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NASA NTRSDate not supplied

Predictions of Line Chilldown Boiling Regime Transitions by a Coupled CFD-Sub-Grid Boiling Model Validated against 1G LN2 Experiments

Propellant storage and transfer during future long-duration missions will involve fuel depot operations in which a donor depot tank is used to fill a receiver spacecraft tank with a cryogenic propellant. Prior to the on-Orbit filling operation both the receiver tank and the transfer line must be cooled. The line chilldown process involves transition between boiling regimes in microgravity that will be quite different from their 1g ground-based counterparts. Since the cryogenic propellant itself will be used to perform the chilldown process, the time constants to cool the wall and the amount of fuel that will be used become important design considerations. In this light, the focus of the present work is to capture the flow boiling characteristics of a cryogenic fluid, namely, liquid nitrogen, during the chill-down of a transfer line using CFD modelling and simulations. The cryogenic chill-down process involves different flow boiling regimes: film boiling, transition boiling and nucleate boiling. The prediction of transition between these regimes in a CFD framework is new and challenging. The present work addresses this challenge by employing a volume-of-fluid (VOF) based methodology with Lee phase change model to predict the film boiling regime of the chill-down process in ANSYS Fluent®. The transition and nucleate boiling regimes are predicted by incorporating a sub-grid model that accounts for bubble nucleation, growth, shedding frequency, and departure diameter. The sub-grid model is implemented into Fluent via a user-defined function for wall-fluid heat flux calculations. The sub-grid model is similar in formulation to the well-known Rensselaer Polytechnic Institute (RPI) boiling model. The CFD model is validated against published experimental data for liquid nitrogen chill-down of a heated stainless-steel pipe in 1g. Predicted results shows good agreement of wall temperature, rewetting temperature, and transition between film and nucleate boiling with the experimental measurements for several different LN2 flowrates in the vertical orientation. The strengths and weaknesses of this modeling approach are presented and discussed.

Cryogenic Fluid Management↗
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 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 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 NTRS1977

Boiling incipience and convective boiling of neon and nitrogen

Forced convection and subcooled boiling heat transfer data for liquid nitrogen and liquid neon were obtained in support of a design study for a 30 tesla cryomagnet cooled by forced convection of liquid neon. This design precludes nucleate boiling in the flow channels as they are too small to handle vapor flow. Consequently, it was necessary to determine boiling incipience under the operating conditions of the magnet system. The cryogen data obtained over a range of system pressures, fluid flow rates, and applied heat fluxes were used to develop correlations for predicting boiling incipience and convective boiling heat transfer coefficients in uniformly heated flow channels. The accuracy of the correlating equations was then evaluated. A technique was also developed to calculate the position of boiling incipience in a uniformly heated flow channel. Comparisons made with the experimental data showed a prediction accuracy of plus or minus 15 percent

Papell, S. S.↗
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 NTRS1977

Boiling incipience and convective boiling of neon and nitrogen

Forced convection and subcooled boiling heat transfer data for liquid nitrogen and liquid neon were obtained in support of a design study for a 30 tesla cryomagnet cooled by forced convection of liquid neon. The cryogen data obtained over a range of system pressures, fluid flow rates, and applied heat fluxes were used to develop correlations for predicting boiling incipience and convective boiling heat transfer coefficients in uniformly heated flow channels. The accuracy of the correlating equations was then evaluated. A technique was also developed to calculate the position of boiling incipience in a uniformly heated flow channel. Comparisons made with the experimental data showed a prediction accuracy of + or - 15 percent.

Papell, S. S.↗
NASA NTRS1999

A Study of Nucleate Boiling with Forced Convection in Microgravity

The ultimate objective of basic studies of flow boiling in microgravity is to improve the understanding of the processes involved, as manifested by the ability to predict its behavior. This is not yet the case for boiling heat transfer even in earth gravity, despite the considerable research activity over the past 30 years. The elements that constitute the nucleate boiling process - nucleation, growth, motion, and collapse of the vapor bubbles (if the bulk liquid is subcooled) - are common to both pool and flow boiling. It is well known that the imposition of bulk liquid motion affects the vapor bubble behavior relative to pool boiling, but does not appear to significantly influence the heat transfer. Indeed, it has been recommended in the past that empirical correlations or experimental data of pool boiling be used for design purposes with forced convection nucleate boiling. It is anticipated that such will most certainly not be possible for boiling in microgravity, based on observations made with pool boiling in microgravity. In earth gravity buoyancy will act to remove the vapor bubbles from the vicinity of the heater surface regardless of how much the imposed bulk velocity is reduced, depending, of course, on the geometry of the system. Vapor bubbles have been observed to dramatically increase in size in pool boiling in microgravity, and the heat flux at which dryout took place was reduced considerably below what is generally termed the critical heat flux (CHF) in earth gravity, depending on the bulk liquid subcooling. However, at heat flux levels below dryout, the nucleate pool boiling process was enhanced considerably over that in earth gravity, in spite of the large vapor bubbles formed in microgravity and perhaps as a consequence. These large vapor bubbles tended to remain in the vicinity of the heater surface, and the enhanced heat transfer appeared to be associated with the presence of what variously has been referred to as a liquid microlayer between the bubble and the heater surface. The enhancement of the boiling process with low velocities in earth gravity for those orientations producing the formation of a liquid macrolayer described above, accompanied by "sliding" vapor bubbles, has been demonstrated. The enhancement was presented as a function of orientation, subcooling, and heated length, while a criterion for the heat transfer for mixed natural/forced convection nucleate boiling was given previously. A major unknown in the prediction and application of flow boiling heat transfer in microgravity is the upper limit of the heat flux for the onset of dryout (or critical heat flux - CHF), for given conditions of fluid-heater surfaces, including geometry, system pressure and bulk liquid subcooling. It is clearly understood that the behavior in microgravity will be no different than on earth with sufficiently high flow velocities, and would require no space experimentation. However, the boundary at which this takes place is still an unknown. Previous results of CHF measurements were presented for low velocity flow boiling at various orientations in earth gravity as a function of flow velocity and bulk liquid subcooling, along with preliminary measurements of bubble residence times on a flat heater surface. This showed promise as a parameter to be used in modeling the CHF, both in earth gravity and in microgravity. The objective of the work here is to draw attention to and show results of current modeling efforts for the CHF, with low velocities in earth gravity at different orientations and subcoolings. Many geometrical possibilities for a heater surface exist in flowing boiling, with boiling on the inner and outer surfaces of tubes perhaps being the most common. If the vapor bubble residence time on and departure size from the heater surface bear a relationship to the CHF, as results to be given indicate, it is important that visualization of and access to vapor bubble growth be conveniently available for research purposes. In addition, it is desirable to reduce the number of variables as much as possible in a fundamental study. These considerations dictated the use of a flat heater surface, which is rectangular in shape, 1.91 cm by 3.81 cm (0.75 x 1.5 inches), consisting either of a 400 Angstrom thick semi-transparent gold film sputtered on a quartz substrate which serves simultaneously as a heater and a resistance thermometer, or a copper substrate of the same size. The heater substrate is a disc which can be rotated so that the heated length in the flow direction can be changed from 1.91 to 3.81 cm (0.75 to 1.5 inches). The fluid is R-113, and the velocities can be varied between 0.5 cm/s and 60 cm/s. For a sufficiently low velocity the CHF can be modeled reasonably well at various orientations by the correlation for pool boiling corrected for the influence of bulk liquid subcooling, multiplied by the square root of q, the angle relative to horizontal. This arises from equating buoyancy and drag forces in the inverted positions where the vapor bubbles are held against the heater surface as they slide. A distortion of the measurements relative to pool boiling occurs as the flow velocity increases. In modeling this effect at different levels of subcooling it appeared appropriate to estimate the volumetric rate of vapor generation, using measurements of bubble frequency (or residence time), void fraction and average bubble boundary layer thickness. These were determined with the use of a platinum hot wire probe 0.025 mm in diameter by 1.3 mm long, applying a constant current to distinguish between contact with liquid or vapor. Two-dimensional spatial variations are obtained with a special mechanism to resolve displacements in increments of 0.025 mm. From such measurements it was determined that the fraction of the surface heat transfer resulting in evaporation varies inversely with the subcooling correction factor for the CHF. The measured inverse bubble residence time is normalized relative to that predicted for an infinite horizontal flat plate at the CHF, and is correlated well with the CHF normalized relative to that for pool boiling, for various orientation angles and subcooling levels. This correspondence is then combined with a normalizing factor for the energy flux leaving the heater surface at the CHF and the computed bubble radius at departure, determined from the balance between the outward velocity of the interface due to evaporation and the buoyance induced velocity of the center of mass of the bubble. The product of the CHF and the corresponding residence time was determined to be a constant for all orientations at a given bulk flow velocity and liquid subcooling, and must be determined empirically for each velocity and subcooling at present. It then becomes possible to predict the CHF for the different orientations, velocities, and subcoolings. These are compared with normalized measurements of the CHF for velocities ranging from 4 cm/s to 55 cm/s, subcoolings from 2.8 to 22.2 K, over orientations angles of 360 degrees.

Merte, Herman, Jr.↗
NASA NTRS2000

Heat Transfer Performances of Pool Boiling on Metal-Graphite Composite Surfaces

Nucleate boiling, especially near the critical heat flux (CHF), can provide excellent economy along with high efficiency of heat transfer. However, the performance of nucleate boiling may deteriorate in a reduced gravity environment and the nucleate boiling usually has a potentially dangerous characteristic in CHF regime. That is, any slight overload can result in burnout of the boiling surface because the heat transfer will suddenly move into the film-boiling regime. Therefore, enhancement of nucleate boiling heat transfer becomes more important in reduced gravity environments. Enhancing nucleate boiling and critical heat flux can be reached using micro-configured metal-graphite composites as the boiling surface. Thermocapillary force induced by temperature difference between the graphite-fiber tips and the metal matrix, which is independent of gravity, will play an important role in bubble detachment. Thus boiling heat transfer performance does not deteriorate in a reduced-gravity environment. Based on the existing experimental data, and a two-tier theoretical model, correlation formulas are derived for nucleate boiling on the copper-graphite and aluminum-graphite composite surfaces, in both the isolated and coalesced bubble regimes. Experimental studies were performed on nucleate pool boiling of pentane on cooper-graphite (Cu-Gr) and aluminum-graphite (Al-Gr) composite surfaces with various fiber volume concentrations for heat fluxes up to 35 W per square centimeter. It is revealed that a significant enhancement in boiling heat transfer performance on the composite surfaces is achieved, due to the presence of micro-graphite fibers embedded in the matrix. The onset of nucleate boiling (the isolated bubble regime) occurs at wall superheat of about 10 C for the Cu-Gr surface and 15 C for the Al-Gr surface, much lower than their respective pure metal surfaces. Transition from an isolated bubble regime to a coalesced bubble regime in boiling occurs at a superheat of about 14 C on Cu-Gr surface and 19 C on Al-Gr surface.

Zhang, Nengli↗
NASA NTRS1999

Enhanced Boiling on Micro-Configured Composite Surfaces Under Microgravity Conditions

In order to accommodate the growing thermal management needs of future space platforms, several two-phase active thermal control systems (ATCSs) have evolved and were included in the designs of space stations. Compared to the pumped single-phase liquid loops used in the conventional Space Transportation System and Spacelab, ATCSs offer significant benefits that may be realized by adopting a two-phase fluid-loop system. Alternately, dynamic power systems (DPSs), based on the Rankine cycle, seem inevitably to be required to supply the electrical power requirements of expanding space activities. Boiling heat transfer is one of the key technologies for both ATCSs and DPSs. Nucleate boiling near critical heat flux (CHF) can transport very large thermal loads with much smaller device size and much lower pumping power. However, boiling performance deteriorates in a reduced gravity environment and operation in the CHF regime is precarious because any slight overload will cause the heat transfer to suddenly move to the film boiling regime, which in turn, will result in burnout of the heat transfer surfaces. New materials, such as micro-configured metal-graphite composites, can provide a solution for boiling enhancement. It has been shown experimentally that this type of material manifests outstanding boiling heat transfer performance and their CHF is also extended to higher values. Due to the high thermal conductivity of graphite fiber (up to 1,200 W/m-K in the fiber direction), the composite surfaces are non-isothermal during the boiling process. The composite surfaces are believed to have a much wider safe operating region (a more uniform boiling curve in the CHF regime) because non-isothermal surfaces have been found to be less sensitive to variations of wall superheat in the CHF regime. The thermocapillary forces formed by the temperature difference between the fiber tips and the metal matrix play a more important role than the buoyancy in the bubble detachment, for the bubble detachment manifests itself by a necking process which should not be weakened by reduced gravity. In addition, the composite surfaces introduce no extra pressure drop, no fouling and do not impose significant primary or maintenance costs. All of these suggest that this type of composite is an ideal material for the challenge of accounting for both reliability and economy of the relevant components applied in the ATCSs, the DPSs and other devices in future space missions. The aim of the proposed work is to experimentally investigate high nucleate pool boiling performance on a micro-configured metal-graphite composite surface and to determine the mechanisms of the nucleate boiling heat transfer both experimentally and theoretically. Freon-113 and water will be used as the test liquids to investigate wettability effects on boiling characteristics. The Cu-Gr and Al-Gr composites with various volume fractions of graphite fibers will be tested to obtain the heat transfer characteristic data in the nucleate boiling region and in the CHF regime. In the experiments, the bubble emission and coalescence processes will be recorded by a video camera with a magnifying borescope probe immersed in the working fluid. The temperature profile in the thermal boundary layer on the composite surfaces will be measured by a group of micro thermocouples consisting of four ultra fine micro thermocouples. This instrument was developed and successfully used to measure the temperature profile of evaporating liquid thin layers by the proposers in a study performed at the NASA/Lewis Research Center. A two tier model to explain the nucleate boiling process and the performance enhancement on the composite surfaces has been suggested by the authors. According to the model, the thicknesses of the microlayer and the macrolayer underneath the bubbles and mushrooms, can be estimated by the geometry of the composite surface. The experimental results will be compared to the predictions from the model, and in turn, to revise and improve it.

Zhang, Nengli↗
NASA NTRSDate not supplied

CFD Predictions of Boiling Regime Transitions during Line Chilldown validated against a 1G LN2 Experiment

Introduction Before filling a propellant tank on the ground or in Space, the transfer line between the donor and receiver tanks must be cooled down preferably by sacrificing a minimum amount of the cryogenic fluid. The cryogenic line chill-down process involves a transition between different flow boiling regimes, namely, film boiling, transition film boiling, and nucleate boiling which are complex and may be quite gravity-dependent. Capturing these boiling phenomena and predicting the transition between them in a CFD framework is new and challenging both for 1g and microgravity applications. Materials & Methods The present work addresses this challenge by employing a two-phase Eulerian approach in the context of a homogeneous fluid mixture together with the Lee phase change model to capture the film boiling regime of the chill-down process using ANSYS Fluent®. The nucleate boiling regime is predicted by incorporating an in-house developed sub-grid model that accounts for bubble nucleation, bubble growth, bubble departure diameter, and their shedding frequency. The sub-grid model is encoded and implemented into Fluent via a user-defined function for the wall-fluid heat flux calculations. The mathematical formulation and numerical implementation of the CFD model are described in detail. The coupled CFD-Subgrid model is validated against published experimental data for liquid nitrogen chill-down of a heated stainless-steel pipe in 1g. Results Numerical simulation results show good agreements between the CFD predictions of the wall temperature evolution, rewetting temperature, and transition between film and nucleate boiling, with the experimental measurements published by Darr et al [2] for several different LN2 flowrates in the vertical pipe orientation. The CFD predictions for the wall temperature distribution indicate a rapid quenching of the wall at two upstream and downstream temperature sensing locations as compared to the experimental measurement. The only tuning parameter in the CFD model is the Lee mass transfer coefficient. The CFD Model predicts the Liedenfrost rewetting temperature in close agreement with the experiment. This marks a transition between stable and transitionary flow boiling regimes. The CFD-predicted boiling curve for the downstream sensor location is also compared against its experimental counterpart and indicates that the model is able to predict all the key temperature and heat flux parameters during the transitions from stable to transitionary film boiling to nucleate boiling in close agreement with the experiment. A sequence of predicted volume fraction, and temperature contours depicting these transitions will be presented.

Evaporation Condensation↗
NASA NTRS1994

Pool and flow boiling in variable and microgravity

As is well known, boiling is an effective mode of heat transfer in that high heat flux levels are possible with relatively small temperature differences. Its optimal application requires that the process be adequately understood. A measure of the understanding of any physical event lies in the ability to predict its behavior in terms of the relevant parameters. Despite many years of research the predictability of boiling is currently possible only for quite specialized circumstances, e.g., the critical heat flux and film boiling for the pool boiling case, and then only with special geometries. Variable gravity down to microgravity provides the opportunity to test this understanding, but possibly more important, by changing the dimensional and time scales involved permits more detailed observations of elements involved in the boiling process, and perhaps discloses phenomena heretofore unknown. The focus here is on nucleate boiling although, as will be demonstrated below, under but certain circumstances in microgravity it can take place concurrently with the dryout process. In the presence of earth gravity or forced convection effects, the latter process is usually referred to as film boiling. However, no vapor film as such forms with pool boiling in microgravity, only dryout. Initial results are presented here for pool boiling in microgravity, and were made possible at such an early date by the availability of the Get-Away-Specials (GAS). Also presented here are some results of ground testing of a flow loop for the study of low velocity boiling, eventually to take place also in microgravity. In the interim, variable buoyancy normal to the heater surface is achieved by rotation of the entire loop relative to earth gravity. Of course, this is at the expense of varying the buoyancy parallel to the heater surface. Two questions which must be resolved early in the study of flow boiling in microgravity are (1) the lower limits of liquid flow velocity where buoyancy effects become significant to the boiling process (2) the effect of lower liquid flow velocities on the Critical Heat Flux when buoyancy is removed. Results of initial efforts in these directions are presented, albeit restricted currently to the ever present earth gravity.

Merte, Herman, Jr.↗
NASA NTRS2002

Length Scale and Gravity Effects on Microgravity Boiling Heat Transfer

Boiling is a complex phenomenon where hydrodynamics, heat transfer, mass transfer, and interfacial phenomena are tightly interwoven. An understanding of boiling and critical heat flux in microgravity environments is of importance to space based hardware and processes such as heat exchange, cryogenic fuel storage and transportation, electronic cooling, and material processing due to the large amounts of heat that can be removed with relatively little increase in temperature. Although research in this area has been performed in the past four decades, the mechanisms by which heat is removed from surfaces in microgravity are still unclear. In earth gravity, buoyancy is an important parameter that affects boiling heat transfer through the rate at which bubbles are removed from the surface. A simple model describing the bubble departure size based on a quasistatic force balance between buoyancy and surface tension is given by the Fritz [I] relation: Bo(exp 1/2) = 0.0208 theta where Bo is the ratio between buoyancy and surface tension forces. For small, rapidly growing bubbles, inertia associated with the induced liquid motion can also cause bubble departure. In microgravity, the magnitude of effects related to natural convection and buoyancy are small and physical mechanisms normally masked by natural convection in earth gravity such as Marangoni convection can substantially influence the boiling and vapor bubble dynamics. CHF (critical heat transfer) is also substantially affected by microgravity. In 1 g environments, Bo has been used as a correlating parameter for CHF. Zuber's CHF model for an infinite horizontal surface assumes that vapor columns formed by the merger of bubbles become unstable due to a Helmholtz instability blocking the supply of liquid to the surface. The jets are spaced lambda(sub D) apart, where lambda(sub D) = 2pi square root of 3[(sigma)/(g(rho(sub l) - rho(sub v)](exp 1/2) = 2pi square root of 3 L Bo(exp -1/2) = square root of 3 lambda(sub c) and is the wavelength that amplifies most rapidly. The critical wavelength, lambda(sub c), is the wavelength below which a vapor layer underneath a liquid layer is stable. For heaters with Bo smaller than about 3 (heaters smaller than lambda(sub D)), the above model is not applicable, and surface tension effects dominate. Bubble coalescence is thought to be the mechanism for CHF under these conditions. Small Bo can result by decreasing the size of a heater in earth gravity, or by operating a large heater in a lower gravity environment. In the microgravity of space, even large heaters can have low Bo, and models based on Helmholtz instability should not be applicable. The macrolayer model of Haramura and Katto is dimensionally equivalent to Zuber's model and has the same dependence on gravity, so it should not be applicable as well. The goal of this work is to determine how boiling heat transfer mechanisms in a low-g environment are altered from those at higher gravity levels. Boiling data using a microheater array was obtained under gravity environments ranging from 1.8 g to 0.02 g with heater sizes ranging from 2.7 mm to 1 mm. The boiling behavior for 2.7 mm at 0.02 g looked quite similar to boiling on the 1 mm heater at 1 g-the formation of a large primary bubble surrounded by smaller satellite bubbles was observed under both conditions. The similarity suggests that for heaters smaller than some fraction of I(sub c), coalescence and surface tension dominate boiling heat transfer. It also suggests that microgravity boiling can be studied by studying boiling on very small heaters.

Kim, Jungho↗
NASA NTRSDate not supplied

Validation of CFD Model Prediction of Flow Boiling Regime Transitions during LN2 Line Chilldown

Propellant storage and transfer during future long-duration missions will involve fuel depot operations in which a donor depot tank is used to fill a receiver spacecraft tank with a cryogenic propellant. Prior to the on-Orbit filling operation both the receiver tank and the transfer line must be cooled. The line chilldown process involves transition between boiling regimes in microgravity that will be quite different from their 1g ground-based counterparts. Since the cryogenic propellant itself will be used to perform the chilldown process, the time constants to cool the wall and the amount of fuel that will be used become important design considerations. In this light, the focus of the present work is to understand the flow boiling characteristics of a cryogenic fluid, namely, liquid nitrogen, during the chill-down of a transfer line using CFD modelling and simulations. The cryogenic chill-down process involves different flow boiling regimes: film boiling, transition boiling and nucleate boiling. The prediction of transition between these regimes in a CFD framework is new and challenging. The present work addresses this challenge by employing a volume-of-fluid (VOF) based methodology with Lee phase change model to predict the film boiling regime of the chill-down process in ANSYS Fluent®. The transition and nucleate boiling regimes are predicted by incorporating a sub-grid model developed by Craft Tech that accounts for bubble nucleation, growth, shedding frequency, and departure diameter. The sub-grid model is implemented into Fluent via a user-defined function for wall-fluid heat flux calculations. The sub-grid model is similar in formulation to the well-known Rensselaer Polytechnic Institute (RPI) boiling model. The model constants are tested for different operating conditions and designated values are reported. The CFD model is validated against published experimental data for liquid nitrogen chill-down of a heated stainless-steel pipe in 1g. Predicted results showing good agreement of wall temperature, rewetting temperature, and transition between film and nucleate boiling with the experimental measurements are presented and discussed.

Boiling regimes↗
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 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 NTRS1994

Transient nucleate pool boiling in microgravity: Some initial results

Variable gravity provides an opportunity to test the understanding of phenomena which are considered to depend on buoyancy, such as nucleate pool boiling. The active fundamental research in nucleate boiling has sought to determine the mechanisms or physical processes responsible for its high effectiveness, manifested by the high heat flux levels possible with relatively low temperature differences. Earlier research on nucleate pool boiling at high gravity levels under steady conditions demonstrated quantitatively that the heat transfer is degraded as the buoyancy normal to the heater surfaced increases. Correspondingly, it was later shown, qualitatively for short periods of time only, that nucleate boiling heat transfer is enhanced as the buoyancy normal to the heater surface is reduced. It can be deduced that nucleate pool boiling can be sustained as a quasi-steady process provided that some means is available to remove the vapor generated from the immediate vicinity of the heater surface. One of the objectives of the research, the initial results of which are presented here, is to quantify the heat transfer associated with boiling in microgravity. Some quantitative results of nucleate pool boiling in high quality microgravity (a/g approximately 10(exp -5)) of 5s duration, obtained in an evacuated drop tower, are presented here. These experiments were conducted as precursors of longer term space experiments. A transient heating technique is used, in which the heater surface is a transparent gold film sputtered on a qua rtz substrate, simultaneously providing the mean surface temperature from resistance thermometry and viewing of the boiling process both from beneath and across the surface. The measurement of the transient mean heater surface temperature permits the computation, by numerical means, of the transient mean heat transfer coefficient. The preliminary data obtained demonstrates that a quasi-steady boiling process can occur in microgravity if the bulk liquid subcooling is sufficiently high and if the imposed heat flux is sufficiently low. This is attributed to suface tension effects at the liquid-vapor-solid junction causing rewetting to take place, sustaining the nucleate boiling. Otherwise, dryout at the heater surface will occur, as observed.

Merte, Herman, Jr.↗
NASA NTRS1998

Bubble Dynamics, Two-Phase Flow, and Boiling Heat Transfer in Microgravity

This report contains two independent sections. Part one is titled "Terrestrial and Microgravity Pool Boiling Heat Transfer and Critical heat flux phenomenon in an acoustic standing wave." Terrestrial and microgravity pool boiling heat transfer experiments were performed in the presence of a standing acoustic wave from a platinum wire resistance heater using degassed FC-72 Fluorinert liquid. The sound wave was created by driving a half wavelength resonator at a frequency of 10.15 kHz. Microgravity conditions were created using the 2.1 second drop tower on the campus of Washington State University. Burnout of the heater wire, often encountered with heat flux controlled systems, was avoided by using a constant temperature controller to regulate the heater wire temperature. The amplitude of the acoustic standing wave was increased from 28 kPa to over 70 kPa and these pressure measurements were made using a hydrophone fabricated with a small piezoelectric ceramic. Cavitation incurred during experiments at higher acoustic amplitudes contributed to the vapor bubble dynamics and heat transfer. The heater wire was positioned at three different locations within the acoustic field: the acoustic node, antinode, and halfway between these locations. Complete boiling curves are presented to show how the applied acoustic field enhanced boiling heat transfer and increased critical heat flux in microgravity and terrestrial environments. Video images provide information on the interaction between the vapor bubbles and the acoustic field. Part two is titled, "Design and qualification of a microscale heater array for use in boiling heat transfer." This part is summarized herein. Boiling heat transfer is an efficient means of heat transfer because a large amount of heat can be removed from a surface using a relatively small temperature difference between the surface and the bulk liquid. However, the mechanisms that govern boiling heat transfer are not well understood. Measurements of wall temperature and heat flux near the wall would add to the database of knowledge which is necessary to understand the mechanisms of nucleate boiling. A heater array has been developed which contains 96 heater elements within a 2.5 mm square area. The temperature of each heater element is held constant by an electronic control system similar to a hot-wire anemometer. The voltage that is being applied to each heater element can be measured and digitized using a high-speed Analog to Digital (A/D) converter, and this digital information can be compiled into a series of heat-flux maps. Information for up to 10,000 heat flux maps can be obtained each second. The heater control system, the A/D system and the heater array construction are described in detail. Results are presented which show that this is an effective method of measuring the local heat flux during nucleate and transition boiling. Heat flux maps are obtained for pool boiling in FC-72 on a horizontal surface. Local heat flux variations are shown to be three to six times larger than variations in the spatially averaged heat flux.

Chung, Jacob N.↗