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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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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Enhanced pool boiling heat transfer with metal foam tubes in inline tube bundle configuration

Flooded evaporators, commonly known as shell-and-tube heat exchangers, are widely used in large-scale industrial refrigeration and air-conditioning systems due to their high pool boiling heat transfer efficiency. However, their bulky configuration requires a large refrigerant inventory, which poses safety challenges—particularly when employing next-generation A2L refrigerants that are mildly flammable. Here, to address this issue, the development of compact heat exchangers with enhanced heat transfer performance is essential. In this study, a novel metal foam tube design is proposed to augment pool boiling heat transfer. Experiments were conducted at a saturation temperature of 20 °C and across a heat flux range of 7–60 kW m −2 . The tests were conducted for both smooth and metal foam tubes with an inline tube bundle configuration and for a pitch–to–diameter (P/D) ratios of 1.3 and 1.5. Pool boiling performance was evaluated for next-generation hydrofluoroolefin (HFO) refrigerants, R1234yf and R1234ze(E), with R134a serving as the baseline fluid. The results indicate that the heat transfer coefficient (HTC) of R1234yf is comparable to R134a, while R1234ze(E) shows slightly lower performance. Importantly, the metal foam tubes achieved up to a 217% enhancement in HTC compared to smooth tubes.

Metal foam tubes↗
NASA NTRS1983

Reynolds number effects on pressure loss and turbulence characteristics of four tube-bundle heat exchangers

The aerodynamic characteristics of pressure loss and turbulence on four tube-bundle configurations representing heat-exchanger geometries with nominally the same heat capacity were measured as a function of Reynolds numbers from about 4000 to 400,000 based on tube hydraulic diameter. Two configurations had elliptical tubes, the other two had round tubes, and all four had plate fins. The elliptical-tube configurations had lower pressure loss and turbulence characteristics than the round-tube configurations over the entire Reynolds number range.

Gentry, L., Jr.↗
NASA NTRS1990

New method of making advanced tube-bundle rocket thrust chambers

An improved method of fabrication rocket chambers for future space applications is described. Included are fabrication demonstrator and test chambers produced by this method. This concept offers the promise of improved cyclic life, reusability, and performance. The performance is improved because of the enhanced enthalpy extraction. The improved cyclic life, reusability, and reliability is improved because of the structural compliance inherent in the construction. The method of construction involves the forming of the combustion chamber by a tube-bundle of high conductivity copper or copper alloy tubes and the bonding of these tubes by a unique electroforming operation. Furthermore, the method of fabrication reduces chamber complexity by incorporating manifolds, and structural stiffeners while having the potential for thrust chamber cost and weight reduction.

Kazaroff, John M.↗
NASA NTRS1990

Advanced tube-bundle rocket thrust chamber

An advanced rocket thrust chamber for future space application is described along with an improved method of fabrication. Potential benefits of the concept are improved cyclic life, reusability, and performance. Performance improvements are anticipated because of the enhanced heat transfer into the coolant which will enable higher chamber pressure in expander cycle engines. Cyclic life, reusability and reliability improvements are anticipated because of the enhanced structural compliance inherent in the construction. The method of construction involves the forming of the combustion chamber with a tube-bundle of high conductivity copper or copper alloy tubes, and the bonding of these tubes by an electroforming operation. Further, the method of fabrication reduces chamber complexity by incorporating manifolds, jackets, and structural stiffeners while having the potential for thrust chamber cost and weight reduction.

Kazaroff, John M.↗
NASA NTRS1990

Advanced tube-bundle rocket thrust chamber

An advanced rocket thrust chamber for future space application is described along with an improved method of fabrication. Potential benefits of the concept are improved cyclic life, reusability, and performance. Performance improvements are anticipated because of the enhanced heat transfer into the coolant which will enable higher chamber pressure in expander cycle engines. Cyclic life, reusability and reliability improvements are anticipated because of the enhanced structural compliance inherent in the construction. The method of construction involves the forming of the combustion chamber with a tube-bundle of high conductivity copper or copper alloy tubes, and the bonding of these tubes by an electroforming operation. Further, the method of fabrication reduces chamber complexity by incorporating manifolds, jackets, and structural stiffeners while having the potential for thrust chamber cost and weight reduction.

Kazaroff, John M.↗
DOE OSTI2024

Novel Full-Ceramic Multi-Tubular Membrane Systems for Pre-Combustion CO2 Capture with Simultaneous H2 Production: Fabrication, Performance Testing, and 3D CFD Modeling

Inorganic membranes show promise for application in pre-combustion CO2 capture with simultaneous H2 production. State-of-the-art systems for use under high temperature and pressure conditions consist of multiple membrane tube bundles prepared in a "candle-filter" configuration, in which the membrane tubes are open at one end and sealed at the other. This configuration is used for practical reasons, specifically the need to minimize potential problems due to thermal expansion mismatch, at high temperatures, between the ceramic tube bundle and the steel housing. The primary technical problem with the candle-filter configuration for use in commercial-scale installations is the inability to purge the permeate side (typically the tube side), a feature that is crucial for high H2 recovery. In this study, we fabricated dual-end open, commercial-size ceramic multiple-tube bundles made of zeolite, palladium (Pd), and carbon molecular sieve (CMS) membranes that enable permeate-side (tube-side) purge for gas separation applications. Experimental gas separation data with these membrane bundles under harsh operating conditions (temperatures up to 350 and pressures up to 800 psig), to be presented at the meeting, manifest excellent performance. Parallel to the membrane bundle construction and testing efforts, we have also developed a detailed 3D CFD modeling package using COMSOL Multiphysics software to gain more insight into the effect on the H2 purity and recovery of the detailed geometry of the multi-tubular membrane system, including the number of tubes used, their dimensions, and placement in the bundle, as well as the number, type, and positioning of internal baffles and other flow-enhancement accessories. The CFD package is validated with experimental data from different systems (1-tube, 3-tube, and 19-tube bundles), and shows high accuracy in predicting the experimental results (<5 % error in all cases). The results of our study show that the detailed internal geometry of these multi-tubular membrane systems has a considerable impact on the performance of the system as the flow maldistribution within the shell-side can substantially decrease (>40%) the H2 recovery.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRS1979

Aerodynamic characteristics at low Reynolds numbers of several heat-exchanger configurations for wind-tunnel use

In response to design requirements of the National Transonic Facility, aerodynamic tests were conducted to determine the pressure-drop, flow-uniformity, and turbulence characteristics of various heat-exchanger configurations as a function of Reynolds number. Data were obtained in air with an indraft flow apparatus operated at ambient temperature and pressure. The unit Reynolds number of the tests varied from about 0.06 x 10 to 6th power to about 1.3 x 10 to 6th power per meter. The test models were designed to represent segments of full-scale tube bundles and included bundles of round tubes with plate fins in both staggered and inline tube arrays, round tubes with spiral fins, elliptical tubes with plate fins, and an inline grouping of tubes with segmented fins.

Johnson, W. G., Jr.↗
NASA NTRS2016

Design, Development, and Testing of a Water Vapor Exchanger for Spacecraft Life Support Systems

Thermal and environmental control systems for future exploration spacecraft must meet challenging requirements for efficient operation and conservation of resources. Maximizing the use of regenerative systems and conserving water are critical considerations. This paper describes the design, development, and testing of an innovative water vapor exchanger (WVX) that can minimize the amount of water absorbed in, and vented from, regenerative CO2 removal systems. Key design requirements for the WVX are high air flow capacity (suitable for a crew of six), very high water recovery, and very low pressure losses. We developed fabrication and assembly methods that enable high-efficiency mass transfer in a uniform and stable array of Nafion tubes. We also developed analysis and design methods to compute mass transfer and pressure losses. We built and tested subscale units sized for flow rates of 2 and 5 cu ft/min (3.4–8.5 cu m/hr). Durability testing demonstrated that a stable core geometry was sustained over many humid/dry cycles. Pressure losses were very low (less than 0.5 in. H2O (125 Pa) total) and met requirements at prototypical flow rates. We measured water recovery efficiency across a range of flow rates and humidity levels that simulate the range of possible cabin conditions. We measured water recovery efficiencies in the range of 80 to 90%, with the best efficiency at lower flow rates and higher cabin humidity levels. We compared performance of the WVX with similar units built using an unstructured Nafion tube bundle. The WVX achieves higher water recovery efficiency with nearly an order of magnitude lower pressure drop than unstructured tube bundles. These results show that the WVX provides uniform flow through flow channels for both the humid and dry streams and can meet requirements for service on future exploration spacecraft. The WVX technology will be best suited for long-duration exploration vehicles that require regenerative CO2 removal systems while needing to conserve water.

Izenson, Michael G.↗
NASA NTRS2014

High-Lift OVERFLOW Analysis of the DLR-F11 Wind Tunnel Model

In response to the 2nd AIAA CFD High Lift Prediction Workshop, the DLR-F11 wind tunnel model is analyzed using the Reynolds-averaged Navier-Stokes flow solver OVERFLOW. A series of overset grids for a bracket-off landing configuration is constructed and analyzed as part of a general grid refinement study. This high Reynolds number (15.1 million) analysis is done at multiple angles-of-attack to evaluate grid resolution effects at operational lift levels as well as near stall. A quadratic constitutive relation recently added to OVERFLOW for improved solution accuracy is utilized for side-of-body separation issues at low angles-of-attack and outboard wing separation at stall angles. The outboard wing separation occurs when the slat brackets are added to the landing configuration and is a source of discrepancy between the predictions and experimental data. A detailed flow field analysis is performed at low Reynolds number (1.35 million) after pressure tube bundles are added to the bracket-on medium grid system with the intent of better understanding bracket/bundle wake interaction with the wing's boundary layer. Localized grid refinement behind each slat bracket and pressure tube bundle coupled with a time accurate analysis are exercised in an attempt to improve stall prediction capability. The results are inconclusive and suggest the simulation is missing a key element such as boundary layer transition. The computed lift curve is under-predicted through the linear range and over-predicted near stall, and the solution from the most complete configuration analyzed shows outboard wing separation occurring behind slat bracket 6 where the experiment shows it behind bracket 5. These results are consistent with most other participants of this workshop.

High-lift↗
NASA NTRS2014

Grid-Adapted FUN3D Computations for the Second High Lift Prediction Workshop

Contributions of the unstructured Reynolds-averaged Navier-Stokes code FUN3D to the 2nd AIAA CFD High Lift Prediction Workshop are described, and detailed comparisons are made with experimental data. Using workshop-supplied grids, results for the clean wing configuration are compared with results from the structured code CFL3D Using the same turbulence model, both codes compare reasonably well in terms of total forces and moments, and the maximum lift is similarly over-predicted for both codes compared to experiment. By including more representative geometry features such as slat and flap brackets and slat pressure tube bundles, FUN3D captures the general effects of the Reynolds number variation, but under-predicts maximum lift on workshop-supplied grids in comparison with the experimental data, due to excessive separation. However, when output-based, off-body grid adaptation in FUN3D is employed, results improve considerably. In particular, when the geometry includes both brackets and the pressure tube bundles, grid adaptation results in a more accurate prediction of lift near stall in comparison with the wind-tunnel data. Furthermore, a rotation-corrected turbulence model shows improved pressure predictions on the outboard span when using adapted grids.

Lee-Rausch, E. M.↗
NASA NTRS1977

Tubular sublimatory evaporator heat sink

An evaporative refrigerator or cooler comprising a bundle of spaced, porous walled tubes closed at one of their ends and vented to a vacuum at the other end is disclosed. The tube bundle is surrounded by a water jacket having a hot water inlet distribution manifold and a cooled water outlet through a plenum chamber. Hot water is pumped into the jacket to circulate around the tubes, and when this water meets the vacuum existing inside the tubes, it evaporates thereby cooling the water in the jacket. If cooling proceeds to the point where water penetrating or surrounding all or part of the tubes freezes, operation continues with local sublimation of the ice on the tubes while the circulating water attempts to melt the ice. Both sublimation and evaporation may take place simultaneously in different regions of the device.

Webbon, B. W.↗
DOE OSTI2025

Compact Counter Flow Fluidized Bed Heat Exchanger (Final Report)

Generation 3 concentrating solar power systems which utilize solid granular media as the heat transfer and storage media hold promise in reducing the levelized cost of electricity relative to generation 2 systems which utilize molten salt. The particles can be heated to temperatures exceeding 800 °C which enables the use of high efficiency supercritical CO 2 Brayton power cycles. A key challenge associate with the use of solid media is its low bulk thermal conductivity which limits the ability to transfer heat from the particles to a working fluid, such as supercritical CO 2 . Tradition shell and tube and shell and plate heat exchangers feature gravity driven particle flow which limits the maximum particle side heat transfer coefficient in these systems to approximately 400 W/m 2 K. A fluidized bed heat exchanger does not rely solely on gravity for particle flow. Instead, enhanced mixing and horizontal conveyance is achieved through fluidization induced through air injection at the bottom of a bed of particles. A tube bundle within the bed conveys the supercritical CO 2 which is heated via the turbulent particle motion at the tube wall.

14 SOLAR ENERGY↗
NASA NTRS1977

Large-scale thermal energy storage using sodium hydroxide /NaOH/

A technique employing NaOH phase change material for large-scale thermal energy storage to 900 F (482 C) is described; the concept consists of 12-foot diameter by 60-foot long cylindrical steel shell with closely spaced internal tubes similar to a shell and tube heat exchanger. The NaOH heat storage medium fills the space between the tubes and outer shell. To charge the system, superheated steam flowing through the tubes melts and raises the temperature of NaOH; for discharge, pressurized water flows through the same tube bundle. A technique for system design and cost estimation is shown. General technical and economic properties of the storage unit integrated into a solar power plant are discussed.

Turner, R. H.↗
NASA NTRS1979

Lean stability augmentation for premixing, prevaporizing combustors

An experimental program was conducted to investigate techniques for improving the lean combustion limits of premixing, prevaporizing combustors applicable to gas turbine engine main burners. Augmented flameholders employing recessed perforated plates, catalyzed tube bundles, and configurations in which pilot fuel was injected into the wakes of V-gutters or perforated plates were designed and tested. Stable operation of the piloted designs was achieved at equivalence ratios as low as 0.25; NOx emissions of less than 1.0 g/kg at simulated turbine engine cruise conditions were obtained. A piloted perforated plate employing four percent pilot fuel flow produced the best performance while meeting severe NOx constraints.

Mcvey, J. B.↗
NASA NTRS1981

Space Shuttle main engine nozzle-steerhorn dynamics

On two occasions during the Space Shuttle main engine development, the LH2 feedline (called the steerhorn, because of its shape) failed during the cutoff transient. A dynamic test was undertaken, and an analytical model was developed and correlated to the dynamic test. Detailed models of the tube bundle were required to obtain the equivalent shell coefficients. All-shell models of the nozzle wall were found better than beam-shell models. The most difficult part of the structure to simulate was the felt-metal pad between the feedline and its mount, which introduced nonlinear stiffness and damping and led to the use of separate low amplitude and high amplitude models. The total structure was found to have 400 modes in the frequency range of interest, 0 to 500 Hz. Good test analysis correlation was obtained and a modified feedline configuration was found to demonstrate a 40% reduction of response stress from the original configuration.

Kiefling, L.↗
NASA NTRS1984

Repairing Hidden Cracks in Coolant Tubes

Repair technique closes leaks in tubes or conduits where access limited to wall opposite crack. Technique applicable to any tubular assembly where tubes bundled together or bonded to supporting shell, such as in heat exchangers. Procedure provides structural support to area failed and uninterrupted flow without significantly altering heat-transfer profile.

Mills, R. C., Sr.↗