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Thermal systems

Find NASA NTRS and DOE OSTI research on heat transfer and thermal systems. Search heat pipes, cooling and thermal management in report titles and abstracts.

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DOE OSTI2022

Design of Phase-Change Thermal Storage Device in a Heat Pump for Building Electric Peak Load Shaving: Preprint

Replacing carbon-intensive fossil fuel heating systems with electric heat pumps powered by renewables is a promising approach to decarbonize the building sector. However, one of the technical barriers of this approach is the large scale of heat demand, which will put excessive stress on the electricity grid. Integrating thermal energy storage (TES) into the heating systems can help alleviate this problem, by shifting thermal load and thus shaving peaks in the building electric load. Therefore, it is critical to understand how to design a thermal storage device in a heat pump for peak load shaving. In this study, we developed a numerical model for a cascaded vapor compression heat pump system integrating a phase change thermal storage device. This novel system can control the net thermal charging and discharging rate of the TES independently from the building's thermal load, which allows for precise control of electric power use. In the current study, we controlled the system to shave building electric peak load during a cold winter morning, and to charge TES during the relatively warm afternoon while still providing space heating. We used the model to evaluate the system performance with and without peak shaving. We also investigated the effect of PCM transition Tt on the peak reduction and electric energy saving potentials. The results show that peak shaving scheme effectively reduces the peak electric power consumption during a predefined discharge time window. When comparing to the no shaving case, for PCM Tt = 10 degrees C, the peak electric load reduction is 23.5%. When comparing to an air-source heat pump with back up electric heater, as Tt increases from 0 to 20 degrees C, the peak reduction increases from 46.1% to 50.9%. Integrating PCM Tt = 10 degrees C with peak shaving leads to the 45.5% of electric energy saving, which is the highest among the three transition temperatures.

electric energy saving↗

DOE OSTI2020

Influence of Irradiation-induced Microstructural Defects on Thermal Transport in Single Crystal Thorium Dioxide

Microstructural defects formed as a result of fission fragment damage are known to drastically alter thermal conductivity, a fuel property that governs the efficiency of a nuclear reactor. A fundamental understanding of radiation-induced effects on thermal transport is critical for the development of advanced fuels. Ion-irradiation has widely been used to simulate the effects of neutron-irradiation by seeding atomic-to-nanoscale defects of controllable size and density. In this work, we investigate the influence of microstructural defects, induced by ion-irradiation, on the thermal properties of single crystal thorium dioxide samples grown using the hydrothermal technique. The samples were irradiated using 2 MeV protons at room temperature. A laser-based modulated thermoreflectance technique was used to measure the thermal diffusivity and conductivity within the damaged ThO2 region. The experimentally measured thermal properties were compared with Boltzmann Transport Equation predictions, to determine the impact of various defect types on the thermal properties of ThO2.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Anisotropy in Thermal Conductivity of Ga2O3 under Irradiation: Ab-initio Investigations

Ga2O3 is a wide-bandgap semiconducting material known for its high breakdown electric field and thermal stability. Its various crystalline forms have shown great potential in power electronics, optoelectronics, and high-temperature applications. Specifically, ß-Ga2O3 has been recognized for its suitability in neutron and gamma radiation detection, making it ideal for sensor and detector applications [1]. Notably, ß-Ga2O3 exhibits anisotropic thermal conductivity, meaning that the magnitude of thermal conductivity varies with the crystallographic direction [2]. Under neutron irradiation, Ga2O3 undergoes a significant phenomenon, resulting in the formation of Helium bubbles within its crystalline matrix. The presence of Helium in Ga2O3 has been found to influence the material's anisotropic thermal conductivity. In this study, the objectives were twofold: firstly, to employ Density Functional Theory (DFT) to determine the most probable sites of Helium occupation in ß-Ga2O3, and secondly, to investigate the anisotropic variation in thermal conductivity when Helium is present in the crystalline matrix of ß-Ga2O3. These ab-initio DFT studies provide crucial insights into understanding the behavior of Helium in Ga2O3 and its impact on thermal conductivity, which can contribute to further advancements in sensor and detector applications based on this wide-bandgap semiconductor.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Development of a phonon-based sampling method for thermal neutron scattering data

Simulations of reactor systems require access to accurate nuclear data. For many systems, thermal neutron scattering data can have large effects on the eigenvalue and neutron flux distributions. Inelastic thermal neutron scattering can excite or de-excite vibrational, rotational, and translational modes in a material, so thermal scattering evaluations are often obtained by summing over the number of phonons created/destroyed by a scattering event. In recent years, the thermal scattering cross sections and angular distributions have greatly improved in accuracy, but the format in which this data is delivered to simulation codes has remained virtually unchanged. Thermal scattering data is typically either compiled into large tables and sorted by incoming neutron energy, outgoing neutron energy, scattering angle, and material temperature, or represented as cumulative distribution functions of momentum exchange or energy exchange. Either method can be quite memory intensive when fine bins are used. In an effort to decrease the amount of space that processed thermal scattering data requires, an alternate format is proposed. The phonon-based sampling method introduced here can sample the number of phonons excited for each collision, the change in neutron energy, and the scattering angle while avoiding pre-computed angular bins and limiting the amount of data that is dependent on incoming energy. Through this method, the generation and storage of large interpolation tables is avoided, which could have benefits in both memory storage and accuracy. While the initial implementation of this method is slower than current alternatives, it is significantly more resistant to grid coarseness errors and has good potential for improvement. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Morphological-informed Thermal Property Prediction in the Engineering Domain

Using first-principle, atomic scale methods to predict thermal carrier (electron and phonon) behavior at nanoscale yields highly resolved thermal properties. Density functional theory simulations can model myriad effects on the transport of phonons and electrons (e.g., phonon and electron coupling, electron correlation, defect presence, carrier scattering), and yield thermal properties for small geometric domains such as thermal and electrical conductivity, or heat capacity. While these thermal properties are accurate in atomistic and nanoscopic systems, they must be scaled up to the microstructural domain to be a useful predictor for experimental basis, as the microscale is where myriad changes and physical phenomenon occur within a material (e.g., grain boundaries, precipitate aggregations, interfaces, defect clusters). My talk will discuss the necessity of thermal property predictions for nuclear fuels applications and more. Additionally I will discuss the necessity in developing multi-physics, multi-scale methods for future applications in predictions for not only nuclear fuels, but other materials applications.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Thermal Optimization and Experimental Demonstration of a Silicon Carbide, Half-Bridge Power Module

This paper describes modeling and experimental work to design and demonstrate a silicon carbide (SiC), single-side-cooled power module. Two SiC metal-oxide-semiconductor field-effect transistors (MOSFET) were used for each switch position and packaged on a metalized ceramic substrate. Thermal modeling was first conducted to optimize the module packaging to minimize junction-to-fluid thermal resistance and device temperature variations. This procedure identified the optimal device placement and baseplate thickness to maximize thermal performance. A heat exchanger - incorporating impinging jets of water-ethylene glycol - was designed to cool the module's baseplate to minimize thermal resistance and pumping power. The heat exchanger used relatively low fluid velocities (<1.5 m/s) to minimize erosion-corrosion effects and relatively large fluid channel sizes (>=1 mm) to prevent clogging. The power module concept was fabricated, and experiments were conducted to measure its thermal performance. Direct current was used to power the module devices, and junction temperatures were measured via device temperature-sensitive parameters. The experimental results were found to be in good agreement with model predictions (within 2%) and yielded junction-to-fluid thermal resistance values as low as about 15 mm2 K/W at relatively low pumping power values. The results demonstrate the improved performance associated with jet impingement cooling and represent an improvement over existing channel-flow-type cold plates, which can enable improvements to power density and reliability.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Stochastic Thermo-Hydro Modeling and Neural Network Surrogate Development for Thermal Resource Assessment of the Galleries-to-Calories Geobattery

The Galleries-to-Calories Geobattery concept explores the use of abandoned coal mine workings for large-scale thermal energy transport and storage. The system involves injecting waste heat from a supercomputing facility into flooded mine galleries, where groundwater flow can store and transport thermal energy for potential recovery in downgradient district heating and cooling applications. To evaluate the feasibility and performance of the Geobattery under geological and operational uncertainty, we developed a suite of stochastic thermo-hydrological (TH) simulations using Monte Carlo sampling of key uncertain parameters (e.g., permeability, porosity, thermal conductivity, specific heat capacity) and operating conditions (e.g., injection rate, injection temperature). Results identified injection rate and temperature as the most influential parameters governing thermal front propagation, while the geometry of the room-and-pillar structure played a critical role in directing the extent and orientation of thermal advancement. Optimal combinations of material properties for maximizing heat recovery were also determined. To address the high computational cost of coupled-process stochastic modeling, we trained a neural network surrogate model on 24,000 physics-based realizations, achieving an R² > 0.99 and MAE < 0.1 for temperature predictions at monitoring locations. This surrogate enabled an additional 100,000 realizations for global sensitivity analysis and probabilistic thermal resource assessment. The integrated stochastic physics–surrogate modeling framework offers a computationally efficient tool for quantifying uncertainty, identifying key drivers, and informing early-stage design decisions for Geobattery systems.

15 - GEOTHERMAL ENERGY↗

DOE OSTI2022

Multilevel Analysis, Design, and Modeling of Coupling Advanced Nuclear Reactors and Thermal Energy Storage in an Integrated Energy System

This report discusses the different options for coupling thermal energy storage (TES) systems to advanced nuclear power plants (A-NPPs) in order to enable flexible and hybrid plant operation. An advanced light-water reactor (A LWR), a high-temperature gas-cooled reactor (HTGR) and a liquid-metal fast reactor (LMFR) were selected as the initial use cases for demonstrating a thermally balanced energy storage coupling design for thermal power extraction. The models presented herein showcase several design considerations, focusing on optimal deployment methodologies for achieving steady-state and transient-state operation with minimum disruption to the nuclear power cycle. This first part of the study presents steady-state models developed using Aspen HYSYS®, with the thermal energy bypass for NPP-TES coupling being varied at up to 50%. The various components were sized using the Aspen Process Economic Analyzer (APEA) and Aspen Exchanger Design and Rating (EDR), when applicable. Cost functions from these models were developed using the latest publicly available data obtained from APEA V11. The TES-coupled A-NPP steady-state models and cost functions then provided a baseline for dynamic operation and process optimization by using Idaho National Laboratory (INL)’s Framework for Optimization of Resources and Economics (FORCE) tools. A stochastic optimization of the various energy storage systems coupled to the A-NPPs was then performed using the Risk Analysis Virtual Environment (RAVEN) and its dispatch optimization plugin, the Holistic Energy Resource Optimization Network (HERON). The signal processing and synthetic history capabilities of RAVEN were used to account for the unpredictable behavior of electricity markets. An autoregressive moving average (ARMA) model was used to analyze price signals from the Pennsylvania-New Jersey-Maryland (PJM) market and were applied to the HERON analysis in order to optimize a system with the best economics. Transient modeling evaluation was then performed using Modelica models within the HYBRID repository, which was developed at INL for the Department of Energy Integrated Energy Systems program for the characterization of dynamic integrated system behavior and feedback. This includes evaluation of the TES-coupled A-LWR systems’ impact on physical and thermal system response during imposed system demands. Additional TES-coupled reactor types, coupling approaches, markets, and TES technologies will be evaluated in future work.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Cabin Thermal Management Analysis for SuperTruck II Next-Generation Hybrid Electric Truck Design

In this article, we present a multistage, coupled thermal management simulation approach, informed by physical testing where available, to aid design decisions for PACCAR's SuperTruck II hybrid truck cabin concept. Focus areas include cabin insulation, battery sizing, and sleeper curtain position, as well as heating, ventilating, and air-conditioning (HVAC) component and accessory configurations, to maintain or improve thermal comfort while saving energy. The authors analyzed weather data and determined the national vehicle miles traveled weighted temperature and solar conditions for long-haul trucks. Example weather day profiles were selected to approximate the 5th and 95th percentile weighted conditions. A daylong drive cycle was developed to impose appropriate external wind conditions during rest and driving periods. Using the National Renewable Energy Laboratory's vehicle HVAC modeling and simulation tool VTCab, HVAC load design trade-off studies for the new truck geometry concept were completed. Parameters analyzed included effects of paint color, insulation, glass transmissivity, and curtain location. Simulation results helped with early design material selections for efficient cabin climate control. A detailed three-dimensional computer-aided engineering (CAE), computational fluid dynamics (CFD), radiation, and human physiology co-simulation, referred to in this article as CAE Thermal-CFD, was used to evaluate thermal comfort and energy impacts of diffuser configurations and air supply settings in driving and hoteling modes. Analysis revealed that it is more difficult to heat the cabin in hoteling mode during the winter than to cool the space in the summer. This seasonal load profile drives the requirement of additional energy storage for heating comfort. To determine the battery capacity requirement, multiday HVAC operation drive cycle simulations were then completed, showing that a 15-kWh battery would be required for HVAC operation during hoteling. Results helped reduce cabin thermal loads, determine component sizing requirements, and improve occupant comfort to save fuel and contribute to the economic viability of the hybrid system.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Predicting defects in laser powder bed fusion using in-situ thermal imaging data and machine learning

Variation in the local thermal history during the Laser Powder Bed Fusion (LPBF) process in Additive Manufacturing (AM) can cause micropore defects, which add to the uncertainty of the mechanical properties (e.g., fatigue life, tensile strength) of the built materials. In-situ sensing has been proposed for monitoring the AM process to minimize defects, but successful minimization requires establishing a quantitative relationship between the sensing data and the porosity, which is particularly challenging with a large number of variables (e.g., laser speed, power, scan path, powder property). Physics-based modeling can simulate such an in-situ sensing-porosity relationship, but it is computationally costly. In this work, we develop Machine Learning (ML) models that can use in-situ thermographic data to predict the micropore of LPBF stainless steel materials. This work considers two identified key features from the thermal histories: the time above the apparent melting threshold ($\tau$) and the maximum radiance ( T max ). These features are computed, stored for each voxel in the built material, and then used as inputs. The binary state of each voxel, either defective or normal, is the output. Different ML models are trained and tested for the binary classification task. In addition to using the thermal features of each voxel to predict its own state, the thermal features of neighboring voxels are also included as inputs. This is shown to improve the prediction accuracy, which is consistent with thermal transport physics around each voxel contributing to its final state. Among the models trained, the F1 scores on test sets reach above 0.96 for Random Forests. Feature importance analysis based on the ML models shows that T max is more important to the voxel state than $\tau$ . The analysis also finds that the thermal history of the voxels above the present voxel is more influential than those beneath it. Our study significantly extends the capability of using in-situ thermographic data to predict porosity in LPBF materials. Finally, since ML models are fast, they may play integral roles in the optimization and control of such AM technologies.

36 MATERIALS SCIENCE↗

NASA NTRS1975

Thermal scale modeling of a manned spacecraft

A manned spacecraft thermal scale modeling program is described. The program consisted of the design, construction, instrumentation, testing, data correlation, and associated analysis of a transient thermal scale model (TSM) of the Subsystem Test Bed (STB). The STB was chosen as a representative manned spacecraft for which detailed thermal vacuum test data were available. The STB is a cylindrical vehicle (15 ft diameter by 8.3 ft high) with four docking hatches and six windows. The pressure shell is insulated with multilayer insulation and protected by meteoroid shields. Four truss assemblies were used to support the STB during testing. It was concluded that thermal scale modeling can be used as an effective thermal design/verification tool for manned spacecraft. Thermal analysis can be used in conjunction with scale model testing to provide a verified math model that can be applied to the prototype manned spacecraft.

Shannon, R. L.↗

NASA NTRS1978

An assessment of thermal design procedures for Shuttle payloads

A review of the thermal design options for unmanned Shuttle payloads is presented. Because many future Shuttle payloads will have budgets and less time available for the definition of their thermal subsystems, simplified design procedures will be the most cost-effective. The thermal interface between an individual payload and the Orbiter is discussed. A simplified, modular thermal control system that will reduce the cost of providing thermal protection by minimizing both the initial procurement cost of any specialized hardware and the need for a detailed thermal interface analysis is described.

Almgren, D. W.↗

NASA NTRS1981

User's Manual: Thermal Radiation Analysis System TRASYS 2

A digital computer software system with generalized capability to solve the radiation related aspects of thermal analysis problems is presented. When used in conjunction with a generalized thermal analysis program such as the systems improved numerical differencing analyzer program, any thermal problem that can be expressed in terms of a lumped parameter R-C thermal network can be solved. The function of TRASYS is twofold. It provides: (a) Internode radiation interchange data; and (b) Incident and absorbed heat rate data from environmental radiant heat sources. Data of both types is provided in a format directly usable by the thermal analyzer programs. The system allows the user to write his own executive or driver program which organizes and directs the program library routines toward solution of each specific problem in the most expeditious manner. The user also may write his own output routines, thus the system data output can directly interface with any thermal analyzer using the R-C network concept.

Jensen, C. L.↗

NASA NTRS1983

Thermal conductance of pressed contacts at liquid helium temperatures

It is pointed out that the optimum design of cryogenic instruments requires accurate thermal models. The present models are limited by a lack of knowledge of the low temperature thermal conductance of the bolted joints which are typically used in the instrument-to-system interface. In connection with studies of pressed contacts, it has been found that the thermal conductance does not obey the Wiedemann-Franz law. The present investigation is concerned with the characterization of the thermal conductance of pressed contacts at liquid helium-4 temperatures, taking into account the dependence of thermal contact conductance on applied force and temperature. It is shown that for the 0.4 micron OFHC copper pressed contact pair, the thermal conductance varies roughly as the second power of the temperature, and increases with increasing applied force.

Salerno, L. J.↗

NASA NTRS1982

The use of thermal infrared images in geologic mapping

Thermal infrared image data can be used as an aid to geologic mapping. Broadband thermal data between 8 and 13 microns is used to measure surface temperature, from which surface thermal properties can be inferred. Data from aircraft multispectral scanners at Pisgah, California which include a broadband thermal channel along with several visible and near-IR spectral channels permit better discrimination between rock type units than the same data set without the thermal data. Data from the HCMM satellite and from aircraft thermal scanners also make it possible to monitor moisture changes in Death Valley, California. Multispectral data in the same 8-13 micron wavelength range can be used to discriminate between surface materials with different spectral emission characteristics, as demonstrated with both aircraft scanner and ground spectrometer data.

Kahle, A. B.↗

NASA NTRS1992

Heat and Mass Transport from Thermally Degrading Thin Cellulosic Materials in a Microgravity Environment

Attention is given to a theoretical model describing the behavior of a thermally thin cellulosic sheet heated by external thermal radiation in a quiescent microgravity environment. This model describes thermal and oxidative degradation of the sheet and the heat and mass transfer of evolved degradation products from the heated cellulosic surface into the gas phase. Two calculations are carried out: heating without thermal degradation, and heating with thermal degradation of the sheet with endothermic pyrolysis, exothermic thermal oxidative degradation, and highly exothermic char oxidation. It is shown that pyrolysis is the main degradation reaction. Self-sustained smoldering is controlled and severely limited by the reduced oxygen supply.

Kushida, G.↗

NASA NTRS1991

SSTAC/ARTS review of the draft Integrated Technology Plan (ITP). Volume 3: Space power and thermal management

Viewgraphs of briefings from the SSTAC/ARTS review of the draft integrated technology plan on thermal power and thermal management are presented. Topics covered include: space energy conversion research and technology; space photovoltaic energy conversion; chemical energy conversion and storage; thermal energy conversion; power management; thermal management; space nuclear power; high capacity power; surface power and thermal management; space platforms power and thermal management; and project SELENE.

Source record↗

NASA NTRS1997

Nonlinear Transient Thermal Analysis by the Force-Derivative Method

High-speed vehicles such as the Space Shuttle Orbiter must withstand severe aerodynamic heating during reentry through the atmosphere. The Shuttle skin and substructure are constructed primarily of aluminum, which must be protected during reentry with a thermal protection system (TPS) from being overheated beyond the allowable temperature limit, so that the structural integrity is maintained for subsequent flights. High-temperature reusable surface insulation (HRSI), a popular choice of passive insulation system, typically absorbs the incoming radiative or convective heat at its surface and then re-radiates most of it to the atmosphere while conducting the smallest amount possible to the structure by virtue of its low diffusivity. In order to ensure a successful thermal performance of the Shuttle under a prescribed reentry flight profile, a preflight reentry heating thermal analysis of the Shuttle must be done. The surface temperature profile, the transient response of the HRSI interior, and the structural temperatures are all required to evaluate the functioning of the HRSI. Transient temperature distributions which identify the regions of high temperature gradients, are also required to compute the thermal loads for a structural thermal stress analysis. Furthermore, a nonlinear analysis is necessary to account for the temperature-dependent thermal properties of the HRSI as well as to model radiation losses.

Balakrishnan, Narayani V.↗