Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “thermal conductivity monitoring”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 271 records · Page 15

ENYGF 2023 - Design of Temperature-controlled Fuel-salt Irradiation Experiment

Idaho National Laboratory (INL) is developing a Molten salt Research Temperature-controlled Irradiation (MRTI) experimental capsule for the Neutron Radiography (NRAD) reactor. The experiment is envisaged to be versatile and able to host a variety of salt-wall material combinations. The first test is designed to contain actinide-bearing chloride salt, which previously has not been subjected to a neutron field. The main objectives of the experiment are to produce irradiated salt samples for Post Irradiation Examination (PIE), to evaluate salt behavior under irradiation, and to test in-situ sensors/instrumentation. The final design for the experiment completed in 2022, and fabrication of the experiment is underway. The salt is double encapsulated providing insulation and redundancy in the case of leakage. A gas-gap between the inner capsule and the outer container enables tuning of thermal conduction to the NRAD coolant by altering its thickness and its gas-mixture. An inert gas mixture ratio in the gas-gap ensures the configurations reached a targeted average salt temperature of 600oC, while avoiding salt freezing or exceeding material limits. A resistive heater placed within a thermowell and controls the temperature of the experiment (both when the reactor is on or off). The selected configurations can contain over 10 cm3 of fuel-bearing chloride salt, which is sufficient for the purposes of the post-irradiation examination (PIE) and provides sufficient volume for two submerged thermocouple probes to monitor salt temperature. The capsule wall material is Inconel 625, and weld qualifications for the assembly have been developed. A glove-box laser weld technique was refined as part of this process to ensure a leak-tight assembly for the salt-bearing assembly and reduce the risks of impurities permeating into the salt. This work was supported through the INL Laboratory Directed Research & Development (LDRD) Program under DOE Idaho Operations Office Contract DE-AC07-05ID14517.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

High temperature thick film sensor development based on doped lanthanum chromites refractory semiconductors materials

High temperature advanced sensing materials have generated high demand due the high accuracy temperature measurements requirements for process optimization, controlling and sensing. Some technological applications of harsh conditions sensing include monitoring tiles of space shuttles, rotating bearings in aircraft engines, turbines, jet engines dynamics and chemical reactors. High temperature conditions limit the sensing strategies, where typically traditional metal thermocouples are unstable, and the sensing options are limited to optical spectroscopy methods. Recently, refractory semiconductors thick- and thin-film thermocouples have been developed and, in many cases, preferred over conventional metallic thermocouples due their spatial resolution, and capability of direct deposition on any surface. Rare earth chromites ceramics materials, exhibit some properties of interest for high temperature sensing technologies development, such as: high microstructure and sintering stability, excellent conductive behavior at high temperatures, and matching thermal expansion coefficients relative to other conductors and refractory ceramics. In this work, high performance ultra-high temperature thermocouples using p-type and n-type doped lanthanum chromites materials were fabricated and tested at temperatures up to 1500 o C. Thermoelectric voltage, Seebeck Coefficients were established for all devices, evidencing high stability and performance in prolongated operational time and harsh conditions.

20 FOSSIL-FUELED POWER PLANTS↗

Enhancement of operational Flexibility of Power Plants Using IN740

Headers are crucial components within diverse industries, especially in the energy sector, as they enable the efficient transfer of fluids. The selection of materials for headers is determined by their specific applications; for example, Grade 91 and Grade 92 steels are commonly utilized. In our research, we recommend the adoption of INCONEL alloy 740 due to its exceptional robustness and heat-resistant characteristics. One critical parameter in header systems is the heat transfer coefficient, which directly influences the efficiency of heat exchange processes and can thereby impact the structural integrity of the headers. This coefficient is closely linked with factors such as the Nusselt number, which is influenced by fluid flow characteristics and thermal properties. The flow direction within headers, whether unidirectional or multidirectional—significantly affects the overall dynamics of heat transfer. This research focuses on exploring the behavior of headers, a specific pipeline system component, using ANSYS simulation software. The study aims to predict heat transfer and mechanical behavior within headers under various conditions through steady-state and transient simulations (parts 1 and 2 of the report). Key parameters such as heat transfer coefficient, velocity, and temperature are examined with the goal of optimizing header design. Part 3 of the report addresses the critical yet underexplored relationship between pressure drop and heat transfer coefficients in the transient flow regime within headers, specifically focusing on smooth horizontal circular tubes. Limited experimental work has been conducted in this area, prompting the need for comprehensive analysis. By leveraging machine learning techniques, this research aims to establish a correlation between pressure drop and heat transfer across various flow conditions, including laminar, transient, quasi-turbulent, and turbulent regimes. The data utilized for this analysis were meticulously gathered from existing literature, capturing simultaneous measurements of pressure drops and heat transfer. Part 4: In the context of power plants, header pipes are essential components that significantly influence system performance by facilitating the collection and distribution of steam. This report highlights the critical role of header pipes in enhancing reliability, efficiency, and overall power plant performance. A key aspect of this investigation is shape optimization, which aims to maximize performance while minimizing material usage. By focusing on shape optimization, this research contributes to improved efficiency and a reduced environmental footprint for power plant installations. The methodology developed in this study emphasizes optimizing header shapes to decrease reliance on expensive alloy materials and lower maintenance costs. Furthermore, a case study was conducted using a header from an operational power plant to validate the proposed optimization techniques. Finally, part 5 addresses the challenges associated with flexible operations in boiler systems, the study outlines several strategies for enhancing the durability and reliability of steam headers. Key approaches include material selection, which involves utilizing advanced materials with superior high-temperature properties and enhanced fatigue resistance to extend the lifespan of steam headers. Design modifications are also recommended, focusing on implementing changes that mitigate thermal stress and cyclic loading to reduce the likelihood of failures under varying operating conditions. Additionally, the study emphasizes the importance of regular inspection and monitoring by establishing rigorous protocols to detect early signs of damage, allowing for timely maintenance and minimizing the risks of catastrophic failures. Furthermore, operational guidelines are developed to minimize the frequency and severity of thermal transients, ensuring stable and efficient operations. Collectively, these strategies provide a robust framework for overcoming the unique challenges posed by flexible operation in boiler systems, ultimately contributing to improved reliability and performance in power plant operations. Through this comprehensive approach, the study not only enhances the understanding of pressure drop and heat transfer relationships but also promotes advancements in design and operation that will benefit the entire power generation industry.

01 COAL, LIGNITE, AND PEAT↗

Lubricant impacts on piston deposit formation in the Enterprise marine diesel research engine

The impact of lubricant formulation on piston deposits was studied using the Enterprise, a reduced-scale, single-cylinder, two-stroke crosshead marine diesel research engine. The Enterprise engine was specially designed for marine diesel lubricant research, with a custom reduced-scale cylinder lubricant injection system and extensive instrumentation of thermal boundary conditions on both the liner and piston. Lubricant conditions typical of full-scale marine diesel engines are obtained by matching mean piston speed, liner temperature profile, and combustion metrics to realistic values.Piston deposit thicknesses were measured after a set period of operation, with a focus on lubricant-based deposits on the lands and ring grooves, using both optical and contact-based measurement techniques. Engine operation for each lubricant was conducted according to a standardized protocol, with precise control of engine speed and load, cylinder lubricant injection rate, coolant temperatures, and system oil temperature; the liner and piston temperatures are continuously monitored during operation. After operation with each lubricant was completed, the engine was disassembled, and the piston and ring deposits were characterized. The piston was then thoroughly cleaned, and the lubricant system flushed, between each lubricant formulation being evaluated. The impacts on piston deposits of the lubricants being evaluated can thus be accurately quantified and are described herein.

Kaul, Brian↗

Using Air Temperature to Quantitatively Predict the MODIS Fractional Snow Cover Retrieval Errors over the Continental US (CONUS)

In the middle to high latitude and alpine regions, the seasonal snow pack can dominate the surface energy and water budgets due to its high albedo, low thermal conductivity, high emissivity, considerable spatial and temporal variability, and ability to store and then later release a winters cumulative snowfall (Cohen, 1994; Hall, 1998). With this in mind, the snow drought across the U.S. has raised questions about impacts on water supply, ski resorts and agriculture. Knowledge of various snow pack properties is crucial for short-term weather forecasts, climate change prediction, and hydrologic forecasting for producing reliable daily to seasonal forecasts. One potential source of this information is the multi-institution North American Land Data Assimilation System (NLDAS) project (Mitchell et al., 2004). Real-time NLDAS products are used for drought monitoring to support the National Integrated Drought Information System (NIDIS) and as initial conditions for a future NCEP drought forecast system. Additionally, efforts are currently underway to assimilate remotely-sensed estimates of land-surface states such as snowpack information into NLDAS. It is believed that this assimilation will not only produce improved snowpack states that better represent snow evolving conditions, but will directly improve the monitoring of drought.

MODIS↗

Autonomous Aerosol and Plasma Co‐Jet Printing of Metallic Devices at Ambient Temperature

Abstract Additive manufacturing of metallic materials holds the potential to revolutionize the fabrication of functional devices unattainable via traditional methods. Despite recent advancements, printing metallic materials typically requires thermal processing at elevated temperatures to form dense structures with desired properties, which presents a major challenge for direct printing and integration with temperature‐sensitive materials. Herein, a unique co‐jet printing (CJP) method is reported integrating an aerosol jet and a non‐thermal, atmospheric pressure plasma jet to enable concurrent aerosol deposition of metal nanoparticle inks and in situ sintering at ambient temperature. A machine learning algorithm is integrated with the CJP to perform real‐time defect detection and autonomous correction, enhancing the yield of printed films with high electrical conductivity from 44% to 94%. Concurrent printing and sintering eliminate the need for post‐printing processing, reducing the overall manufacturing time by multiple folds depending on product size. CJP enables direct printing of functional devices on a variety of temperature‐sensitive materials including biological materials. Direct printing of hydration sensors on living plant leaves is demonstrated for long‐duration monitoring of hydration level in the plant. The versatile CJP method opens tremendous opportunities to harmoniously integrate abiotic and biotic materials for emerging applications in wearable/implantable devices and biohybrid systems.

Du, Yipu [Department of Aerospace and Mechanical E↗

High T(sub c) leads for remote sensing applications

Several NASA programs designed to monitor the Earth's atmosphere from space utilize infrared detectors which operate at or below 4.2 K for optimum performance. At present, the detectors are maintained at cryogenic temperatures by a stored volume of liquid helium. These detectors must be electrically linked to amplification electronics data storage instruments maintained at 80 K. The electrical connections over the temperature gradient account for approximately 20% of the total heat load on the Dewar for some systems, accelerating the boil-off of liquid helium cryogen and reducing the operational lifetime of the space-borne instruments. The recent discovery of high temperature superconductors has provided an opportunity to develop electrically conductive, thermally insulating links to bridge this thermal gradient. This paper describes the modelling of the thermal transport properties of thick film, high T(sub c) electrical bridges across a 4.2-80 K temperature gradient and the impact of such devices on a spaceborne remote sensing system.

Selim, R.↗

Blackbody Cavity for Calibrations at 200 to 273 K

A laboratory blackbody cavity has been designed and built for calibrating infrared radiometers used to measure radiant temperatures in the range from about 200 to about 273 K. In this below-room-temperature range, scattering of background infrared radiation from room-temperature surfaces could, potentially, contribute significantly to the spectral radiance of the blackbody cavity, thereby contributing a significant error to the radiant temperature used as the calibration value. The present blackbody cavity is of an established type in which multiple reflections from a combination of conical and cylindrical black-coated walls are exploited to obtain an effective emissivity greater than the emissivity value of the coating material on a flat exposed surface. The coating material in this case is a flat black paint that has an emissivity of approximately of 0.91 in the thermal spectral range and was selected over other, higher-emissivity materials because of its ability to withstand thermal cycling. We found many black coatings cracked and flaked after thermal cycling due to differences in the coefficient of expansion differences. On the basis of theoretical calculations, the effective emissivity is expected to approach 0.999. The cylindrical/conical shell enclosing the cavity is machined from copper, which is chosen for its high thermal conductivity. In use, the shell is oriented vertically, open end facing up, and inserted in a Dewar flask filled with isopropyl alcohol/dry-ice slush. A flange at the open end of the shell is supported by a thermally insulating ring on the lip of the Dewar flask. The slush cools the shell (and thus the black-body cavity) to the desired temperature. Typically, the slush starts at a temperature of about 194 K. The slush is stirred and warmed by bubbling dry air or nitrogen through it, thereby gradually increasing the temperature through the aforementioned calibration range during an interval of several hours. The temperature of the slush is monitored by use of a precise thermocouple probe.

Howell, Dane↗

Prediction and Analysis of Utah FORGE Injection Activities using a Coupled Thermo-hydro-mechanical and Earthquake (THM+E) Modeling Workflow

A coupled thermo-hydro-mechanical (THM) numerical workflow that is capable of modeling seismic slip is critical for the successful development of enhanced geothermal systems (EGS). By integrating key physical processes, this workflow enables accurate simulation of temperature and pressure diffusions, stress changes, and induced seismicity. As a result, it serves as a vital tool for predicting induced seismicity and optimizing reservoir stimulation strategies. The Utah FORGE (Frontier Observatory for Research in Geothermal Energy) project, located near Milford, Utah, is a U.S. Department of Energy initiative aimed at advancing EGS technology. In April 2024, eight new stimulation stages (Stages 3R-10) were conducted in well 16A (injection well) subsequent to the first series of stimulation (Stages 1-3) performed in April, 2022. To monitor the induced seismicity, geophones were deployed in wells 58-32, 56-32, and 78B-32, while fiber optic cables were also installed in wells 16B, 78-32, and 78B-32 to collect microseismic data and detect frac hits Preliminary analyses of microseismic catalogs and fiber optic data suggest that the stimulated fractures in Stages 3R–6 closely align with that generated during Stage 3, indicating that the new stimulations were likely reactivating the previously stimulated fracture. To better understand the underlying process, a comprehensive modeling approach that can accurately capture thermal, hydrological, mechanical, and seismic responses is essential. In this work, we propose and utilize a coupled thermo-hydro-mechanical and earthquake (THM+E) simulation workflow to numerically investigate the stimulation activities on well 16A. The specific objective is to confirm whether the new stimulation stages (Stages 3R–6) reactivated fractures previously stimulated during Stage 3. For this purpose, we perform THM+E simulations individually for Stages 3, 3R, 4, and 5, incorporating the discrete fracture networks (DFNs) created by the plane-fitting technique based on the microseismic catalogs. The simulation workflow consists of two separate models: a THM model and an earthquake model, coupled in a one-way manner. Detailed descriptions of the workflow are provided in Section 3. Simulation results are presented in terms of injection pressure, permeability evolution, and predicted seismic catalogs, which are then compared with field data for further analyses. This report is structured as follows. In Section 2, we present detailed analyses of the field data and propose the hypothesis that the new stimulation stages (Stages 3R–6) were probably reactivating the previously stimulated fractures in Stage 3. In Section 3, we introduce the coupled THM+E workflow and the problem setup to validate our hypothesis, followed by the simulation results for each stage in Section 4. Meanwhile, discussions are included to analyze the model predictions and their comparison with field data. Lastly, we conclude the report and outline future plans in Section 5.

15 GEOTHERMAL ENERGY↗

Distributed Coaxial Cable Sensors for In-Situ Condition Based Monitoring of Coal-Fired Boiler Tubes

The increasing contributions of renewable energy sources present new challenges to the operation and maintenance of the existing coal-fired power plants. One of the major operational risks is the unexpected failure of superheater boiler tubes, leading to the most unplanned power plant outrages. The boiler tube failure is difficult to predict due to the harsh operating environments. Therefore, condition-based monitoring (CBM) with a reliable high temperature sensor becomes necessary to produce a meaningful assessment of the health condition of boiler tubes and their remaining lifetime. In this work, the stainless-steel and quartz coaxial cable sensor (SSQ-CCS) is proposed for in-situ distributed monitoring of the boiler tube temperatures in existing coal-fired power plants. Comprehensive tests have been conducted with an in-house testing facility at Clemson University to study and evaluate the sensors’ performance in the temperature range of 100℃ to 600℃. The results indicated that the measurement resolution of the SSQ-CCS sensor is better than 1℃, and the drift is less than 2% over long-period testing. Meanwhile, multi-physics finite element analysis has been conducted to optimize the design and evaluate the safety of the SSQ-CCS temperature sensor under various operational conditions. Based on the performance obtained in the laboratory-scale testing, a field test has been implemented at a power plant. Four SSQ-CCS temperature sensors were installed for in-situ monitoring of the temperatures of a power plant’s superheat tube assembles. The data acquisition system has been successfully set up and collected sensing signals for more than three months. The sensing signals have been post-processed, and the monitored temperature history through the SSQ-CCS temperature sensor has been validated and compared with the conventional high temperature thermal couple data.

Jiao, Xinyu↗

Doped Lanthanum Chromite-refractory Based Composites Sensors for High Temperature Monitoring in Harsh Environments Systems

In order to test and monitor the operational stability and conditions of various energy, and manufacturing systems and their components, development of accurate sensors capable of operating at temperatures in excess of 1000 °C in various environments for long durations is required. In addition, many of these harsh-environment systems do not permit sensors to be directly inserted, so these sensors need to be embedded into thermal protective materials. In this work were developed high-temperature embedded thermocouples composed of various doped lanthanum chromites-refractory based composites synthesized by a mixed-oxide route and directly embedded into a Al2O3 based refractory. The electrical properties were specifically manipulated by altering the level of percolation of the conductive phase within the refractory constituent. Chemical stability of sensors was determined by phase development analysis by X-ray diffraction and X-ray photoelectron spectroscopy; Seebeck coefficients were determined by thermoelectric voltages measurements at temperature up to 1400 oC.

Perovskite LaCrO3, High-temperature conductivity, ↗

Experimental design for the evaluation of high-T(sub c) superconductive thermal bridges in a sensor satellite

Infrared sensor satellites, which consist of cryogenic infrared sensor detectors, electrical instrumentation, and data acquisition systems, are used to monitor the conditions of the earth's upper atmosphere in order to evaluate its present and future changes. Currently, the electrical connections (instrumentation), which act as thermal bridges between the cryogenic infrared sensor and the significantly warmer data acquisition unit of the sensor satellite system, constitute a significant portion of the heat load on the cryogen. As a part of extending the mission life of the sensor satellite system, the researchers at the National Aeronautics and Space Administration's Langley Research Center (NASA-LaRC) are evaluating the effectiveness of replacing the currently used manganin wires with high-temperature superconductive (HTS) materials as the electrical connections (thermal bridges). In conjunction with the study being conducted at NASA-LaRC, the proposed research is to design a space experiment to determine the thermal savings on a cryogenic subsystem when manganin leads are replaced by HTS leads printed onto a substrate with a low thermal conductivity, and to determine the thermal conductivities of HTS materials. The experiment is designed to compare manganin wires with two different types of superconductors on substrates by determining the heat loss by the thermal bridges and providing temperature measurements for the estimation of thermal conductivity. A conductive mathematical model has been developed and used as a key tool in the design process and subsequent analysis.

Scott, Elaine P.↗

Ultraviolet and visible flare observations of EQ Pegasi B

EQ Peg AB (dM43+dM5.5e) was monitored in the visible at the Whipple Observatory and ultraviolet with IUE on September 2, 1981. In the visible spectrophotometry of EQ Peg B the H-beta emission strengthened by a factor of 2 relative to the nearby stellar continuum within a few minutes and decayed over an hour. This flare in EQ Peg B was coincident with the enhancement of ultraviolet emission lines of C IV 1550 A, He II 1640 A, and C II 1335 A in the combined light of EQ Peg AB. The ultraviolet fluxes during the flare can be interpreted as similar to those either in the thermal phases of large two-ribbon solor flares where radiative cooling balances thermal conduction or in gas cooling quickly from X-ray emitting temperatures. The appearance of the ultraviolet continuum at 1700-1900 A and ratio of H-alpha to H-beta fluxes during the flare are consistent with models producing these emissions in the chromosphere.

Baliunas, S. L.↗

Numerical simulation of heat and mass transport during space crystal growth with MEPHISTO

The MEPHISTO space experiments are collaborative United States and French investigations aimed at understanding the fundamentals of crystal growth. Microgravity experiments were conducted aboard the USMP-1 and -2 missions on STS-52 and 62 in October 1992 and March 1994 respectively. MEPHISTO is a French designed and built Bridgman type furnace which uses the Seebeck technique to monitor the solid/liquid interface temperature and Peltier pulsing to mark the location and shape of the solid/liquid interface. In this paper the Bridgman growth of Sn-Bi and Bi-Sn under terrestrial and microgravity conditions is modeled using the finite element code, FIDAP*. The numerical model considers fully coupled heat and mass transport, fluid motion and solid/liquid phase changes in the crystal growth process. The primary goals of this work are: to provide a quantitative study of the thermal buoyancy-induced convection in the melt for the two flight experiments; to compare the vertical and horizontal growth configurations and systematically evaluate the effects of various gravity levels on the solute segregation. Numerical results of the vertical and horizontal Bridgman growth configurations are presented.

Yao, Minwu↗

Orbital Thermal Control of the Mercury Capsule

The approach to orbital thermal control of the Project Mercury capsule environment is relatively unsophisticated compared with that for many unmanned satellites. This is made possible by the relatively short orbital flight of about 4 1/2 hours and by the presence of the astronaut who is able to monitor the capsule systems and compensate for undesirable thermal conditions. The general external features of the Mercury configuration as it appears in the orbital phase of flight are shown. The conical afterbody is a double-wall structure. The inner wall serves as a pressure vessel for the manned compartment, and the outer wall, of shingle type construction, acts as a radiating shield during reentry. Surface treatment of the shingles calls for a stably oxidized surface to minimize reentry temperatures. The shingles are supported by insulated stringers attached to the inner skin. Areas between stringers are insulated by blankets of Thermoflex insulation. This insulation is especially effective at high altitude due to the reduction of its thermal conductivity with decreasing pressure. As a result of the design of the afterbody for the severe reentry conditions, the heat balance on the manned compartment indicates the necessity for moderate internal cooling to compensate for the heat generation due to human and electrical sources. This cooling is achieved by the controlled vaporization of water in the cabin and astronaut-suit heat exchangers.

Weston, Kenneth C.↗

ATI SAA Annex 3 Button Tensile Test Report I

This report documents the results of a study carried out under Splace Act Agreement SAA-EA-10-004 between the National Aeronautics and Space Administration (NASA) and Astro Technology Incorpporated (ATI). NASA and ATI have entered into this agreement to collaborate on the development of technologies that can benefit both the US government space programs and the oil and gas industry. The report documents the results of a test done on an adnesive system for attaching new monitoring sensor devices to pipelines under Annex III of SAA-EA-10-004: "Proof-of-Concept Design and Testing of a Post Installed Sensing Device on Subsea Risers and Pipelines". The tasks of Annex III are to design and test a proof-of-concept sensing device for in-situ installation on pipelines, risers, or other structures deployed in deep water. The function of the sensor device is to measure various signals such as strain, stress and temperature. This study complements the work done, in Annex I of the SAA, on attaching a fiber optic sensing device to pipe via adhesive bonding. Both Annex I and Annex III studies were conducted in the Crew and Thermal System Division (CTSD) at the Johnson Space Center (JSC) in collaboration with ATI.

Tang, Henry H.↗

ISS Radiator Face Sheet Anomaly Investigation and Return to Function

Maintaining sufficient heat rejection on the International Space Station (ISS) is critical to the function of the Low-Earth Orbit station. The External Active Thermal Control System (EATCS) rejects the excess heat generated by the US On-Orbit Segment (USOS) modules. The system uses single-phase liquid ammonia to collect the heat and reject it to six radiators (three on the Starboard side, three on the Port side). Each radiator is made up of eight panels. In September 2008, imagery of the Starboard radiators was conducted and showed one of the panels’ face sheets had peeled up from the internal honeycomb core structure. Out of an abundance of caution, the radiator was isolated from the rest of the EATCS and the ammonia was vented to space. Since the radiator was vented, periodic imagery of all radiator panels was taken to monitor any changes in the face sheet and inspect for other radiator anomalies. In January 2025, after years of trending and inspections, the radiator was reintegrated into the system to increase heat rejection capabilities. This paper will document the multi-year investigation that took place to determine root cause and mitigations implemented to reduce risk to the system. A summary of the data since the investigation will show rationale for reintegrating the radiator even with the damaged panel. The goal of the paper is to document the investigation for historical purposes and provide future programs with findings discovered during the investigation.

Aaron Rodriguez↗

ISS Radiator Face Sheet Anomaly Investigation and Return to Function

Maintaining sufficient heat rejection on the International Space Station (ISS) is critical to the function of the Low-Earth Orbit station. The External Active Thermal Control System (EATCS) rejects the excess heat generated by the US On-Orbit Segment (USOS) modules. The system uses single-phase liquid ammonia to collect the heat and reject it to six radiators (three on the Starboard side, three on the Port side). Each radiator is made up of eight panels. In September 2008, imagery of the Starboard radiators was conducted and showed one of the panels’ face sheets had peeled up from the internal honeycomb core structure. Out of an abundance of caution, the radiator was isolated from the rest of the EATCS and the ammonia was vented to space. Since the radiator was vented, periodic imagery of all radiator panels was taken to monitor any changes in the face sheet and inspect for other radiator anomalies. In January 2025, after years of trending and inspections, the radiator was reintegrated into the system to increase heat rejection capabilities. This paper will document the multi-year investigation that took place to determine root cause and mitigations implemented to reduce risk to the system. A summary of the data since the investigation will show rationale for reintegrating the radiator even with the damaged panel. The goal of the paper is to document the investigation for historical purposes and provide future programs with findings discovered during the investigation.

Aaron Rodriguez↗