Engineering topics
Publications and source records attributed to Alario, J..
Aluminum heat pipe extruded with reentrant axial grooves, which give better overall performance than conventional rectangular grooves. Reentrant grooves increase wicking height of cryogenic fluids and also lower amount of fluid charge required.
The development of the monogroove heat pipe, a fundamentally new high-performance device suitable for multi-kilowatt space radiator heat-rejection systems, is reported. The design separates heat transport and transfer functions, so that each can be separately optimized to yield heat transport capacities on the order of 25 kW/m. Test versions of the device have proven the concept of heat transport capacity control by pore dimensions and the permeability of the circumferential wall wick structure, which together render it insensitive to tilt. All cases tested were for localized, top-side heat input and cooling and produced results close to theoretical predictions.
Various active heat exchange concepts were identified from among three generic categories: scrapers, agitators/vibrators and slurries. The more practical ones were given a more detailed technical evaluation and an economic comparison with a passive tube-shell design for a reference application. Two concepts selected for hardware development are a direct contact heat exchanger in which molten salt droplets are injected into a cooler counterflowing stream of liquid metal carrier fluid, and a rotating drum scraper in which molten salt is sprayed onto the circumference of a rotating drum, which contains the fluid heat sink in an internal annulus near the surface. A fixed scraper blade removes the solidified salt from the surface which has been nickel plated to decrease adhesion forces. Suitable phase change material (PCM) storage media with melting points in the temperature range of interest (250 C to 400 C) were investigated. The specific salt recommended for laboratory tests was a chloride eutectic (20.5KCl-24/5 NaCl-55.0MgCl 2% by wt.), with a nominal melting point of 385 C.
Various active heat exchange concepts were identified from among three generic categories: scrapers, agitators/vibrators and slurries. The more practical ones were given a more detailed technical evaluation and an economic comparison with a passive tube-shell design for a reference application (300 MW sub t storage for 6 hours). Two concepts were selected for hardware development: (1) a direct contact heat exchanger in which molten salt droplets are injected into a cooler counterflowing stream of liquid metal carrier fluid, and (2) a rotating drum scraper in which molten salt is sprayed onto the circumference of a rotating drum, which contains the fluid salt is sprayed onto the circumference of a rotating drum, which contains the fluid heat sink in an internal annulus near the surface. A fixed scraper blade removes the solidified salt from the surface which was nickel plated to decrease adhesion forces. In addition to improving performance by providing a nearly constant transfer rate during discharge, these active heat exchanger concepts were estimated to cost at least 25% less than the passive tube-shell design.
Current heat pipe radiator technology is reviewed and the results from three state-of-the-art hardware programs are summarized. Heat pipe radiators are shown to be an improvement over all-fluid loop panels for long duration space missions, when micrometeoroid survivability is important. Finally, several heat pipe radiator design concepts are presented which would enhance Shuttle mission capabilities by either extending mission life and/or augmenting heat rejection capability.
Re-entrant groove technology was extended to hydrogen heat pipes. Parametric analyses are presented which optimize the theoretical design while considering the limitations of state-of-the-art extrusion technology. The 6063-T6 aluminum extrusion is 14.6 mm OD with a wall thickness of 1.66 mm and contains 20 axial grooves which surround a central 9.3 mm diameter vapor core. Each axial groove is 0.775 mm diameter with a 0.33 mm opening. An excess vapor reservoir is provided at the evaporator to minimize the pressure containment hazard during ambient storage. Modifications to the basic re-entrant groove profile resulted in improved overall performance. While the maximum heat transport capacity decreased slightly to 103 w-m the static wicking height increased markedly to 4.5 cm. The heat pipe became operational between 20 and 30 K after a cooldown from 77 K without any difficulty. Steady state performance data taken over a 19 to 23 K temperature range indicated: (1) maximum heat transport capacity of 5.4 w-m; (2) static wicking height of 1.42 cm; and (3) overall heat pipe conductance of 1.7 watts/deg C.
The development of spiral artery cryogenic thermal diode heat pipes was continued. Ethane was the working fluid and stainless steel the heat pipe material in all cases. The major tasks included: (1) building a liquid blockage (blocking orifice) thermal diode suitable for the HEPP space flight experiment; (2) building a liquid trap thermal diode engineering model; (3) retesting the original liquid blockage engineering model, and (4) investigating the startup dynamics of artery cryogenic thermal diodes. An experimental investigation was also conducted into the wetting characteristics of ethane/stainless steel systems using a specially constructed chamber that permitted in situ observations.
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Heat-Pipe panel assembled by joining series of Heat-Pipe modules is presented. Each module is identical and includes own radiator Fin and Fluid-Header section. Arrangement gives high turn-down ratio permitting ammonia heat pipes to freeze under low conditions.
This paper extends the development of reentrant groove technology to hydrogen heat pipes. Parametric analyses are presented which optimize the theoretical design while considering the limitations of state-of-the-art extrusion technology. Acceptable production-type runs of extruded lengths (over 300 m) could only be achieved at the expense of a wider nominal groove opening than specified (0.33 mm vs. 0.20 mm). However, dimensional variations of other critical dimensions were within 0.05 mm, which exceeded expectations. The 6063-T6 aluminum extrusion is 14.6 mm OD with a wall thickness of 1.66 mm and contains 20 axial grooves which surround a central 9.3-mm-diam vapor core. Each axial groove is 0.775-mm-diam with a 0.33 mm opening. An excess vapor reservoir is provided at the evaporator to minimize the pressure containment hazard during ambient storage. Details of the instrumentation and helium-cooled test installation are also presented.
A 15,000 watt spacecraft waste heat rejection system utilizing heat pipe radiator panels was investigated. Of the several concepts initially identified, a series system was selected for more in-depth analysis. As a demonstration of system feasibility, a nominal 500 watt radiator panel was designed, built and tested. The panel, which is a module of the 15,000 watt system, consists of a variable conductance heat pipe (VCHP) header, and six isothermalizer heat pipes attached to a radiating fin. The thermal load to the VCHP is supplied by a Freon-21 liquid loop via an integral heat exchanger. Descriptions of the results of the system studies and details of the radiator design are included along with the test results for both the heat pipe components and the assembled radiator panel. These results support the feasibility of using heat pipes in a spacecraft waste heat rejection system.
Heat pipe (HP) thermal control systems designed for possible space shuttle applications were built and tested under this program. They are: (1) a HP augmented cold rail, (2) a HP/phase change material (PCM) modular heat sink and (3) a HP radiating panel for compartment temperature control. The HP augmented cold rail is similar to a standard two-passage fluid cold rail except that it contains an integral, centrally located HP throughout its length. The central HP core helps to increase the local power density capability by spreading concentrated heat inputs over the entire rail. The HP/PCM modular heat sink system consists of a diode HP connected in series to a standard HP that has a PCM canister attached to its mid-section. It is designed to connect a heat source to a structural heat sink during normal operation, and to automatically decouple from it and sink to the PCM whenever structural temperatures are too high. The HP radiating panel is designed to conductively couple the panel feeder HPs directly to a fluid line that serves as a source of waste heat. It is a simple strap-on type of system that requires no internal or external line modifications to distribute the heat to a large radiating area.
Discussion of six specific applications for heat pipe (HP) devices on the space shuttle. These applications were chosen from 27 concepts formulated as part of a study to evaluate the potential benefits associated with HP use. The formulation process is briefly described along with the applications which evolved. The bulk of the discussion deals with the 'top' six - namely, HP radiators for waste heat rejection, an HP augmented cold rail, an HP circuit for electronic equipment cooling, modular heat sink for control of remote packages, an HP temperature control for compartments, and air-cooled equipment racks. The philosophy, physical design details, and performance data are presented for each concept along with a comparison with the baseline design where applicable.