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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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The X-38 V-201 Fin Fold Actuation Mechanism

The X-38 Vehicle 201 (V-201) is a space flight prototype lifting body vehicle that was designed to launch to orbit in the Space Shuttle orbiter payload bay. Although the project was cancelled in May 2003, many of the systems were nearly complete. This paper will describe the fin folding actuation mechanism flight subsystems and development units as well as lessons learned in the design, assembly, development testing, and qualification testing. The two vertical tail fins must be stowed (folded inboard) to allow the orbiter payload bay doors to close. The fin folding actuation mechanism is a remotely or extravehicular activity (EVA) actuated single fault tolerant system consisting of seven subsystems capable of repeatedly deploying or stowing the fins.

Lupo, Christian↗

Single-Phase Jet Impingement Cooling for a Power-Dense Silicon Carbide Power Module

The adoption of silicon carbide (SiC) devices in the electric vehicle (EV) industry is increasing due to their superior performance over silicon devices. SiC devices enable further miniaturization of EV inverters, increasing their power density, which results in thermal management challenges. Here in this paper, the limits of single-phase jet impingement cooling are explored for an automotive SiC power module. We propose embedding pin fins in the direct-bonded-copper (DBC) substrate of the power module package using laser powder bed fusion additive manufacturing. The thermalhydraulic performance of the DBC-embedded pin fins is compared against folded fins that are directly soldered to the DBC substrate. A heat conduction analysis was conducted on a SiC package to determine the target heat transfer coefficient (HTC) for the heat sink. A water-ethylene glycol (WEG) jet impingement on the proposed concepts was studied using unit-cell models to achieve the target HTC. The studied designs put emphasis on the reliability and manufacturability requirements of the automotive industry. The thermal performance of DBC-embedded pin fins outperformed the DBC-soldered folded fins. The performance of the DBC-embedded pin fins is benchmarked against WEG-based cooling systems of commercial EVs. With the proposed cooling solution, we have shown a pathway of reducing the specific thermal resistance by 75% compared to BMW i3 thermal management system without any penalty on pressure drop or parasitic power.

33 ADVANCED PROPULSION SYSTEMS↗

Investigation of Ejection Releases of an MB-1 Rocket from a 0.04956-Scaled Model of the Convair F-106A Airplane at Several Mach Numbers and Simulated Altitudes

As a continuation of an investigation of the ejection release characteristics of an internally carried MB-1 rocket in the Convair F-106A airplane, fin modifications at additional Mach numbers and simulated altitudes have been studied in the 27- by 27-inch preflight jet of the Langley Pilotless Aircraft Research Station at Wallops Island, Va. The MB-1 rocket was ejected with fins open, fins closed, fins closed with a shroud around the fins, and fins folded with a "boattail" placed in between the fins. Dynamically scaled models (0.0^956 scale) were tested at simulated altitudes of 12,000, 18,850, and 27,500 feet at subsonic Mach numbers and at 18,850, 27,500, and 40,000 feet for Mach numbers of 1-39, 1-59, and 1.98. Successful ejections can be obtained for over 10 store diameters from release point by the use of a shroud around the folded fins with the proper ejection velocity and nose-down pitching moment at release. In one case investigated it was found desirable to close off the front one-third of the bomb bay. It appeared that the fins should be opened after release and within 5 "to 6 rocket diameters if no modifications are made on the rocket. An increase in fuselage angle of attack caused higher nose-up pitch rates after release.

Lee, J. B.↗

Creep and Fatigue Characterization of High Strength Alloy Thin Sections in Advanced CO2 Heat Exchangers

The objective of this work was to characterize and model elevated temperature creep and fatigue behavior for thin sheet and foil forms of gamma-prime strengthened alloys in wrought form and as-processed folded and brazed constructions. This work was motivated by the demanding temperature and pressure service conditions of the GEN3 Concentrated Solar Power (CSP) and supercritical CO2 (sCO2) power cycle working fluid. More specifically, the possibility of leveraging the superior creep strength of gamma-prime alloys in folded-fin and brazed-plate heat exchanger constructions. Gamma-prime alloys represent a step-change in raw-material strength over solid-solution strengthened alloys. And the folded-fin and brazed-plate heat exchanger architecture is lightweight and leverages cost-effective material stock forms. The investigation contained two parallel paths. (1) The first is referred to as a fundamental investigation where Oak Ridge National Laboratory conducts uniaxial creep testing on thin sheet and foil in wrought form. This effort aimed to serve as a benchmark against a relatively sparse existing database and a baseline comparison for path number 2. (2) The second path is referred to as the practical investigation where Brayton Energy manufactures plate-fin heat exchangers and performs pressurized creep and fatigue testing. This effort aimed to de-risk heat exchanger manufacturing process for service under sCO2 CSP conditions. A total of 14 uniaxial creep tests were completed using Haynes 282 thin sheet and foil. A variety of heat treatments were specified to coincide with path number 2. Baseline metallography of test samples and creep strength performance are contained. Benchmarks relatively to existing thick-form Haynes 282 are made, as well as to other thin-form Nickel-based superalloys. Description of a wrought-form modeling approach for thin gamma-prime alloys is also discussed. A total of 11 pressurized creep and fatigue tests were completed successfully with Haynes 282 heat exchanger prototypes. Manufacturing processing details, testing details, testing results, and failure analysis are discussed. Additionally, creep modeling techniques to predict failure are discussed, and modeling to support technological-to-market. In conclusion, Haynes 282 foils were demonstrated to yield rupture two-to-three orders of magnitude higher than Haynes 230 foils under similar conditions. And the manufactured heat exchanger prototypes demonstrated strength similar to the wrought constituents. Both of which contribute to elevated performance potential or cost savings in practice. Discussion is included.

14 SOLAR ENERGY↗

A numerical investigation of the aerodynamics of biconic and non-circular flared configurations

Two families of biconic flares and three noncircular flares were studied at Mach numbers from 2 to 4 using a parabolized Navier-Stokes code. All configurations had cone-cyclinder forebodies. The biconic flares were examined to determine if drag could be reduced without significant loss of stability. Only slight drag reduction was found; however, meaningful volume increases were possible with negligible drag penalty. Significant decreases in drag were obtained with the noncircular flares. These configurations maintain considerable pitch stability but sacrifice nearly all yaw stability. The latter can be corrected with fold-out fins that could be readily accommodated on the noncircular flares.

Cottrell, C. J.↗

Cavity door effects on aerodynamic loadings of compressed-carriage store configurations separating from cavities at supersonic speeds

An experimental wind-tunnel investigation has been conducted at supersonic Mach numbers to determine the effects of cavity doors on the aerodynamic characteristics of compressed-carriage store configurations during separation from a shallow box cavity (closed cavity flow) located in a simulated generic parent aircraft. The tests were conducted in the Langley Unitary Plan Wind Tunnel at free-stream Mach numbers of 1.70, 2.00, and 2.65 for a constant Reynolds number per foot of two million. Results are summarized to show the effects of cavity door opening angles, vertical door height, folded and unfolded tail fins, and Mach number on the near-field aerodynamic separation characteristics of a single missile-type store with in-line cruciform wings and tail fins.

Blair, A. B., Jr.↗

A Comparison of Three-Dimensional Simulations of Traveling-Wave Tube Cold-Test Characteristics Using CST MICROWAVE STUDIO and MAFIA

Previously, it was shown that MAFIA (solutions of Maxwell's equations by the Finite Integration Algorithm), a three-dimensional simulation code, can be used to produce accurate cold-test characteristics including frequency-phase dispersion, interaction impedance, and attenuation for traveling-wave tube (TWT) slow-wave structures. In an effort to improve user-friendliness and simulation time, a model was developed to compute the cold-test parameters using the electromagnetic field simulation software package CST MICROWAVE STUDIO (MWS). Cold-test parameters were calculated for several slow-wave circuits including a ferruled coupled-cavity, a folded waveguide, and a novel finned-ladder circuit using both MWS and MAFIA. Comparisons indicate that MWS provides more accurate cold-test data with significantly reduced simulation times. Both MAFIA and MWS are based on the finite integration (FI) method; however, MWS has several advantages over MAFIA. First, it has a Windows based interface for PC operation, making it very user-friendly, whereas MAFIA is UNIX based. MWS uses a new Perfect Boundary Approximation (PBA), which increases the accuracy of the simulations by avoiding stair step approximations associated with MAFIA's representation of structures. Finally, MWS includes a Visual Basic for Applications (VBA) compatible macro language that enables the simulation process to be automated and allows for the optimization of user-defined goal functions, such as interaction impedance.

Chevalier, C. T.↗

Enhanced Selectivity and Stability of Finned Ferrierite Catalysts in Butene Isomerization

Abstract Designing zeolite catalysts with improved mass transport properties is crucial for restrictive networks of either one‐ or two‐dimensional pore topologies. Here, we demonstrate the synthesis of finned ferrierite (FER), a commercial zeolite with two‐dimensional pores, where protrusions on crystal surfaces behave as pseudo nanoparticles. Catalytic tests of 1‐butene isomerization reveal a 3‐fold enhancement of catalyst lifetime and an increase of 12 % selectivity to isobutene for finned samples compared to corresponding seeds. Electron tomography was used to confirm the identical crystallographic registry of fins and seeds. Time‐resolved titration of Brønsted acid sites confirmed the improved mass transport properties of finned ferrierite compared to conventional analogues. These findings highlight the advantages of introducing fins through facile and tunable post‐synthesis modification to impart material properties that are otherwise unattainable by conventional synthesis methods.

Dai, Heng↗

Enhanced Selectivity and Stability of Finned Ferrierite Catalysts in Butene Isomerization

Designing zeolite catalysts with improved mass transport properties is crucial for restrictive networks of either one- or two-dimensional pore topologies. In this paper we demonstrate the synthesis of finned ferrierite (FER), a commercial zeolite with two-dimensional pores, where protrusions on crystal surfaces behave as pseudo nanoparticles. Catalytic tests of 1-butene isomerization reveal a 3-fold enhancement of catalyst lifetime and an increase of 12 % selectivity to isobutene for finned samples compared to corresponding seeds. Electron tomography was used to confirm the identical crystallographic registry of fins and seeds. Time-resolved titration of Brønsted acid sites confirmed the improved mass transport properties of finned ferrierite compared to conventional analogues. These findings highlight the advantages of introducing fins through facile and tunable post-synthesis modification to impart material properties that are otherwise unattainable by conventional synthesis methods.

2D zeolite↗

Development of an Integrated Thermal Energy Storage Heat Exchanger for Concentrating Solar Power

In this design and development effort a latent-heat energy storage heat exchanger was designed for a 10MW e sCO 2 power plant as a basis for detailed design and testing of a new phase-change heat exchanger technology. High efficiency thermal conductors of graphite foam or folded copper were employed within chloride salt phase-change volumes bounded by alternating high density compact plate-fin heat exchange cells in this new heat exchanger technology. Test articles were constructed at Brayton Energy and tested at Argonne National Laboratory. Copper-conducting samples were constructed and tested at Brayton Energy.

14 SOLAR ENERGY↗

Internally drained condenser for spacecraft thermal management

This paper presents the results obtained to date in a program to develop a high heat flux condenser for use in two-phase spacecraft thermal management loops. The objective is to obtain a several fold increase in condensation heat transfer coefficient over those which can be achieved with shear-controlled or capillary-wick condensers. The internally drained condenser relies on shaped fins to develop a capillary pressure gradient over the surface of the fins and drive the condensate toward narrow drainage grooves separating the fins. The condensate then flows through a drainage network embedded in the condenser walls. Heat transfer coefficients of up to 8 W/sq cm C were measured in steam, providing a heat transfer enhancement ratio greater than a factor of 8. In the paper the proof-of-concept experiments are described and simplified models to predict the performance of the internally drained condenser are presented.

Valenzuela, Javier A.↗

Experimental Investigation of Crossing Shock Wave-Turbulent Boundary Layer-Bleed Interaction

Results of an experimental investigation of a symmetric crossing shock wave/turbulent boundary layer/bleed interaction are presented for a freestream unit Reynolds number of 1.68 x 10(exp 7)/m, a Mach number of 2.81, and deflection angles of 8 degrees. The data obtained in this study are bleed mass flow rate using a trace gas technique, qualitative information in the form of oil flow visualization, flow field Pitot pressures, and static pressure measurements using pressure sensitive paint. The main objective of this test is two-fold. First, this study is conducted to explore boundary layer control through mass flow removal near a large region of separated flow caused by the interaction of a double fin-induced shock wave and an incoming turbulent boundary layer. Also, a comprehensive data set is needed for computational fluid dynamics code validation.

Kim, Hyun↗

Challenges and payoff of composites in transport aircraft: 777 empennage and future applications

The Boeing 777 is the first of a new family of wide body airplanes. The new large twin is sized to accommodate 360 to 390 passengers in typical two-class configurations and planned growth beyond that. The 777 offers airlines three engine options, extremely attractive operating costs, and compatibility with existing airport gates and taxiways. The 777 has a wingspan of nearly 197 feet and is offered with a wing-tip folding mechanism that will reduce the span to 156 feet. Extensive use of advance composite is included in the 777. The application range from fiberglass fairing to primary structures. The 777 empennage includes vertical fin and a horizontal stabilizer. The material used for the empennage is a new, toughened epoxy materials. The material provides outstanding resistance to impact damage.

Quinlivan, John↗

Aeroservoelastic DAP missile fin development

The development of an active aeroservoelastic missile fin using directionally attached piezoelectric (DAP) actuator elements is detailed. Several different types of actuator elements are examined, including piezoelectric polymers, piezoelectric fiber composites, and conventionally attached piezoelectric (CAP) and DAP elements. These actuator elements are bonded to the substrate of a torque plate. The root of the torque plate is attached to a fuselage hard point or folding pivot. The tip of the plate is bonded to an aerodynamic shell which undergoes a pitch change as the plate twists. The design procedures used on the plate are discussed. A comparison of the various actuator element shows that DAP elements provide the highest deflections with the highest torsional stiffness. A torque plate was constructed from 0.2032 mm thick DAP elements bonded to a 0.127 mm thick AISI 1010 steel substrate. The torque plate produced static twist deflections in excess of +/- 3 deg. An aerodynamic shell with a modified NACA 0012 profile was added to the torque plate. This fin was tested in a wind tunnel at speeds up to 50 ms/sec. The static deflection of the fin was predicted to within 6 percent of the experimental data.

Barrett, Ron↗

Interaction of two glancing, crossing shock waves with a turbulent boundary-layer at various Mach numbers

A preliminary experimental investigation was conducted to study two crossing, glancing shock waves of equal strengths, interacting with the boundary-layer developed on a supersonic wind tunnel wall. This study was performed at several Mach numbers between 2.5 and 4.0. The shock waves were created by fins (shock generators), spanning the tunnel test section, that were set at angles varying from 4 to 12 degrees. The data acquired are wall static pressure measurements, and qualitative information in the form of oil flow and schlieren visualizations. The principle aim is two-fold. First, a fundamental understanding of the physics underlying this flow phenomena is desired. Also, a comprehensive data set is needed for computational fluid dynamic code validation. Results indicate that for small shock generator angles, the boundary-layer remains attached throughout the flow field. However, with increasing shock strengths (increasing generator angles), boundary layer separation does occur and becomes progressively more severe as the generator angles are increased further. The location of the separation, which starts well downstream of the shock crossing point, moves upstream as shock strengths are increased. At the highest generator angles, the separation appears to begin coincident with the generator leading edges and engulfs most of the area between the generators. This phenomena occurs very near the 'unstart' limit for the generators. The wall pressures at the lower generator angles are nominally consistent with the flow geometries (i.e. shock patterns) although significantly affected by the boundary-layer upstream influence. As separation occurs, the wall pressures exhibit a gradient that is mainly axial in direction in the vicinity of the separation. At the limiting conditions the wall pressure gradients are primarily in the axial direction throughout.

Hingst, Warren R.↗

Effect of Various Modifications on Drag and Longitudinal Stability and Control Characteristics at Transonic Speeds of a Model of the XF7U-1 Tailless Airplane: NACA Wing-FLow Method, TED No. NACA DE 307

An investigation was made by the NACA wing-flow method to determine the drag, pitching-moment, lift, and angle-of-attack characteristics at transonic speeds of various configurations of a semispan model of an early configuration of the XF7U-1 tailless airplane. The results of the tests indicated that for the basic configuration with undeflected ailavator, the zero-lift drag rise occurred at a Mach number of about 0.85 and that about a five-fold increase in drag occurred through the transonic speed range. The results of the tests also indicated that the drag increment produced by -8.0 degrees deflection of the ailavator increased with increase in normal-force coefficient and was smaller at speeds above than at speeds below the drag rise. The drag increment produced by 35 degree deflection of the speed brakes varied from 0.040 to 0.074 depending on the normal-force coefficient and Mach number. These values correspond to drag coefficients of about 0.40 and 0.75 based on speed-brake frontal area. Removal of the fin produced a small positive drag increment at a given normal-force coefficient at speeds during the drag rise. A large forward shift of the neutral-point location occurred at Mach numbers above about 0.90 upon removal of the fin, and also a considerable forward shift throughout the Mach number range occurred upon deflection of the speed brakes. Ailavator ineffectiveness or reversal at low deflections, similar to that determined in previous tests of the basic configuration of the model in the Mach number range from about 0.93 to 1.0, was found for the fin-off configuration and for the model equipped with skewed (more highly sweptback) hinge-line ailavators. With the speed brakes deflected, little or no loss in the incremental pitching moment produced by deflection of the ailavator from O degrees to -8.00 degrees occurred in the Mach number range from 0.85 to 1.0 in contrast to a considerable loss found in previous tests with the speed brakes off.

Sawyer, Richard H.↗