written for each heat pipe region for each operating condition during startup from the frozen state. The various models were checked against analytical and experimental data available in the literature for three specific types of operation. Computations using the methods developed were made for a space shuttle reentry mission where a heat pipe cooled leading edge was used on the wing.
A heat-pipe-cooled Space Shuttle orbiter wing leading edge was compared and evaluated against three alternate leading edge candidates: a refurbishable ablative design, and two other reusable versions employing coated columbium and carbon-carbon high-temperature segments. Each candidate concept was shown feasible in the Phase B environment. The reusable versions were all found to cost nearly the same and substantially less than the nonreusable ablative version. However, since current Shuttle trajectories produce higher heating rates than those used in this study, the carbon-carbon and heat pipe concepts are now the prime candidates for Shuttle leading edge thermal protection.
A numerical analysis of transient heat pipe performance including nonconventional heat pipes with nonuniform heat distributions is presented. A body-fitted grid system was applied to a three-dimensional wall and wick model, which was coupled with a transient compressible quasi-one-dimensional vapor flow model. The numerical results were first compared with experimental data from cylindrical heat pipes with good agreement. Numerical calculations were then made for a leading edge heat pipe with localized high heat fluxes. Performance characteristics different from conventional heat pipes are illustrated and some operating limits concerning heat pipe design are discussed.
The desire to increase the range and speed of hypersonic vehicles requires sharp, shape-stable Wing Leading Edges (WLE) with performance capabilities well beyond the current state of the art. The concentrated heat flux on sharp leading edges can lead to runaway thermal and mechanical failures. Heat pipes provide a passive solution to minimize the peak temperature, thermal gradients, and resulting thermal stresses near the WLE. Conventional heat pipes have been shown to address these issues at conditions as high as Mach 8. Oscillating heat pipes (OHPs) could be used to extend this benefit to missions with higher Mach numbers since their heat transport capacity typically exceeds that of conventional heat pipes. In the current investigation, several identical liquid metal high-temperature oscillating heat pipes (LMHOHPs) were constructed and tested to demonstrate the concept. The LMHOHPs had six turns, internal diameters of 2 mm, and total lengths of 100 mm. They were additively manufactured from C103 niobium alloy and charged with lithium to reach a fill ratio of approximately 50%. The boundary conditions of the experiment were designed to resemble those of various hypersonic flight profiles. Testing was performed with a system consisting of flow-controlled acetylene torch heating and radiation dominated heat rejection. The LMHOHP’s performance was measured using temperature data from an infrared camera and pyrometer. The experimental results were used to evaluate the capability of C103/lithium LMHOHPs under various flight regimes. A heat transfer model of the LMHOHP was proposed and validated against test data. Insights from the model were then extrapolated to evaluate a Tungsten-RHC/Gallium LMHOHP with anticipated capabilities beyond that of the C103/lithium system.
A fixed, linear, ground-based primary reflector having an extended curved sawtooth-contoured surface covered with a metalized polymeric reflecting material, reflects solar energy to a movably supported collector that is kept at the concentrated line focus reflector primary. The primary reflector may be constructed by a process utilizing well known freeway paving machinery. The solar energy absorber is preferably a fluid transporting pipe. Efficient utilization leading to high temperatures from the reflected solar energy is obtained by cylindrical shaped secondary reflectors that direct off-angle energy to the absorber pipe. A seriatim arrangement of cylindrical secondary reflector stages and spot-forming reflector stages produces a high temperature solar energy collection system of greater efficiency.
The current project was performed under the direction of Dr. Byron Pipes as its lead investigator from January 2001 to August 2004. With the permission of the NASA, the project was transferred to Dr. Thein Kyu as the principle investigator for the period of September 2004 - June 2005. There were two major thrust areas in the original proposal; (1) experimental characterization and kinematics of foam structure formation and (2) determination of the mechanical, physical, and thermal properties, although these thrust areas were further sub- divided into 7 tasks. The present project has been directed primarily to elucidate kinematics of micro-foam formation (tasks 1 and 3) and to characterize micro-foam structures, since the control of the micro-structure of these foams is of paramount importance in determining their physical, mechanical and thermal properties. The first thrust area was accomplished in a timely manner; however, the second thrust area of foam properties (tasks 2,4-7) has yet to be completed because the area of kinematics of foam structure formation turned out to be extremely complex and thus consumed more time than what have been anticipated. As will be reported in what follows, the present studies have greatly enhances the in-depth understanding of mechanisms and kinematics of the micro-foam formation from solid powders. However, in order to implement all objectives of the second thrust areas regarding investigations of mechanical, physical, and thermal properties and establishment of the correlation of structure - properties of the foams, the project needs additional time and resources. The technical highlights of the accomplishment are summarized as follows. The present study represents a first approach to understanding the complexities that act together in the powder foaming process to achieve the successful inflation of polyimide microstructures. This type of study is novel as no prior work had dissected the fundamentals that govern the inflation process in this type of systems. The systematic approach to each of the different phenomena (i.e. morphological, diffusive, kinetic and dynamic) brings into context each of them in a way that allows separate understanding and analysis. Of the different phenomena studied, probably the one that gives a higher level of control over the inflation process has been shown to be the morphological aspects of the precursor particles. It is a major contribution of the present work to isolate and identify this phenomenon and highlight the features that with careful control during the synthesis of the precursor material can lead to a highly optimized and specialized final product (neat foam or microstructure). Some of these accomplishments have been presented in various national meetings and some of which are either published in refereed journals or still in various stages of publications. One of the presentations was selected for "Best of ANTEC 2004" Online Presentation Series of the Society of Plastics Engineers (SPE) (September 2004)