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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 NTRSDate not supplied

Validation and Sensitivity Analyses of Arc-Jet Performance of Woven Thermal Protection Entry Systems

A material response model is developed for the determination of erosion rates and thermal response of woven materials to enable accurate thermal protection material sizing and future missions to Venus and giant planets. The stagnation-point thermal response is further evaluated using a Monte Carlo global sensitivity analysis to determine the interactions between key parameters in the material surface energy balance, such as, convective blowing correction parameter and weave material properties including isotropic and orthotropic thermal conductivites. The time-accurate material response for the dual layer weave erosion and surface temperatures show excellent agreement with stagnation flat face arc-jet tests involving time-varying aeroheating-cooling cycles. The high-fidelity Monte Carlo sensitivity analysis technique was used to address challenges in thermal protection sizing for the Adaptive Deployable Entry and Placement Technology (ADEPT) system, a low ballistic coefficient hypersonic decelerator. The results represent new correlations for such weaves involving Carbon-air oxidation equilibrium chemistry. Through the multi-variate regression analyses and uncertainty rankings performed, only three properties were found to contribute to the transient thermal response of the gore, with emissivity contributing to nearly 95% of the total output uncertainty.

Pratibha Raghunandan↗

NASA NTRS2021

Validation and Sensitivity Analyses of Arc-Jet Performance of Woven Thermal Protection Entry Systems

Pratibha Raghunandan↗

NASA NTRSDate not supplied

Additive Manufacture of Porous Zirconium Carbide for Nuclear Thermal Propulsion In-Core Insulators

Nuclear Thermal Propulsion (NTP) requires the use of in-core insulators to manage to thermal environment between high temperature fuel elements and lower temperature structural components. The unforgiving in-core operating conditions severely limit potential material candidates. Zirconium Carbide (ZrC) is a promising candidate due to a high melting temperature, high compressive strength, hardness, wear resistance, hydrogen compatibility, and low neutron absorption cross sections. However, fully dense ZrC is not an insulator but it has been found that the thermal conductivity of ZrC decreases by increasing porosity to approximately 60 % theoretical density (%TD). Previous methods for generating porous ZrC were difficult, expensive, and time consuming. Binder jet additive manufacture (AM) can print ceramic materials to near net shape. Binder jet AM is not utilized in many applications due to an inherently low post-sintering density on the order of 60 %TD. For this specific application the inherent lower density is leveraged as an advantage in production porous ZrC in order to control the thermal conductivity. A feasibility study was conducted to investigate binder jet AM parameter development for ZrC, heat treatment optimization (burn-out and sinter), microstructural characterization, mechanical testing, and thermal testing to generate near-net shape ZrC components with ~60 %TD with the desired thermal conductivity and mechanical strength.

Zirconium Carbide Additive Manufacture↗

NASA NTRSDate not supplied

Additive Manufacture of Porous Zirconium Carbide for Nuclear Thermal Propulsion In-Core Insulators

Zirconium Carbide Additive Manufacture↗

NASA NTRSDate not supplied

Evaluation of Coatings for the Electrodynamic Dust Shield Application on Thermal Radiators

Dust acts as a blackbody, becoming hot if left in direct sunlight. This is a problem for thermal radiators where the main function is to radiate heat away from an object. If dust lands on the thermal radiator, the unit will less effectively reject heat, and it will overheat. This can lead to electrical or system failure. The current state-of-the-art in active dust mitigation is the Electrodynamic Dust Shield (EDS) which uses an electric field generated by alternating high positive and negative voltages (low current) to eject the charged dust off surfaces. An EDS made from copper coated Kapton is an ideal candidate to be bonded to a thermal radiator and coated with a low solar absorptance, high heat-emitter coating. This work compares the dust removal of copper-Kapton EDSs covered with different thermal radiator coatings in air and vacuum environments. The coatings include AZ-93 paint, Thermal Bright, and Solar White, a coating developed by the Applied Physics Lab (APL) at NASA Kennedy Space Center (KSC). The resistance and the thickness of the various coatings impact how well it works as an insulative layer for the EDS. Preliminary results indicate that Solar White may have better properties for dust removal and thermal rejection than the other coatings.

Krystal L Acosta↗

NASA NTRS2022

Updraft Dynamics and Microphysics: On the Added Value of the Cumulus Thermal Reference Frame in Simulations of Aerosol–Deep Convection Interactions

One fundamental question about atmospheric moist convection processes that remains debated is whether or under what conditions a relevant variability in background aerosol concentrations may have a significant dynamical impact on convective clouds and their associated precipitation. Furthermore, current climate models must parameterize both the microphysical and the cumulus convection processes, but this is usually implemented separately, whereas in nature there is a strong coupling between them. As a first step to improve our understanding of these two problems, we investigate how aerosol concentrations modify key properties of updrafts in eight large-eddy permitting regional simulations of a case study of scattered convection over Houston, Texas, in which convection is explicitly simulated and microphysical processes are parameterized. Dynamical and liquid-phase microphysical responses are investigated using two different reference frames: static cloudy-updraft grid cells versus tracked cumulus thermals. In both frameworks we observe the expected microphysical responses to higher aerosol concentrations, such as higher cloud number concentrations and lower rain number concentrations. In terms of the dynamical responses, both frameworks indicate weak impacts of varying aerosol concentrations relative to the noise between simulations over the observationally derived range of aerosol variability for this case study. On the other hand, results suggest that thermals are more selective than cloudy-updraft grid cells in terms of sampling the most active convective air masses. For instance, vertical velocity from thermals is significantly higher at upper levels than when sampled from cloudy-updraft grid points, and several microphysical variables have higher average values in the cumulus thermal framework than in the cloudy-updraft framework. In addition, the thermal analysis is seen to add rich quantitative information about the rates and covariability of microphysical processes spatially and throughout tracked thermal lifecycles, which can serve as a stronger foundation for improving subgrid-scale parameterizations.

Daniel Hernandez-Deckers↗

NASA NTRS2021

Europa Environmental Testing of Thermal Hardware for the Mapping Imaging Spectrometer for Europa (MISE) Instrument

The Europa Clipper spacecraft, scheduled for launch in June 2022, hosts a suite of instruments including the Mapping Imaging Spectrometer for Europa (MISE). MISE is a high-optical through-put pushbroom infrared imaging spectrometer that can collect measurements within Europa’s challenging radiation environment. It is externally mounted to the spacecraft and as a result is exposed to high radiation levels and cold temperatures. The instrument consists of a scan mirror assembly, an optical bench including a Dyson spectrometer and a telescope, and a structure that supports a cryocooler and a radiator. The cryocooler is used to actively cool the focal plane array and the spectrometer. The heat from the cryocooler is rejected through pyrolytic graphite sheet thermal straps to a honeycomb radiator. MISE will implement thermal hardware that will either not be used on other parts of the spacecraft or have a more extreme environment than the spacecraft. As a result, the MISE instrument performed numerous environmental tests on its thermal hardware. This paper discusses the results of the thermal cycling and radiation tests performed on the MISE thermal hardware including a Lockheed Martin Micro1-2 cryocooler, Pyrolytic graphite sheet thermal straps, Annealed pyrolytic graphite K-Core, Rosemount Platinum Resistance Thermometers, Tayco Kapton Thermofoil heaters, Dale Ohm resistors, and aluminum honeycomb and facesheets.

Strong, Patrick↗

NASA NTRS2021

Instrument Thermal Management for Lunar Night Survival without Radioisotopes

This paper summarizes the technology development progress on two JPL projects focused on developing thermal designs/technologies that enable lunar instrument overnight survival without radioisotopes. Through an internal project known as ARTEMIS, JPL has developed lunar night survivable designs for magnetometer, seismometer, and IR spectrometer science payloads (SPs). These designs incorporate four hyper-isolative thermal management features under development on the NASA GCD-funded PALETTE project: (a) a dual enclosure system with high strength, low k tension cable (TC) supports and a variable conductance thermal link (VCTL) composed of a reverse-operation DTE thermal switch (ROD-TSW) in series with a miniaturized loop heat pipe (mini-LHP); (b) a parabolic reflector radiator (PRR) for low-to-mid latitude lunar sites; (c) ultra-low e* “spacerless” MLI, in which individual layers are hung from the TC supports; and (d) ultra-low G thermal isolators made with polymeric material or polymer/TC assemblies. Each instrument design incorporates solar panels, batteries, telecom, C&DH, and other features necessary for self-sufficient, extended-duration operation on the lunar surface. This paper will provide an overview of the ARTEMIS and PALETTE projects and provide a top-level description of the instrument thermal management approach.

Lin, Ying↗

NASA NTRS2021

Europa Clipper Magnetometer Thermal Design Evolution, Validation, and Verification

Europa Clipper Spacecraft is exposed to a high radiation environment and is limited with power. This makes the thermal design of Europa Clipper magnetometer more challenging. The design is required to be highly insulated and at the same time magnetically clean. This paper describes the thermal design evolution of Europa Clipper Magnetometer. A thermal vacuum test is conducted in Europa Clipper orbit’s relevant environment to characterize the requirements and estimate the power consumption. A flight-like engineering model magnetometer from the University of California at Los Angeles (UCLA) is used for this test. Magnetically clean Cernox temperature measurement sensors with the accuracy of ±0.1ºC are used to measure the temperature value inside the sensor head and across the main frame interfaces. This level of accuracy in temperature measurement is required to capture the temperature gradient across the sensor head in a relevant environment which impacts the magnetometer measurement accuracy. Test data is used to correlate the thermal model and characterize the heat leak across the interfaces. Validated thermal model is used as a verification tool for power consumption and thermal requirements.

Caron, Ryan↗

NASA NTRS2022

Solar Flare Heating with Turbulent Suppression of Thermal Conduction

During solar flares plasma is typically heated to very high temperatures, and the resulting redistribution of energy via thermal conduction is a primary mechanism transporting energy throughout the flaring solar atmosphere. The thermal flux is usually modeled using Spitzer’s theory, which is based on local Coulomb collisions between the electrons carrying the thermal flux and those in the background. However, often during flares, temperature gradients become sufficiently steep that the collisional mean free path exceeds the temperature gradient scale size, so that thermal conduction becomes inherently non-local. Further, turbulent angular scattering, which is detectable in nonthermal widths of atomic emission lines, can also act to increase the collision frequency and so suppress the heat flux. Recent work by Emslie & Bian (2018) extended Spitzer’s theory of thermal conduction to account for both non-locality and turbulent suppression. We have implemented their theoretical expression for the heat flux (which is a convolution of the Spitzer flux with a kernel function) into the RADYN flare-modeling code and performed a parameter study to understand how the resulting changes in thermal conduction affect flare dynamics and hence the radiation produced. We find that models with reduced heat fluxes predict slower bulk flows, less intense line emission, and longer cooling times. By comparing features of atomic emission lines predicted by the models with Doppler velocities and nonthermal line widths deduced from a particular flare observation, we find that models with suppression factors between 0.3 to 0.5 relative to the Spitzer value best reproduce observed Doppmission lines forming over a wide range of temperatures. Interestingly, the model that best matches observed nonthermal line widths has a kappa-type velocity distribution function.

Joel C. Allred↗

NASA NTRS2022

Solar Flare Heating with Turbulent Suppression of Thermal Conduction

During solar flares plasma is typically heated to very high temperatures, and the resulting redistribution of energy via thermal conduction is a primary mechanism transporting energy throughout the flaring solar atmosphere. The thermal flux is usually modeled using Spitzer’s theory, which is based on local Coulomb collisions between the electrons carrying the thermal flux and those in the background. However, often during flares, temperature gradients become sufficiently steep that the collisional mean free path exceeds the temperature gradient scale size, so that thermal conduction becomes inherently non-local. Further, turbulent angular scattering, which is detectable in nonthermal widths of atomic emission lines, can also act to increase the collision frequency and so suppress the heat flux. Recent work by Emslie & Bian (2018) extended Spitzer’s theory of thermal conduction to account for both non-locality and turbulent suppression. We have implemented their theoretical expression for the heat flux (which is a convolution of the Spitzer flux with a kernel function) into the RADYN flare-modeling code and performed a parameter study to understand how the resulting changes in thermal conduction affect flare dynamics and hence the radiation produced. We find that models with reduced heat fluxes predict slower bulk flows, less intense line emission, and longer cooling times. By comparing features of atomic emission lines predicted by the models with Doppler velocities and nonthermal line widths deduced from a particular flare observation, we find that models with suppression factors between 0.3 to 0.5 relative to the Spitzer value best reproduce observed Doppler velocities across emission lines forming over a wide range of temperatures. Interestingly, the model that best matches observed nonthermal line widths has a kappa-type velocity distribution function

Solar flares↗

NASA NTRSDate not supplied

Evaluation of Coatings for the Electrodynamic Dust Shield Application on Thermal Radiators

Space dust acts as a blackbody, becoming hot if left in direct sunlight. This is a problem for thermal radiators used in space missions, where the main function is to radiate heat away from an object. If dust lands on the thermal radiator, the unit will less effectively reject heat, and it will overheat, leading to electrical or system failure. The current state-of-the-art in active dust mitigation is the Electrodynamic Dust Shield (EDS) which uses an electric field generated by alternating high positive and negative voltages (low current) to eject the charged dust off surfaces. An EDS made from copper coated Kapton is an ideal candidate to be bonded to a thermal radiator and coated with a low solar absorptance, high heat-emitter coating. This work compares the dust removal of copper-Kapton EDSs covered with different thermal radiator coatings in air and vacuum environments. The coatings include AZ-93 paint, Thermal Bright, and Solar White, a coating developed by the Applied Physics Lab (APL) at NASA Kennedy Space Center (KSC). The resistance and the thickness of the various coatings impact how well it works as an insulative layer for the EDS. Preliminary results indicate that Solar White may have better properties for dust removal and thermal rejection than the other coatings.

Krystal L. Acosta↗

NASA NTRSDate not supplied

Spacecraft Window Design from a Thermal Perspective

This paper gives a rudimentary introduction to spacecraft window design from a thermal engineering perspective. Windows have always been integral parts of all of NASA’s flown, crewed spacecraft missions and will continue to be included on future crewed vehicles. They are part of the primary structure and require high structural reliability. Often neglected by non-thermal engineers, there are important thermal impacts to including windows on a spacecraft design. Thermal radiation from the sun, planetary bodies, or other vehicles can enter the vehicle and heat the interior. Windows can also be heat leaks to space during cold operations. Windows may also serve as part of the vehicle Thermal Protection System for entry vehicles. Like all other parts of the spacecraft, windows must be included in thermal models to predict temperatures; the transparency of pane materials and the addition of coatings increase modeling complexity. Testing of windows is also more complex than typical spacecraft structure due to the uniqueness of each pane (depending on material), transmittance, and the challenge of physically measuring window material temperature during testing.

Cheyn L Worn↗

NASA NTRS2024

Bringing the Heat: Thermal Protection Systems for Low Earth Orbit Transportation and Lunar Exploration

Thermal protection systems (TPS) protect spacecraft from the heating associated with hypersonic flight through a planet’s atmosphere. The materials are subjected to extreme heating and the overall system must be engineered to reliably protect the spacecraft structure during atmospheric entry. The talk will introduce TPS and describe three NASA-led efforts to develop TPS materials and manufacturing processes. The first effort studied thermally stable ceramic aerogels for use in thermal barriers and high temperature seals. A design framework for such materials is proposed, linking the thermal stability performance data with existing material property measurements. The second project, Additive Manufacturing of Thermal Protection Systems (AMTPS), developed an automated, additive approach for ablative heat shield manufacturing. Novel material systems and manufacturing methods were developed to reduce the time required to manufacture ablative TPS heat shields. The third effort tackles a critical challenge of material obsolescence for silica fiber based reusable TPS. The properties and performance of heritage silica fiber are quantified and compared to modern alternatives to support qualification for flight. The talk will also describe other work in TPS conducted by the Thermal Design Branch at NASA JSC and opportunities for students and faculty to get involved with NASA.

Nathaniel Olson↗

NASA NTRS2024

A Thermally-Conductive Martian Core and Implications for Its Dynamo Cessation

Mars experienced a dynamo process that generated a global magnetic field ~4.3 (or earlier) to 3.6 billion years ago (Ga). The cessation of this dynamo strongly affected Mars’ history and is expected to be linked to thermochemical evolution of Mars’ iron-rich liquid core, which is strongly influenced by its thermal conductivity. Here, we directly measured thermal conductivities of solid iron-sulfur alloys to pressures relevant to the Martian core and temperatures to 1023 Kelvin. Our results show that a Martian core with 16 weight % sulfur has a thermal conductivity of ~19 to 32 Watt meter −1 Kelvin −1 from its top to the center, much higher than previously inferred from electrical resistivity measurements. Our modeled thermal conductivity profile throughout the Martian deep-mantle and core indicates a ~4- to 6-fold discontinuity across the core-mantle boundary. The core’s efficient cooling resulting from the depth-dependent, high conductivity diminishes thermal convection and forms thermal stratification, substantially contributing to cessation of Martian dynamo.

Wen-Pin Hsieh↗

NASA NTRS2026

xEMU Spacesuit Boot Lunar South Pole Thermal Vacuum Testing

The Exploration Extravehicular Mobility Unit (xEMU) spacesuit lunar boot was evaluated in the Jet Propulsion Lab (JPL) CITADEL thermal vacuum chamber at lunar South Pole conditions. The JPL CITADEL chamber provides a radiation environment and contact plate temperature of 48K, simulating the temperature of a lunar Permanently Shadowed Region (PSR) at the South Pole of the Moon. The main objectives of the test series are: to evaluate the risk lunar PSRs pose to advanced spacesuit boots, validate the xEMU lunar boot thermal model, and to develop a test methodology to evaluate lunar spacesuit boots. To simulate the thermal effects of a crewmember’s foot inside the boot, a thermal manikin foot was developed to inject heat into the spacesuit boot. Thermal data was collected through a variety of sensors including thermocouples, thermistors, heat flux sensors, and infrared cameras. A test matrix was developed to investigate the variables of foot contact force, simulated skin temperature, external contact plate temperature, and ventilation flowrate. The JPL CITADEL chamber includes a loadlock (airlock) that afforded the ability to simulate the transition of the boot from a thermally neutral IVA condition to a cold EVA condition within seconds. This paper will document the test design, test objectives, success criteria, test support equipment, spacesuit boot to chamber interfaces, and configuration of the test article. Additionally, this paper will document the high-level results of the testing. More detailed test results will be presented in a different paper.

Ben Swartout↗

NASA NTRS2026

Investigating Dual Electrospinning as a Means of Enhancing Passive Thermal Control Coatings for Cryogenic Propellant Storage in Extraterrestrial Environments

Passive thermal control is necessary as space exploration becomes increasingly widespread. Materials with superior optical properties (high solar reflectance and infrared emittance) are critical for passive thermal control because they can reject most of the incident solar radiation and promote thermal emission from cryogenic propellant storage tanks, enabling the extraterrestrial storage of cryogens. We have demonstrated in previous studies that electrospun nanofibers exhibit exceptional optical properties, offering significant benefits for passive radiative cooling in space. Particularly, electrospun polyvinylidene fluoride-co-hexafluoropropylene PVDF-HFP nanofibers demonstrate exceptionally high solar reflectance (>99%) and strong thermal emittance (measured at ~300 K). However, they exhibit nanostructural changes in the presence of atomic oxygen, which is prevalent in Low Earth Orbit. This study focuses on creating a unique blend of polymeric (PVDF-HFP) and ceramic-based (silica) nanofibers by leveraging the chemical stability and atomic oxygen resistance of silica, using the dual electrospinning manufacturing method. This approach aims to preserve the structural properties of the polymeric counterpart without compromising its optical performance, thereby providing an innovative method for manufacturing environmentally resilient passive thermal control nanofibers with desirable optical and thermal control functionalities for extraterrestrial storage of cryogenic propellants.

Chieloka Ibekwe↗

NASA NTRS2026

Assessing the Adhesion of Nanofibrous PVDF-HFP as Passive Thermal Control Coatings for the Extraterrestrial Storage of Cryogenic Propellants

Cryogenic propellant passive thermal management techniques in space are essential complements to active thermal management methods, helping reduce absolute dependence on the latter. Particularly, materials with superior optical properties (high solar reflectance and infrared emittance) would be beneficial for passive thermal control to reject most of the incident solar radiation and enhance thermal emission from the storage tank, leading to self-cooling. We developed a nanofibrous, porous passive thermal control material by electrospinning polyvinylidene fluoride-co-hexafluoropropylene (PVDF-HFP) co-polymer onto an aluminum foil substrate. The material exhibits a very high solar reflectance (>99%) and infrared emittance (~86%) when characterized in the ultraviolet-visible-near infrared and mid-infrared wavelengths. This study focuses on the adhesion of the nanofibrous PVDF-HFP to the substrate. We incorporated in-lab fabricated and commercial adhesives, under normal room conditions, between the nanofibers and the aluminum foil substrate to improve their adhesion. Some samples were also exposed to space-like conditions – vacuum and thermal cycling, to investigate their effects on the strengths of adhesives. Subsequently, adhesion peel tests were conducted on all the samples to assess the peel strengths of the bonds. Peel test strengths after space environment conditioning of the adhesives were generally higher than those observed in the pristine, unaged samples. The results are discussed in this study.

Chieloka Ibekwe↗