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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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

Thermal performance of a multi-evaporator loop heat pipe with thermal masses and thermal electrical coolers

This paper describes thermal performance of a loop heat pipe (LHP) with two evaporators and two condensers in ambient testing. Each evaporator has an outer diameter of 15mm and a length of 76mm, and has an integral compensation chamber (CC). An aluminum mass of 500 grams is attached to each evaporator to simulate the instrument mass. A thermal electric cooler (TEC) is installed on each CC to provide heating as well as cooling for CC temperature control. A flow regulator is installed in the condenser section to prevent vapor from going back to the evaporators in the event that one of condenser is fully utilized. Ammonia was used ad the working fluid. Tests conducted included start-up, power cycle, heat load sharing, sink temperature cycle, operating temperature control with TECs, and capillary limit tests. Experimental data showed that the loop could start with a heat load of less than 1OW even with added thermal masses. The loop operated stably with even and uneven evaporator heat loads, and even and uneven condenser sink temperatures. The operating temperature could be controlled within +/-0.5K of the set point temperature using either or both TECs, and the required TEC control heater power was less than 2W under most test conditions. Heat load sharing between the two evaporators was also successfully demonstrated. The loop had a heat transport capability of 120W to 140W, and could recover from a dry-out when the heat load was reduced. The 500-gram aluminum mass on each evaporator had a negligible effect on the loop operation. Existing LHPs servicing the orbiting spacecraft have a single evaporator with an outer diameter of about 25mm. Important performance characteristics demonstrated by this LHP included: 1) Operation of an LHP with 15mm diameter evaporators; 2) Robustness and reliability of an LHP with multiple evaporators and multiple condensers under various test conditions; 3) Heat load sharing among LHP evaporators; 4) Effectiveness of TECs in controlling the LHP operating temperature; and 5) Effectiveness of the flow regulator in preventing vapor from going back the evaporators.

loop heat pipes↗
NASA NTRS2007

Gas Foil Bearing Technology Advancements for Closed Brayton Cycle Turbines

Closed Brayton Cycle (CBC) turbine systems are under consideration for future space electric power generation. CBC turbines convert thermal energy from a nuclear reactor, or other heat source, to electrical power using a closed-loop cycle. The operating fluid in the closed-loop is commonly a high pressure inert gas mixture that cannot tolerate contamination. One source of potential contamination in a system such as this is the lubricant used in the turbomachine bearings. Gas Foil Bearings (GFB) represent a bearing technology that eliminates the possibility of contamination by using the working fluid as the lubricant. Thus, foil bearings are well suited to application in space power CBC turbine systems. NASA Glenn Research Center is actively researching GFB technology for use in these CBC power turbines. A power loss model has been developed, and the effects of a very high ambient pressure, start-up torque, and misalignment, have been observed and are reported here.

Howard, Samuel A.↗
NASA NTRS2007

Catalytic Ignition and Upstream Reaction Propagation in a Platinum Tube

A challenge for catalytic combustion in monolithic reactors at elevated temperatures is the start-up or "light-off" from a cold initial condition. In this work, we demonstrate a concept called "back-end catalytic ignition that potentially can be utilized in the light-off of catalytic monoliths. An external downstream flame or Joule heating raises the temperature of a small portion of the catalyst near the outlet initiating a localized catalytic reaction that propagates upstream heating the entire channel. This work uses a transient numerical model to demonstrate "back-end" ignition within a single channel which can characterize the overall performance of a monolith. The paper presents comparisons to an experiment using a single non-adiabatic channel but the concept can be extended to the adiabatic monolith case. In the model, the time scales associated with solid heat-up are typically several orders of magnitude larger than the gas-phase and chemical kinetic time-scales. Therefore, the model assumes a quasi-steady gas-phase with respect to a transient solid. The gas phase is one-dimensional. Appropriate correlations, however, account for heat and mass transfer in a direction perpendicular to the flow. The thermally-thin solid includes axial conduction. The gas phase, however, does not include axial conduction due to the high Peclet number flows. The model includes both detailed gas-phase and catalytic surface reactions. The experiment utilizes a pure platinum circular channel oriented horizontally though which a CO/O2 mixture (equivalence ratios ranging from 0.6 to 0.9) flows at 2 m/s.

Struk, P. M.↗
NASA NTRS2007

Loop Heat Pipe Operation with Thermoelectric Converters and Coupling Blocks

This paper presents theoretical and experimental studies on using thermoelectric converters (TECs) and coupling blocks to control the operating temperature of a miniature loop heat pipes (MLHP). The MLHP has two parallel evaporators and two parallel condensers, and each evaporator has its own integral compensation chamber (CC). A TEC is attached to each CC, and connected to the evaporator via a copper thermal strap. The TEC can provide both heating and cooling to the CC, therefore extending the LHP operating temperature over a larger range of the evaporator heat load. A bi-polar power supply is used for the TEC operation. The bipolar power supply automatically changes the direction of the current to the TEC, depending on whether the CC requires heating or cooling, to maintain the CC temperature at the desired set point. The TEC can also enhance the startup success by maintaining a constant CC temperature during the start-up transient. Several aluminum coupling blocks are installed between the vapor line and liquid line. The coupling blocks serve as a heat exchanger which preheats the cold returning liquid so as to reduce the amount of liquid subcooling, and hence the power required to maintain the CC at the desired set point temperature. This paper focuses on the savings of the CC control heater power afforded by the TECs when compared to traditional electric heaters. Tests were conducted by varying the evaporator power, the condenser sink temperature, the CC set point temperature, the number of coupling blocks, and the thermal conductance of the thermal strap. Test results show that the TECs are able to control the CC temperature within k0.5K under all test conditions, and the required TEC heater power is only a fraction of the required electric heater power.

Ku, Jentung↗
NASA NTRS2007

A Microfabricated Involute-Foil Regenerator for Stirling Engines

A segmented involute-foil regenerator has been designed, microfabricated and tested in an oscillating-flow rig with excellent results. During the Phase I effort, several approximations of parallel-plate regenerator geometry were chosen as potential candidates for a new microfabrication concept. Potential manufacturers and processes were surveyed. The selected concept consisted of stacked segmented-involute-foil disks (or annular portions of disks), originally to be microfabricated from stainless-steel via the LiGA (lithography, electroplating, and molding) process and EDM (electric discharge machining). During Phase II, re-planning of the effort led to test plans based on nickel disks, microfabricated via the LiGA process, only. A stack of nickel segmented-involute-foil disks was tested in an oscillating-flow test rig. These test results yielded a performance figure of merit (roughly the ratio of heat transfer to pressure drop) of about twice that of the 90% random fiber currently used in small ~ 100 W Stirling space-power convertors in the Reynolds Number range of interest (50-100). A Phase III effort is now underway to fabricate and test a segmented-involute-foil regenerator in a Stirling convertor. Though funding limitations prevent optimization of the Stirling engine geometry for use with this regenerator, the Sage computer code will be used to help evaluate the engine test results. Previous Sage Stirling model projections have indicated that a segmented-involute-foil regenerator is capable of improving the performance of an optimized involute-foil engine by 6-9%; it is also anticipated that such involute-foil geometries will be more reliable and easier to manufacture with tight-tolerance characteristics, than random-fiber or wire-screen regenerators. Beyond the near-term Phase III regenerator fabrication and engine testing, other goals are (1) fabrication from a material suitable for high temperature Stirling operation (up to 850 C for current engines; up to 1200 C for a potential engine-cooler for a Venus mission), and (2) reduction of the cost of the fabrication process to make it more suitable for terrestrial applications of segmented involute foils. Past attempts have been made to use wrapped foils to approximate the large theoretical figures of merit projected for parallel plates. Such metal wrapped foils have never proved very successful, apparently due to the difficulties of fabricating wrapped-foils with uniform gaps and maintaining the gaps under the stress of time-varying temperature gradients during start-up and shut-down, and relatively-steady temperature gradients during normal operation. In contrast, stacks of involute-foil disks, with each disk consisting of multiple involute-foil segments held between concentric circular ribs, have relatively robust structures. The oscillating-flow rig tests of the segmented-involute-foil regenerator have demonstrated a shift in regenerator performance strongly in the direction of the theoretical performance of ideal parallel-plate regenerators.

Tew, Roy↗
NASA NTRS2006

Testing of a Miniature Loop Heat Pipe with Multiple Evaporators and Multiple Condensers for Space Applications

Thermal performance of a miniature loop heat pipe (MLHP) with two evaporators and two condensers is described. A comprehensive test program, including start-up, high power, low power, power cycle, and sink temperature cycle tests, has been executed at NASA Goddard Space Flight Center for potential space applications. Experimental data showed that the loop could start with heat loads as low as 2W. The loop operated stably with even and uneven evaporator heat loads, and even and uneven condenser sink temperatures. Heat load sharing between the two evaporators was also successfully demonstrated. The loop had a heat transport capability of l00W to 120W, and could recover from a dry-out by reducing the heat load to evaporators. Low power test results showed the loop could work stably for heat loads as low as 1 W to each evaporator. Excellent adaptability of the MLHP to rapid changes of evaporator power and sink temperature were also demonstrated.

Nagano, Hosei↗
NASA NTRS2007

A Microfabricated Involute-Foil Regenerator for Stirling Engines

A segmented involute-foil regenerator has been designed, microfabricated and tested in an oscillating-flow rig with excellent results. During the Phase I effort, several approximations of parallel-plate regenerator geometry were chosen as potential candidates for a new microfabrication concept. Potential manufacturers and processes were surveyed. The selected concept consisted of stacked segmented-involute-foil disks (or annular portions of disks), originally to be microfabricated from stainless-steel via the LiGA (lithography, electroplating, and molding) process and EDM. During Phase II, re-planning of the effort led to test plans based on nickel disks, microfabricated via the LiGA process, only. A stack of nickel segmented-involute-foil disks was tested in an oscillating-flow test rig. These test results yielded a performance figure of merit (roughly the ratio of heat transfer to pressure drop) of about twice that of the 90 percent random fiber currently used in small approx.100 W Stirling space-power convertors-in the Reynolds Number range of interest (50 to 100). A Phase III effort is now underway to fabricate and test a segmented-involute-foil regenerator in a Stirling convertor. Though funding limitations prevent optimization of the Stirling engine geometry for use with this regenerator, the Sage computer code will be used to help evaluate the engine test results. Previous Sage Stirling model projections have indicated that a segmented-involute-foil regenerator is capable of improving the performance of an optimized involute-foil engine by 6 to 9 percent; it is also anticipated that such involute-foil geometries will be more reliable and easier to manufacture with tight-tolerance characteristics, than random-fiber or wire-screen regenerators. Beyond the near-term Phase III regenerator fabrication and engine testing, other goals are (1) fabrication from a material suitable for high temperature Stirling operation (up to 850 C for current engines; up to 1200 C for a potential engine-cooler for a Venus mission), and (2) reduction of the cost of the fabrication process to make it more suitable for terrestrial applications of segmented involute foils. Past attempts have been made to use wrapped foils to approximate the large theoretical figures of merit projected for parallel plates. Such metal wrapped foils have never proved very successful, apparently due to the difficulties of fabricating wrapped-foils with uniform gaps and maintaining the gaps under the stress of time-varying temperature gradients during start-up and shut-down, and relatively-steady temperature gradients during normal operation. In contrast, stacks of involute-foil disks, with each disk consisting of multiple involute-foil segments held between concentric circular ribs, have relatively robust structures. The oscillating-flow rig tests of the segmented-involute-foil regenerator have demonstrated a shift in regenerator performance strongly in the direction of the theoretical performance of ideal parallel-plate regenerators.

Tew, Roy↗
NASA NTRS1997

System for operating solid oxide fuel cell generator on diesel fuel

A system is provided for operating a solid oxide fuel cell generator on diesel fuel. The system includes a hydrodesulfurizer which reduces the sulfur content of commercial and military grade diesel fuel to an acceptable level. Hydrogen which has been previously separated from the process stream is mixed with diesel fuel at low pressure. The diesel/hydrogen mixture is then pressurized and introduced into the hydrodesulfurizer. The hydrodesulfurizer comprises a metal oxide such as ZnO which reacts with hydrogen sulfide in the presence of a metal catalyst to form a metal sulfide and water. After desulfurization, the diesel fuel is reformed and delivered to a hydrogen separator which removes most of the hydrogen from the reformed fuel prior to introduction into a solid oxide fuel cell generator. The separated hydrogen is then selectively delivered to the diesel/hydrogen mixer or to a hydrogen storage unit. The hydrogen storage unit preferably comprises a metal hydride which stores hydrogen in solid form at low pressure. Hydrogen may be discharged from the metal hydride to the diesel/hydrogen mixture at low pressure upon demand, particularly during start-up and shut-down of the system.

Singh, Prabhu↗
NASA NTRS2001

Generation of mechanical oscillation applicable to vibratory rate gyroscopes

To achieve a drive-axis oscillation with improved frequency and amplitude stability, additional feedback loops are used to adjust force-feedback loop parameters. An amplitude-control loop measures oscillation amplitude, compares this value to the desired level, and adjusts damping of the mechanical sense-element to grow or shrink oscillation amplitude as appropriate. A frequency-tuning loop measures the oscillation frequency, compares this value with a highly stable reference, and adjusts the gain in the force-feedback loop to keep the drive-axis oscillation frequency at the reference value. The combined topology simultaneously controls both amplitude and frequency. Advantages of the combined topology include improved stability, fast oscillation start-up, low power consumption, and excellent shock rejection.

Lemkin, Mark A.↗
NASA NTRS2004

Design and assembly of a catalyst bed gas generator for the catalytic decomposition of high concentration hydrogen peroxide propellants and the catalytic combustion of hydrocarbon/air mixtures

A method for designing and assembling a high performance catalyst bed gas generator for use in decomposing propellants, particularly hydrogen peroxide propellants, for use in target, space, and on-orbit propulsion systems and low-emission terrestrial power and gas generation. The gas generator utilizes a sectioned catalyst bed system, and incorporates a robust, high temperature mixed metal oxide catalyst. The gas generator requires no special preheat apparatus or special sequencing to meet start-up requirements, enabling a fast overall response time. The high performance catalyst bed gas generator system has consistently demonstrated high decomposition efficiency, extremely low decomposition roughness, and long operating life on multiple test articles.

Lohner, Kevin A.↗
NASA NTRS1983

Motor power factor controller with a reduced voltage starter

A power factor type motor controller in which the conventional power factor constant voltage command signal is replaced during a starting interval with a graduated control voltage. The present invention adds to the three-phase system of pending application Ser. No. 199,765, filed Oct. 23, 1980, means for modifying the operation of the system for a motor start-up interval of 5 to 30 seconds. The modification is that of providing via ramp generator 174 an initial ramp-like signal which replaces a constant power factor signal supplied by potentiometer 70. The ramp-like signal is applied to terminal 40 where it is summed with an operating power factor signal from phase detectors 32, 34, and 36 to thereby obtain a control signal for ultimately controlling SCR devices 12, 14, and 16 to effect a gradual turn-on of motor 10. The significant difference of the present invention over prior art is that the SCR devices are turned on at an advancing rate with time responsive to the combination signal described rather than simply a function of a ramp-like signal alone. The added signal, the operating power factor signal, enables the production of a control signal which effectively eliminates a prior problem with many motor starting circuits, which is that of accompanying motor instabilities.

Nola, Frank J.↗
NASA NTRS2008

5-kWe Free-piston Stirling Engine Convertor

The high reliability, long life, and efficient operation of Free-Piston Stirling Engines (FPSEs) make them an attractive power system to meet future space power requirements with less mass, better efficiency, and less total heat exchanger area than other power convertor options. FPSEs are also flexible in configuration as they can be coupled with many potential heat sources and various heat input systems, heat rejection systems, and power management and distribution systems. Development of a 5-kWe Stirling Convertor Assembly (SCA) is underway to demonstrate the viability of an FPSE for space power. The design is a scaled-down version of the successful 12.5-kWe Component Test Power Converter (CTPC) developed under NAS3-25463. The ultimate efficiency target is 25% overall convertor efficiency (electrical power out over heat in). For the single cylinder prototype now in development, cost and time constraints required use of economical and readily available materials (steel versus beryllium) and components (a commercially available linear alternator) and thus lower efficiency. The working gas is helium at 150 bar mean pressure. The design consists of a displacer suspended on internally pumped gas bearings and a power piston/alternator supported on flexures. Non-contacting clearance seals are used between internal volumes. Heat to and from the prototype convertor is done via pumped liquid loops passing through shell and tube heat exchangers. The preliminary and detail designs of the convertor, controller, and support systems (heating loop, cooling loop, and helium supply system) are complete and all hardware is on order. Assembly and test of the prototype at Foster- Miller is planned for early 2008, when work will focus on characterizing convertor dynamics and steady-state operation to determine maximum power output and system efficiency. The device will then be delivered to Auburn University where assessments will include start-up and shutdown characterization and transient response to temperature and load variations. Future activities may include testing at NASA GRC.

Chapman, Peter A.↗
NASA NTRS2008

Thermal Vacuum Testing of a Multi-Evaporator Miniature Loop Heat Pipe

Under NASA's New Millennium Program Space Technology 8 Project, four experiments are being developed for future small system applications requiring low mass, low power, and compactness. GSFC is responsible for developing the Thermal Loop experiment, which is an advanced thermal control system consisting of a miniature loop heat pipe (MLHP) with multiple evaporators and condensers. The objective is to validate the operation of an MLHP, including reliable start-ups, steady operation, heat load sharing, and tight temperature control over the range of 273K to 308K. An MLHP Breadboard has been built and tested for 1200 hours under the laboratory environment and 500 hours in a thermal vacuum chamber. Results of the TV tests are presented here.

Ku, Jentung↗
NASA NTRS2008

Design and Fabrication of a 5-kWe Free-Piston Stirling Power Conversion System

Progress in the design and fabrication of a 5-kWe free-piston Stirling power conversion system is described. A scaled-down version of the successful 12.5-kWe Component Test Power Converter (CTPC) developed under NAS3-25463, this single cylinder prototype incorporates cost effective and readily available materials (steel versus beryllium) and components (a commercial linear alternator). The design consists of a displacer suspended on internally pumped gas bearings and a power piston/alternator supported on flexures. Non-contacting clearance seals are used between internal volumes. Heat to and from the prototype is supplied via pumped liquid loops passing through shell and tube heat exchangers. The control system incorporates several novel ideas such as a pulse start capability and a piston stroke set point control strategy that provides the ability to throttle the engine to match the required output power. It also ensures stable response to various disturbances such as electrical load variations while providing useful data regarding the position of both power piston and displacer. All design and analysis activities are complete and fabrication is underway. Prototype test is planned for summer 2008 at Foster-Miller to characterize the dynamics and steady-state operation of the prototype and determine maximum power output and system efficiency. Further tests will then be performed at Auburn University to determine start-up and shutdown characteristics and assess transient response to temperature and load variations.

Chapman, Peter A.↗
NASA NTRS2008

Development of a Smooth Trajectory Maneuver Method to Accommodate the Ares I Flight Control Constraints

Six degree-of-freedom (DOF) launch vehicle trajectories are designed to follow an optimized 3-DOF reference trajectory. A vehicle has a finite amount of control power that it can allocate to performing maneuvers. Therefore, the 3-DOF trajectory must be designed to refrain from using 100% of the allowable control capability to perform maneuvers, saving control power for handling off-nominal conditions, wind gusts and other perturbations. During the Ares I trajectory analysis, two maneuvers were found to be hard for the control system to implement; a roll maneuver prior to the gravity turn and an angle of attack maneuver immediately after the J-2X engine start-up. It was decided to develop an approach for creating smooth maneuvers in the optimized reference trajectories that accounts for the thrust available from the engines. A feature of this method is that no additional angular velocity in the direction of the maneuver has been added to the vehicle after the maneuver completion. This paper discusses the equations behind these new maneuvers and their implementation into the Ares I trajectory design cycle. Also discussed is a possible extension to adjusting closed-loop guidance.

Pinson, Robin M.↗
NASA NTRS2009

Development of Life on Early Mars

Exploration of Mars has begun to unveil the history of the planet. Combinations of remote sensing, in situ compositional measurements and photographic observations have shown Mars had a dynamic and active geologic evolution. Mars geologic evolution encompassed conditions that were suitable for supporting life. A habitable planet must have water, carbon and energy sources along with a dynamic geologic past. Mars meets all of these requirements. The first 600 My of Martian history were ripe for life to develop because of the abundance of (i) Water- as shown by carved canyons and oceans or lakes with the early presence of near surface water shown by precipitated carbonates in ALH84001, well-dated at ~3.9 Gy, (ii) Energy from the original accretional processes, a molten core which generated a strong magnetic field leaving a permanent record in the early crust, active volcanism continuing throughout Martian history, and continuing impact processes, (iii) Carbon, water and a likely thicker atmosphere from extensive volcanic outgassing (i.e. H20, CO2, CH4, CO, O2, N2, H2S, SO2, etc.) and (iv) crustal tectonics as revealed by faulting and possible plate movement reflected by the magnetic pattern in the crust [1]. The question arises: "Why would life not develop from these favorable conditions on Mars in its first 600 My?" During this period, environmental near-surface conditions on Mars were more favorable to life than at any later time. Standing bodies of water, precipitation and flowing surface water, and possibly abundant hydrothermal energy would favor the formation of early life. (Even if life developed elsewhere on Earth, Venus, or on other bodies-it was transported to Mars where surface conditions were suitable for life to evolve). The commonly stated requirement that life would need hundreds of millions of year to get started is only an assumption; we know of no evidence that requires such a long interval for the development of life, if the proper habitable conditions are meet. Perhaps it could start in a very short interval during the first tens of millions of years after crustal formation. Even with impact-driven extinction events, such a short start-up time would allow life to restart multiple times until it persevered. If panspermia is considered, life could be introduced as soon as liquid surface water was present and could instantly thrive and spread.

Gibson, Everett K.↗
NASA NTRS2009

Experimental and Analytical Performance of a Dual Brayton Power Conversion System

The interactions between two closed Brayton cycle (CBC) power conversion units (PCU) which share a common gas inventory and heat source have been studied experimentally using the Dual Brayton Power Conversion System (DBPCS) and analytically using the Closed- Cycle System Simulation (CCSS) computer code. Selected operating modes include steady-state operation at equal and unequal shaft speeds and various start-up scenarios. Equal shaft speed steady-state tests were conducted for heater exit temperatures of 840 to 950 K and speeds of 50 to 90 krpm, providing a system performance map. Unequal shaft speed steady-state testing over the same operating conditions shows that the power produced by each Brayton is sensitive to the operating conditions of the other due to redistribution of gas inventory. Startup scenarios show that starting the engines one at a time can dramatically reduce the required motoring energy. Although the DBPCS is not considered a flight-like system, these insights, as well as the operational experience gained from operating and modeling this system provide valuable information for the future development of Brayton systems.

Lavelle, Thomas A.↗
NASA NTRS2009

Recovering Aerodynamic Side Loads on Rocket Nozzles using Quasi-Static Strain-Gage Measurements

During over-expanded operation of rocket nozzles, which is defined to be when the exit pressure is greater than internal pressure over some part of the nozzle, the nozzle will experience a transverse forcing function due to the pressure differential across the nozzle wall. Over-expansion occurs during the nozzle start-up and shutdown transient, even in high-altitude engines, because most test facilities cannot completely reproduce the near-vacuum pressures at those altitudes. During this transient, the pressure differential moves axially down the nozzle as it becomes pressurized, but this differential is never perfectly symmetric circumferentially. The character of the forcing function is highly complex and defined by a series of restricted and free shock separations. The subject of this paper is the determination of the magnitude of this loading during sub-scale testing via measurement of the structural dynamic response of the nozzle and its support structure. An initial attempt at back-calculating this load using the inverse of the transfer function was performed, but this attempt was shown to be highly susceptible to numerical error. The final method chosen was to use statically calibrated strain data and to filter out the system fundamental frequency such that the measured response yields close to the correct dynamic loading function. This method was shown to capture 93% of the pressure spectral energy using controlled load shaker testing. This method is one of the only practical ways for the inverse determination of the forcing function for non-stationary excitations, and, to the authors' knowledge, has not been described in the literature to date.

Brown, Andrew↗