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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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NASA NTRS2001

Integrated Thermal Response Tool for Earth Entry Vehicles

A system is presented for multi-dimensional, fully-coupled thermal response modeling of hypersonic entry vehicles. The system consists of a two-dimensional implicit thermal response, pyrolysis and ablation program (TITAN), a commercial finite-element thermal and mechanical analysis code (MARC), and a high fidelity Navier-Stokes equation solver (GIANTS). The simulations performed by this integrated system include hypersonic flow-field, fluid and solid interaction, ablation, shape change, pyrolysis gas generation and flow, and thermal response of heatshield and structure. The thermal response of the ablating and charring heatshield material is simulated using TITAN, and that of the underlying structural is simulated using MARC. The ablating heatshield is treated as an outer boundary condition of the structure, and continuity conditions of temperature and heat flux are imposed at the interface between TITAN and MARC. Aerothermal environments with fluid and solid interaction are predicted by coupling TITAN and GIANTS through surface energy balance equations. With this integrated system, the aerothermal environments for an entry vehicle and the thermal response of both the heatshield and the structure can be obtained simultaneously. Representative computations for a proposed blunt body earth entry vehicle are presented and discussed in detail.

Chen, Y.-K.↗

NASA NTRS2002

Thermal Response Modeling System for a Mars Sample Return Vehicle

A multi-dimensional, coupled thermal response modeling system for analysis of hypersonic entry vehicles is presented. The system consists of a high fidelity Navier-Stokes equation solver (GIANTS), a two-dimensional implicit thermal response, pyrolysis and ablation program (TITAN), and a commercial finite element thermal and mechanical analysis code (MARC). The simulations performed by this integrated system include hypersonic flowfield, fluid and solid interaction, ablation, shape change, pyrolysis gas generation and flow, and thermal response of heatshield and structure. The thermal response of the heatshield is simulated using TITAN, and that of the underlying structural is simulated using MARC. The ablating heatshield is treated as an outer boundary condition of the structure, and continuity conditions of temperature and heat flux are imposed at the interface between TITAN and MARC. Aerothermal environments with fluid and solid interaction are predicted by coupling TITAN and GIANTS through surface energy balance equations. With this integrated system, the aerothermal environments for an entry vehicle and the thermal response of the entire vehicle can be obtained simultaneously. Representative computations for a flat-faced arc-jet test model and a proposed Mars sample return capsule are presented and discussed.

Chen, Y.-K.↗

NASA NTRS2002

Thermal Design Overview of the Mars Exploration Rover Project

Contents include the following: Mission Overview. Thermal Environments. Driving Thermal Requirements. Thermal Design Approach. Thermal Control Block Diagram. Thermal Design Description. Thermal Analysis Results Summary. Testing Plans. Issues & Concerns.

Tsuyuki, Glenn↗

NASA NTRS2003

Surface Cracking and Interface Reaction Associated Delamination Failure of Thermal and Environmental Barrier Coatings

In this paper, surface cracking and interface reactions of a BSAS coating and a multi-layer ZTO2-8wt%Y2O3 and mullite/BSAS/Si thermal and environmental barrier coating system on SiC/SiC ceramic matrix composites were characterized after long-term combined laser thermal gradient and furnace cyclic tests in a water vapor containing environment. The surface cracking was analyzed based on the coating thermal gradient sintering behavior and thermal expansion mismatch stress characteristics under the thermal cyclic conditions. The interface reactions, which were largely enhanced by the coating surface cracking in the water vapor environment, were investigated in detail, and the reaction phases were identified for the coating system after the long- term exposure. The accelerated coating delamination failure was attributed to the increased delamination driving force under the thermal gradient cyclic loading and the reduced interface adhesion due to the detrimental interface reactions.

Zhu, Dongming↗

NASA NTRS2003

Surface Cracking and Interface Reaction Associated Delamination Failure of Thermal and Environmental Barrier Coatings

In this paper, surface cracking and interface reactions of a BSAS coating and a multi-layer ZrO2-8wt%Y2O3 and mullite/BSAS/Si thermal and environmental barrier coating system on SiC/SiC ceramic matrix composites were characterized after long-term combined laser thermal gradient and furnace cyclic tests in a water vapor containing environment. The surface cracking was analyzed based on the coating thermal gradient sintering behavior and thermal expansion mismatch stress characteristics under the thermal cyclic conditions. The interface reactions, which were largely enhanced by the coating surface cracking in the water vapor environment, were investigated in detail, and the reaction phases were identified for the coating system after the long-term exposure. The accelerated coating delamination failure was attributed to the increased delamination driving force under the thermal gradient cyclic loading and the reduced interface adhesion due to the detrimental interface reactions.

Zhu, Dong-Ming↗

NASA NTRS2004

Weight Optimization of Active Thermal Management Using a Novel Heat Pump

Efficient lightweight power generation and thermal management are two important aspects for space applications. Weight is added to the space platforms due to the inherent weight of the onboard power generation equipment and the additional weight of the required thermal management systems. Thermal management of spacecraft relies on rejection of heat via radiation, a process that can result in large radiator mass, depending upon the heat rejection temperature. For some missions, it is advantageous to incorporate an active thermal management system, allowing the heat rejection temperature to be greater than the load temperature. This allows a reduction of radiator mass at the expense of additional system complexity. A particular type of active thermal management system is based on a thermodynamic cycle, developed by the authors, called the Solar Integrated Thermal Management and Power (SITMAP) cycle. This system has been a focus of the authors research program in the recent past (see Fig. 1). One implementation of the system requires no moving parts, which decreases the vibration level and enhances reliability. Compression of the refrigerant working fluid is accomplished in this scheme via an ejector.

Lear, William E.↗

NASA NTRS2005

Low Conductivity Thermal Barrier Coatings

Thermal barrier coatings will be more aggressively designed to protect gas turbine engine hot-section components in order to meet future engine higher fuel efficiency and lower emission goals. In this presentation, thermal barrier coating development considerations and requirements will be discussed. An experimental approach is established to monitor in real time the thermal conductivity of the coating systems subjected to high-heat-flux, steady-state and cyclic temperature gradients. Advanced low conductivity thermal barrier coatings have also been developed using a multi-component defect clustering approach, and shown to have improved thermal stability. The durability and erosion resistance of low conductivity thermal barrier coatings have been improved utilizing advanced coating architecture design, composition optimization, in conjunction with more sophisticated modeling and design tools.

Zhu, Dong-Ming↗

NASA NTRS2007

High Thermal Conductivity Polymer Matrix Composites (PMC) for Advanced Space Radiators

High temperature polymer matrix composites (PMC) reinforced with high thermal conductivity (approx. 1000 W/mK) pitch-based carbon fibers are evaluated for a facesheet/fin structure of large space radiator systems. Significant weight reductions along with improved thermal performance, structural integrity and space durability toward its metallic counterparts were envisioned. Candidate commercial resin systems including Cyanate Esters, BMIs, and polyimide were selected based on thermal capabilities and processability. PMC laminates were designed to match the thermal expansion coefficient of various metal heat pipes or tubes. Large, but thin composite panels were successfully fabricated after optimizing cure conditions. Space durability of PMC with potential degradation mechanisms was assessed by simulated thermal aging tests in high vacuum, 1-3 x 10(exp -6) torr, at three temperatures, 227 C, 277 C, and 316 C for up to one year. Nanocomposites with vapor-grown carbon nano-fibers and exfoliated graphite flakes were attempted to improve thermal conductivity (TC) and microcracking resistance. Good quality nanocomposites were fabricated and evaluated for TC and durability including radiation resistance. TC was measured in both in-plan and thru-the-thickness directions, and the effects of microcracks on TC are also being evaluated. This paper will discuss the systematic experimental approaches, various performance-durability evaluations, and current subcomponent design and fabrication/manufacturing efforts.

Shin, E. Eugene↗

NASA NTRS2007

Development of High Fidelity, Fuel-Like Thermal Simulators for Non-Nuclear Testing

Non-nuclear testing can be a valuable tool in development of a space nuclear power or propulsion system. In a non-nuclear test bed, electric heaters are used to simulate the heat from nuclear fuel. Work at the NASA Marshall Space Flight Center seeks to develop high fidelity thermal simulators that not only match the static power profile that would be observed in an operating, fueled nuclear reactor, but to also match the dynamic fuel pin performance during feasible transients. Comparison between the fuel pins and thermal simulators is made at the fuel clad surface, which corresponds to the sheath surface in the thermal simulator. Static and dynamic fuel pin performance was determined using SINDA-FLUINT analysis, and the performance of conceptual thermal simulator designs was compared to the expected nuclear performance. Through a series of iterative analysis, a conceptual high fidelity design will be developed, followed by engineering design, fabrication, and testing to validate the overall design process. Although the resulting thermal simulator will be designed for a specific reactor concept, establishing this rigorous design process will assist in streamlining the thermal simulator development for other reactor concepts.

Bragg-Sitton, S. M.↗

NASA NTRS2007

Dynamic Snap-Through of Thermally Buckled Structures by a Reduced Order Method

The goal of this investigation is to further develop nonlinear modal numerical simulation methods for application to geometrically nonlinear response of structures exposed to combined high intensity random pressure fluctuations and thermal loadings. The study is conducted on a flat aluminum beam, which permits a comparison of results obtained by a reduced-order analysis with those obtained from a numerically intensive simulation in physical degrees-of-freedom. A uniformly distributed thermal loading is first applied to investigate the dynamic instability associated with thermal buckling. A uniformly distributed random loading is added to investigate the combined thermal-acoustic response. In the latter case, three types of response characteristics are considered, namely: (i) small amplitude vibration around one of the two stable buckling equilibrium positions, (ii) intermittent snap-through response between the two equilibrium positions, and (iii) persistent snap-through response between the two equilibrium positions. For the reduced-order analysis, four categories of modal basis functions are identified including those having symmetric transverse, anti-symmetric transverse, symmetric in-plane, and anti-symmetric in-plane displacements. The effect of basis selection on the quality of results is investigated for the dynamic thermal buckling and combined thermal-acoustic response. It is found that despite symmetric geometry, loading, and boundary conditions, the anti-symmetric transverse and symmetric in-plane modes must be included in the basis as they participate in the snap-through behavior.

Przekop, Adam↗

NASA NTRS1989

Solar energy thermally powered electrical generating system

A thermally powered electrical generating system for use in a space vehicle is disclosed. The rate of storage in a thermal energy storage medium is controlled by varying the rate of generation and dissipation of electrical energy in a thermally powered electrical generating system which is powered from heat stored in the thermal energy storage medium without exceeding a maximum quantity of heat. A control system (10) varies the rate at which electrical energy is generated by the electrical generating system and the rate at which electrical energy is consumed by a variable parasitic electrical load to cause storage of an amount of thermal energy in the thermal energy storage system at the end of a period of insolation which is sufficient to satisfy the scheduled demand for electrical power to be generated during the next period of eclipse. The control system is based upon Kalman filter theory.

Owens, William R.↗

NASA NTRS2008

JWST ISIM Harness Thermal Evaluation

The James Webb Space Telescope (JWST) will be a large infrared telescope with a 6.5-meter primary mirror. Launch is planned for 2013. JWST wl1 be the premier observatory of the next decade serving thousands of astronomers worldwide. The Integrated Science Instrument Module (ISIM) is the unit that will house thc four main JWST instruments. The ISIM enclosure passively cooled to 37 Kelvin and has a tightly managed thermal budget. A significant portion of the ISIM heat load is due to parasitic heat gains from the instrument harnesses. These harnesses provide a thermal path from the Instrument Electronics Control (IEC) to the ISIM. Because of the impact of this load to the ISIM thermal design, understanding the harness parasitic heat gains is critical. To this effect, a thermal test program has been conducted in order to characterize these parasitic loads and verify harness thermal models. Recent parasitic heat loads tests resulted in the addition of a dedicated multiple stage harness radiator. In order for the radiator to efficiently reject heat from the harness, effective thermal contact conductance values for multiple harnesses had to be determined. This presentation will describe the details and the results of this test program.

Kobel, Mark↗

NASA NTRS2006

Thermal Challenge for Sun-Viewing Instruments on Solar Probe 3 R(sub s) from Sun

The Solar Probe science team at NASA GSFC is considering enhance science observations by adding the nadir viewing Plasma Spectrometer instrument and using heat shields to protect the Plasma Wave antennas to permit full extension at 3 R. The electrostatic mirror of the Plasma Spectrometer is thermally protected from the Sun by a miniature sunshield that consists of two carbon-carbon composite layers, and a much smaller carbon-carbon heat shield. The sun-viewing surface of the miniature sunshield has an Al2O3 thin film coating. The slope of the sunshield is minimized to the smallest possible extent so that it can still accommodate the elliptical electrostatic mirror. Two small MLI flaps minimize the heat radiation from the Plasma Spectrometer to the spacecraft bus. This design meets the thermal requirements. Each of the four Plasma Wave wire antennas is 5 m long, and thermally protected from the Sun by a sunshield. The sunshield consists of two carbon-carbon composite sheets. One sheet views the Sun, and one does not. The slope of most of the sun-viewing sheet is 23deg with the nadir axis. For mechanical reason, it gradually increases to 37.5deg at the tip. The exterior of the sun viewing surfaces has a thin film of Al2O3. The exterior of the shaded sheets has a thin film of vapor deposited rhodium. It minimizes the heat radiation to the spacecraft bus. A high temperature MLI blanket between the carbon-carbon sheets radiatively isolates them. The thermal design meets the temperature requirements, but exceeds the 20 W limit of heat radiation to the spacecraft bus by 20 W. Thermal options to reduce the heat radiation include reducing the alpha to epsilon ratio of the Al2O3 thin film and reducing the number of antennas to three. Testing in 2006 includes thermal model validation and materials testing. High temperature ovens and a high light intensity Vortex Lamp will be used.

Choi, Michael K.↗

NASA NTRS2009

Electrochromic Radiator Coupon Level Testing and Full Scale Thermal Math Modeling for Use on Altair Lunar Lander

In order to control system and component temperatures, many spacecraft thermal control systems use a radiator coupled with a pumped fluid loop to reject waste heat from the vehicle. Since heat loads and radiation environments can vary considerably according to mission phase, the thermal control system must be able to vary the heat rejection. The ability to "turn down" the heat rejected from the thermal control system is critically important when designing the system.. Electrochromic technology as a radiator coating is being investigated to vary the amount of heat being rejected by a radiator. Coupon level tests were performed to test the feasibility of the technology. Furthermore, thermal math models were developed to better understand the turndown ratios required by full scale radiator architectures to handle the various operation scenarios during a mission profile for Altair Lunar Lander. This paper summarizes results from coupon level tests as well as thermal math models developed to investigate how electrochromics can be used to provide the largest turn down ratio for a radiator. Data from the various design concepts of radiators and their architectures are outlined. Recommendations are made on which electrochromic radiator concept should be carried further for future thermal vacuum testing.

Sheth, Rubik↗

NASA NTRS2009

Overview of Altair's Thermal Control System and the Associated Technology Development Efforts

Abstract In early 2004, President Bush announced a bold vision for space exploration. One of the goals included in this vision is a return to the moon by 2020. In response to this vision, NASA established the Constellation Program, which includes several project offices. One of the Constellation projects is Altair, which is the next generation Lunar Lander. The future Altair missions are very different than the Lunar missions accomplished during the Apollo era. As such, there are several project risks and design challenges that have never before been addressed. Due to the unique thermal environment associated with this mission, many of these risks and design challenges are associated with the vehicle's thermal control system. NASA's Exploration Systems Mission Directorate (ESMD) includes the Exploration Technology Development Program (ETDP). ETDP consists of several technology development projects. The project chartered with mitigating the aforementioned risks and design challenges is the Thermal Control System Development for Exploration Project. The current paper will summarize the Altair mission profile, the operational phases, and the thermal design challenges unique to this particular vehicle. The paper will also describe the technology development efforts being performed to mitigate the risks and design challenges. The technology development project is performing a rigorous development effort that includes thermal control system fluids, evaporators, heat exchangers, and Lunar surface radiators. Constellation Program, there are several project offices. One of these projects includes the development of NASA's new lunar lander vehicle. The overall mission architecture for this vehicle, Altair, is very similar to Apollo's architecture. This paper will provide the reader with an overview of the Altair vehicle. In addition, Altair's thermal control system, including the functionality and the hardware, will be discussed. The paper will also describe the technology development process and the various technology developments currently underway.

Stephan, Ryan A.↗

NASA NTRS2011

Analysis of Solar-Heated Thermal Wadis to Support Extended-Duration Lunar Exploration

The realization of the renewed exploration of the Moon presents many technical challenges; among them is the survival of lunar-surface assets during periods of darkness when the lunar environment is very cold. Thermal wadis are engineered sources of stored solar energy using modified lunar regolith as a thermal storage mass that can supply energy to protect lightweight robotic rovers or other assets during the lunar night. This paper describes an analysis of the performance of thermal wadis based on the known solar illumination of the Moon and estimates of producible thermal properties of modified lunar regolith. Analysis has been performed for the lunar equatorial region and for a potential outpost location near the Lunar South Pole. The calculations indicate that thermal wadis can provide the desired thermal energy and temperature control for the survival of rovers or other equipment during periods of darkness.

Balasubramaniam, R.↗

NASA NTRS2010

Mineralogy and Thermal Properties of V-Type Asteroid 956 Elisa: Evidence for Diogenitic Material from the Spitzer IRS (5-35 Micrometers) Spectrum

We present the thermal infrared (5-35 micrometer) spectrum of 956 Elisa as measured by the Spitzer Infrared Spectrograph ("IRS"; Houck,1.R. et .11. [20041. Astrophys, 1. SuppL 154, 18-24) together with new ground-based lightcurve data and near-IR spectra. From the visible lightcurve photometry, we determine a rotation period of 16.494 +/- 0.001 h, identify the rotational phase of the Spitzer observations, and estimate the visible absolute magnitude (Hv) at that rotational phase to be 12.58 +/- 0.04. From radiometric analysis of the thermal flux spectrum, we find that at the time of observation 956 Elisa had a projected radius of 5.3 +/- 0.4 km with a visible albedo pv = 0.142+/- 0.022, significantly lower than that of the prototype V-type asteroid, 4 Vesta. (This corresponds to a radius of 5.2 +/- 0.4 km at lightcurve mean.) Analysis with the standard thermal model (STM) results in a sub-solar temperature of 292.3 +/- 2.8 K and beaming parameter eta = 1.16 +/- 0.05. Thermophysical modeling places a lower limit of 20 J m(exp -2)K(exp -1)s(exp -1/2) on the thermal inertia of the asteroid's surface layer (if the surface is very smooth) but more likely values fall between 30 and 150 J m(exp -2)K(exp -1)s(exp -1/2) depending on the sense of rotation. The emissivity spectrum, calculated by dividing the measured thermal flux spectrum by the modeled thermal continuum, exhibits mineralogically interpretable spectral features within the 9-12 micrometer reststrahlen band, the 15-16.5 micrometer Si-O-Si stretching region, and the 16-25 micrometer reststrahlen region that are consistent with pyroxene of diogenitic composition: extant diogenitic pyroxenes fall within the narrow compositional range W0(sub 2+/-1)En(sub 74+/-2)Fs(sub 24+/-1). Spectral deconvolution of the 9-12 micrometer reststrahlen features indicates that up to approximately 20% olivine may also be present, suggesting an olivine-diogenite-like mineralogy. The mid-IR spectrum is inconsistent with non-cumulate eucrite as the major component on the surface of 956 Elisa, although cumulate eucrite material may be present at abundances lower than that of the diogenite component. Analysis of new near-IR spectra of 956 Elisa with the Modified Gaussian Model (MGM; Sunshine, J,M., Pieters, C.M., Pratt, S.F.[1990]. J. Geophys. Res, 95 (May), 6955-6966) results in two pyroxene compositions: 75% magnesian low-Ca pyroxene and 25% high-Ca pyroxene. High-Ca pyroxene is not evident in the mid-IR data, but may belong to a component that is underrepresented in the mid-IR spectrum either because of its spatial distribution on the asteroid or because of its particle size. High-Ca pyroxenes that occur as exsolution lamellae may also be more evident spectrally in the NIR than in the mid-IR. In any case, we find that the mid-IR spectrum of 956 Elisa is dominated by emission from material of diogenite- like composition, which has very rarely been observed among asteroids.

Lim, Lucy F.↗

NASA NTRS2011

Simulating Thermal Cycling and Isothermal Deformation Response of Polycrystalline NiTi

A microstructure-based FEM model that couples crystal plasticity, crystallographic descriptions of the B2-B19' martensitic phase transformation, and anisotropic elasticity is used to simulate thermal cycling and isothermal deformation in polycrystalline NiTi (49.9at% Ni). The model inputs include anisotropic elastic properties, polycrystalline texture, DSC data, and a subset of isothermal deformation and load-biased thermal cycling data. A key experimental trend is captured.namely, the transformation strain during thermal cycling is predicted to reach a peak with increasing bias stress, due to the onset of plasticity at larger bias stress. Plasticity induces internal stress that affects both thermal cycling and isothermal deformation responses. Affected thermal cycling features include hysteretic width, two-way shape memory effect, and evolution of texture with increasing bias stress. Affected isothermal deformation features include increased hardening during loading and retained martensite after unloading. These trends are not captured by microstructural models that lack plasticity, nor are they all captured in a robust manner by phenomenological approaches. Despite this advance in microstructural modeling, quantitative differences exist, such as underprediction of open loop strain during thermal cycling.

Manchiraju, Sivom↗