Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “thermal load”

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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
NASA NTRS1998

Nonlinear Analysis of the Space Shuttle Superlightweight LO2 Tank: Bahavior Under Booster Ascent Loads - Part 1

Results of linear bifurcation and nonlinear analyses of the Space Shuttle superlightweight (SLWT) external liquid-oxygen (LO2) tank for an important early booster ascent loading condition are presented. These results for thin-walled linear elastic shells that are subjected to combined mechanical and thermal loads illustrate an important type of response mode that may be encountered in the design of other liquid-fuel launch vehicles. Linear bifurcation analyses are presented that predict several nearly equal eigenvalues that correspond to local buckling modes in the forward ogive section of the LO2 tank. In contrast, the nonlinear response phenomenon is shown to consist of short-wavelength bending deformations in the forward ogive and barrel sections of the LO2 tank that growing amplitude in a stable manner increasing load. Imperfection sensitivity analyses are presented that show that the presence of several nearly equal eigenvalues does not lead to a premature general instability mode for the forward ogive section. For the linear bifurcation and nonlinear analyses, the results show that accurate predictions of the response of the shield generally require a large-scale, high-fidelity finite-element model. Results are also presented that show that the SLWT LO2 tank can support loads in excess of approximately 2.6 times the values of the operational loads considered.

Young, Richard D.↗
NASA NTRSDate not supplied

Thermal-Fluid Analysis of a Liquid-Cooled Battery Module for Electrified Aircraft

The development of safe, energy-dense batteries is critical to advancing hybrid electric and fully electrified aircraft propulsion. Achieving this capability requires a thermal management system that can maintain battery performance and safety under demanding operational conditions. The objective of this project is to support the maturation of next-generation lithium-ion batteries for electrified aircraft by conducting performance testing on integrated battery modules, specifically a 2-cell series configuration module housed within an aluminum enclosure. Designed to operate at a nominal 7.2 V with discharge rates up to 2.5C, the module will eventually be used to power an electric motor and DC-DC converter, generating substantial thermal loads that must be effectively managed to increase the usable energy and power density of electrified aircraft. To address these thermal challenges, this study presents the development and thermal-fluid analysis of a liquid-cooled thermal management system. While the full aircraft architecture utilizes an eight-string configuration, the present work evaluates a representative single-string water coolant loop to characterize baseline performance. The active cooling loop circulates water through a reservoir, pump, the battery module, and a variable area flow meter. Key performance metrics including component-level temperatures, mass flow rates, and pressure drops are quantified across the loop. Across discharge rates ranging from 0.5C to 2.5C, the active thermal loop consistently and effectively removed heat from the module, validating the design approach and confirming readiness for further development. The validated thermal performance indicates a path toward scalable battery modules that could enable energy and power dense systems for hybrid electric aircraft.

Electrified Aircraft↗
DOE OSTI2020

IMPACT OF SOIL TEMPERATURE VARIATION ON PERFORMANCE MODELING OF A NOVEL SHALLOW BORE GROUND HEAT EXCHANGER

A novel shallow bore (< 6 m deep) ground heat exchanger is proposed to substitute the conventional vertical bore ground heat exchanger (> 60 m deep) for ground source heat pump systems. A series of simulations were carried out to evaluate the impacts of the vertical soil temperature profile on the performance of the shallow bore ground heat exchanger in response to thermal loads of a ground source heat pump system, with various lengths of the shallow bore ground heat exchanger and ground thermal properties. The results indicate that the vertical soil temperature profile has a noticeable influence on the thermal response of the shallow bore ground heat exchanger. Moreover, for shallow bore ground heat exchangers with the same volume and buried depth, the one with greater length and narrower diameter has lower tank water temperature fluctuations over the year due to relatively more stable soil temperature, and the larger surface to volume ratio.

Shi, Liang↗
DOE OSTI2026

Status and performance of the GlueX DIRC

In support of the future physics program at Ce+BAF, we propose a prototype positron target. The prototype target consists of a tungsten disk mounted on a water-cooled copper support structure to enhance heat removal. The primary goals of this work are to benchmark CFD simulations, ensure vacuum integrity at the 10^-6 Pa level, achieve stable target rotation up to 10 Hz, and implement efficient water-based cooling for sustained high-power operation. To manage the thermal load, the target is designed to rotate, allowing the deposited heat to spread over a larger region, and thereby reducing localized thermal stress while maintaining the maximum temperature below 1000 K. To experimentally evaluate the thermal performance and structural stability of the target, we plan to conduct high-power laser heating tests at Laser Lab 5, LERF Building, JLab. These tests will serve as a stepping-stone for the positron production target at CEBAF.

Stevens, J.R. [College of William and Mary, Willia↗
DOE OSTI2022

Coupled Heat Power Operation of Smart Buildings via Modular Pumped Hydro Storage

In the United States, building sector is responsible for around 40% of total energy consumption and contributes about 40% of carbon emissions since 2012. Within the past several years, various optimization models and control strategies have been studied to improve buildings’ energy efficiency and reduce operational expenses under the constraints of satisfying occupants’ comfort requirements. However, the majority of these studies consider building electricity demand and thermal load being satisfied by unidirectional electricity flow from the power grid or on-site renewable energy generation to electrical and thermal home appliances. Opportunities for leveraging low-grade heat for electricity have largely been overlooked due to impracticality at small scale. In 2016, a modular pumped hydro storage technology was invented in Oak Ridge National Laboratory, named Ground Level Integrated Diverse Energy Storage (GLIDES). In GLIDES, employing high-efficiency hydraulic machinery instead of gas compressor/turbine, liquid is pumped to compress gas inside high-pressure vessel creating head on ground level. This unique design eliminates the geographical limitation associated with the existing state-of-the-art energy storage technologies. It is easy to be scaled for building level, community level, and grid level applications. By using this novel hydro-pneumatic storage technology, opportunities for leveraging low-grade heat in building can be economical. In this research, the potential of utilizing low-grade thermal energy to augment electricity generation of GLIDES is investigated. Since GLIDES relies on gas expansion in the discharge process and the gas temperature drops during this non-isothermal process, available thermal energy, e.g., from thermal storage, combined cooling, heat and power system (CCHP), can be utilized by GLIDES to counter the cooling effect of the expansion process and elevate the gas temperature and pressure and boost the roundtrip efficiency. Here, several groups of comparison experiments have been conducted, and the experimental results show that a maximum 12.9% cost saving could be achieved with unlimited heat source for GLIDES, and a moderate 3.8% cost improvement can be expected when operated coordinately with CCHP and thermal energy storage in a smart building.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1984

Burner liner thermal/structural load modelling

A serious problem exists interfacing the output temperatures and temperature gradients from either the heat transfer codes or engine tests with the input to stress analysis codes. A thermal load transfer code was developed and was used in conjunction with a three-dimensional model of a combustor liner for verification. The 3D heat transfer and stress analysis models of combustor liners and turbine blades were used to validate the mapped temperature produced by the transfer module. Verification cases were made for both finite element and finite difference heat transfer codes. A user manual for the code was written and is available.

Maffeo, R. J.↗
NASA NTRS2002

Thermal Cyclic Behavior of Thermal and Environmental Barrier Coatings Investigated Under High-Heat-Flux Conditions

Environmental barrier coatings (EBC's) have been developed to protect silicon-carbide- (SiC) based ceramic components in gas turbine engines from high-temperature environmental attack. With continuously increasing demands for significantly higher engine operating temperature, future EBC systems must be designed for both thermal and environmental protection of the engine components in combustion gases. In particular, the thermal barrier functions of EBC's become a necessity for reducing the engine-component thermal loads and chemical reaction rates, thus maintaining the required mechanical properties and durability of these components. Advances in the development of thermal and environmental barrier coatings (TBC's and EBC's, respectively) will directly impact the successful use of ceramic components in advanced engines. To develop high-performance coating systems, researchers must establish advanced test approaches. In this study, a laser high-heat-flux technique was employed to investigate the thermal cyclic behavior of TBC's and EBC's on SiC-reinforced SiC ceramic matrix composite substrates (SiC/SiC) under high thermal gradient and thermal cycling conditions. Because the laser heat flux test approach can monitor the coating's real-time thermal conductivity variations at high temperature, the coating thermal insulation performance, sintering, and delamination can all be obtained during thermal cycling tests. Plasma-sprayed yttria-stabilized zirconia (ZrO2-8 wt% Y2O3) thermal barrier and barium strontium aluminosilicate-based environmental barrier coatings (BSAS/BSAS+mullite/Si) on SiC/SiC ceramic matrix composites were investigated in this study. These coatings were laser tested in air under thermal gradients (the surface and interface temperatures were approximately 1482 and 1300 C, respectively). Some coating specimens were also subject to alternating furnace cycling (in a 90-percent water vapor environment at 1300 C) and laser thermal gradient cycling tests (in air), to investigate the water vapor effect. All cyclic tests were conducted using a 60-min hot-time temperature.

Zhu, Dongming↗
NASA NTRS2017

Thermal Analysis of the X3 Hall Thruster

Electric propulsion has generated significant interest recently as a mass efficient thrust option for deep space missions. This increased interest has drawn a renewed focus on improving the efficiency of electric propulsion thrusters, specifically Hall thrusters. Hall thrusters are a specific subset of ion engines that accelerate charged particles using a Hall current. Recent research into the 12.5 kW HERMeS (Hall Effect Rocket with Magnetic Shielding) for use on the proposed Asteroid Redirect Robotic Mission (ARRM) has shown the desire to use these devices on flight missions outside of earth orbit. This paper will focus on another Hall thruster, the X3. The X3 is a 100 kW class Hall effect thruster used for laboratory technology development. What makes the X3 unique, relative to more contemporary Hall thrusters beyond the order of magnitude increase in discharge power, is that the X3 is a 3 channel, nested Hall thruster. Common Hall thrusters typically have one annular channel where the plasma is constrained and used to charge the fuel and accelerated. The X3’s 3 channels are nested in a concentric format, with each channel fitting in a single plane. This presents very unique thermal modeling challenges with respect to quantifying the impact of plasma thermal loading and cross talk between the power dissipating components for each channel. This work will discuss the development of the X3 thermal model and the efforts to validate it with experimental data. Furthermore, some of the unique challenges that appear when trying to model high power components will be discussed. The X3 represents a challenging and interesting example of the issues affecting thermal modeling of high power electric propulsion thrusters which will become more prevalent as their use becomes more common. II

Hofer, Richard Jr.↗
DOE OSTI2021

Heat Based Power Augmentation for Modular Pumped Hydro Storage in Smart Buildings Operation

In the U.S., building sector is responsible for around 40% of total energy consumption and contributes about 40% of carbon emissions since 2012. Within the past several years, various optimization models and control strategies have been studied to improve buildings energy efficiency and reduce operational expenses under the constraints of satisfying occupants’ comfort requirements. However, the majority of these studies consider building electricity demand and thermal load being satisfied by unidirectional electricity flow from the power grid or on-site renewable energy generation to electrical and thermal home appliances. Opportunities for leveraging low grade heat for electricity have largely been overlooked due to impracticality at small scale. In 2016, a modular pumped hydro storage technology was invented in Oak Ridge National Laboratory, named Ground Level Integrated Diverse Energy Storage (GLIDES). In GLIDES, employing high efficiency hydraulic machinery instead of gas compressor/turbine, liquid is pumped to compress gas inside high-pressure vessel creating head on ground-level. This unique design eliminates the geographical limitation associated with existing state of the art energy storage technologies. It is easy to be scaled for building level, community level and grid level applications. Using this novel hydro-pneumatic storage technology, opportunities for leveraging low-grade heat in building can be economical. In this research, the potential of utilizing low-grade thermal energy to augment electricity generation of GLIDES is investigated. Since GLIDES relies on gas expansion in the discharge process and the gas temperature drops during this non-isothermal process, available thermal energy, e.g. from thermal storage, Combined Cooling, Heat and Power system (CCHP), can be utilized by GLIDES to counter the cooling effect of the expansion process and elevate the gas temperature and pressure and boost the roundtrip efficiency. Several groups of comparison experiments have been conducted and the experimental results show that a maximum 12.9% cost saving could be achieved with unlimited heat source for GLIDES, and a moderate 3.8% cost improvement can be expected when operated coordinately with CCHP and thermal energy storage in a smart building.

Chen, Yang↗
DOE OSTI2025

Cryogenic Gear System for ADMX Tuning Cavity

The Axion Dark Matter Experiment (ADMX) searches for axions by converting them into detectable photons using resonant microwave cavities at cryogenic temperatures. A precise tuning system is needed to adjust cavity frequency without adding thermal load or electromagnetic interference. This project developed and tested a 1000 to 1 gear reduction system made from PEEK, a low thermal conductivity plastic with good dimensional stability and self lubrication at low temperatures. A compound gear train design of five 3 to 1 stages and one 4 to 1 stage achieves high reduction within a 40 mm diameter compact housing. Prototypes were 3D printed and later CNC machined in PEEK using Fusion 360 and Bantam Tools to confirm manufacturability. Prototype testing showed smooth gear engagement and no slipping. The final gearbox improves cavity tuning precision for axion searches while protecting cryogenic conditions.

Ortega, Giancarlo [Marquette U.]↗
NASA NTRS2008

Ongoing Capabilities and Developments of Re-Entry Plasma Ground Tests at EADS-ASTRIUM

During re-entry, spacecrafts are subjected to extreme thermal loads. On mars, they may go through dust storms. These external heat loads are leading the design of re-entry vehicles or are affecting it for spacecraft facing solid propellant jet stream. Sizing the Thermal Protection System require a good knowledge of such solicitations and means to model and reproduce them on earth. Through its work on European projects, ASTRIUM has developed the full range of competences to deal with such issues. For instance, we have designed and tested the heat-shield of the Huygens probe which landed on Titan. In particular, our plasma generators aim to reproduce a wide variety of re-entry conditions. Heat loads are generated by the huge speed of the probes. Such conditions cannot be fully reproduced. Ground tests focus on reproducing local aerothermal loads by using slower but hotter flows. Our inductive plasma torch enables to test little samples at low TRL. Amongst the arc-jets, one was design to test architecture design of ISS crew return system and others fit more severe re-entry such as sample returns or Venus re-entry. The last developments aimed in testing samples in seeded flows. First step was to design and test the seeding device. Special diagnostics characterizing the resulting flow enabled us to fit it to the requirements.

Jullien, Pierre↗
DOE OSTI2021

Mechanical and Thermophysical Properties of 3D-Printed SiC before and after Neutron Irradiation – FY21

This report presents the mechanical and thermophysical properties of 3D-printed SiC before and after neutron irradiation that have been evaluated to assess the fuel matrix material for the Transformational Challenge Reactor (TCR). The TCR fuel form consists of an additively-manufactured silicon carbide (SiC) matrix and uranium nitride tristructural isotropic (UN TRISO) fuel particles, which is manufactured through a newly developed processing route combining binderjet 3D printing, TRISO fuel particle loading, and chemical vapor infiltration (CVI). Because the fuel matrix is a primary component of the TCR core and its response to mechanical and thermal loads during operation is one of the most influential factors on the integrity of TCR core, testing and evaluation have focused on producing mechanical and thermophysical properties data for the binderjet/CVI SiC. Baseline mechanical and thermophysical properties were measured from the disk specimens printed for different and sizes orientations, which included equibiaxial flexural failure strength, elastic constants, thermal diffusivity and conductivity, density, and the coefficient of thermal expansion. Flexural failure strength datasets showed similar Weibull distributions regardless of sample variants including different orientations. The mean failure strengths of the 3D-printed SiC variants were in the range of 280–310 MPa, which are slightly lower than that of the chemical vapor deposition (CVD) SiC. Thermophysical test results showed that specific heat and thermal expansion are not sensitive to the build direction of SiC samples, while thermal conductivity is highly dependent on the build direction and can be correlated to the anisotropic character of the 3D-printed SiC. Neutron irradiation tests were carried out on the 3D-printed 6-mm diameter SiC disk specimens. Irradiation was carried to 2.3 dpa over a temperature range of 360–880°C. No significant degradation in strength was observed in SiC after irradiations in various conditions and with different orientations. Anisotropy that had been observed in the thermal conductivity of 3D-printed SiC prior to irradiation vanished after irradiation as the irradiation defect thermal resistivity accumulated in the material. Electron microscopy of the microstructure after neutron irradiation showed distinct defect morphologies in the heterogenous material, but no evidence for irradiation-induced cracking or degradation in the microstructure was observed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

NiGa 2 O 4 interfacial layers in NiO/Ga 2 O 3 heterojunction diodes at high temperature

NiO/Ga 2 O 3 heterojunction diodes have attracted attention for high-power applications, but their high temperature performance and reliability remain underexplored. Here, we report the time evolution of the electrical properties in the widely studied p-NiO/n-Ga 2 O 3 heterojunction diodes and formation of NiGa 2 O 4 interfacial layers at high temperatures. Results of our thermal cycling experiment show an initial leakage current increase which stabilizes after sustained thermal load, due to reactions at the NiO–Ga 2 O 3 interface. High-resolution TEM microstructure analysis of the devices after thermal cycling indicates that the NiO–Ga 2 O 3 interface forms a ternary compound at high temperatures, and thermodynamic calculations suggest the formation of the spinel NiGa 2 O 4 layer between NiO and Ga 2 O 3 . First-principles defect calculations find that NiGa 2 O 4 shows low p-type intrinsic doping and hence can serve to limit electric field crowding at the interface. Vertical NiO/ Ga 2 O 3 diodes with intentionally grown 5 nm thin spinel-type NiGa 2 O 4 interfacial layers show an excellent device ON/OFF ratio of >10 10 (± 3 V), V ON of ~1.9 V, and increased breakdown voltage of ~1.2 kV for an initial unoptimized 300 lm diameter device. These p–n heterojunction diodes are promising for high-voltage, high temperature applications.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2025

High-temperature seals for supercritical carbon-dioxide (sCO 2 ) turbines (Final Report)

This is the final report for project DE-FE0031924 titled “High-temperature seals for supercritical carbon-dioxide (sCO 2 ) turbines.” The report provides a summary of the entire project efforts from October 2020 through December 2024 including the high-temperature commercial dry gas seal (DGS) tests and thermal modeling of Task 2, as well as the high-temperature, large-diameter seal design and high-temperature tests of large-diameter seals in Task 3. A key outcome of Task 2 was the testing completion of specially instrumented commercial DGS in the GE-SwRI Apollo sCO 2 compressor (27,000 rpm). Test data from the DGS showed elevated temperatures upwards of 350 o F, which are close to the higher operating temperature limit of the DGS. The temperature measurements provide insight into the expected thermal loads on DGS operating in high-speed sCO 2 compressor and provided test data for validation of an in-house thermal model of the compressor/seal. Under Task 2.0, this report also presents the development of a steady-state conjugate heat-transfer model of the DGS operating in the sCO 2 compressor – a first of its kind model for modeling heat transfer of sCO 2 in an actual operating compressor. The findings of the thermal model show a reasonable match between temperature predictions of the model and the measured temperature data, also pointing out the validity of the approach and assumptions made in modeling the flows, heat transfer coefficients and windage modeling in the rig. Under Task 3.0, this report presents the preliminary design of a large-diameter hybrid face seal (14 inch and 26-inch diameter) for field testing in a land-based GE turbine. The preliminary seal design effort presented in this report under project DE-FE0031924 builds on the development and successful laboratory testing for such large diameter hybrid face seal under the prior DE-FE0024007 project. Key aspects of seal fluid analyses with CFD, mechanical design considerations and assembly considerations in a land-based turbine are presented. Finally, under Task 3.0, this report also presents the continued high-temperature testing of the 14-inch diameter hybrid face seal developed previously under the DE-FE0024007 program. Specifically, test data demonstrating successful non-contact seal operation and seal effective leakage of 0.001-inch with seal inlet temperatures above 700 o F are presented in this report. Successful hybrid seal operation in a laboratory environment for a large diameter (14-inch) seal at temperatures above 700 o F is a major technological milestone for this technology.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS1990

Finite element analysis of thermal distortion effects on optical performance of solar dynamic concentrator for Space Station Freedom

An analysis was performed to predict the thermal distortion of the solar dynamic concentrator for Space Station Freedom in low earth orbit and to evaluate the effects of that thermal distortion on concentrator on-orbit performance. The analysis required substructural finite element modeling of critical concentrator structural subsystems, structural finite element modeling of the concentrator, mapping of thermal loading onto the structural finite element model, and the creation of specialized postprocessors to assist in interpreting results. Concentrator temperature distributions and thermally induced displacements and slope errors and the resulting receiver flux distribution profiles are discussed. Results determined for a typical orbit indicate that concentrator facet rotations are less than 0.2 mrad and that the change in facet radius due to thermal flattening is less than 5 percent. The predicted power loss due to thermal distortion effects is less than 0.3 percent. As a consequence the thermal distortions of the solar dynamic concentrator in low earth orbit will have a negligible effect on the flux distribution profiles within the receiver.

Doherty, Michael P.↗
NASA NTRS2016

Active CryoCubeSat

The Active CryoCubeSat project will demonstrate an advanced thermal control system for a 6-Unit (6U) CubeSat platform. A miniature, active thermal control system, in which a fluid is circulated in a closed loop from thermal loads to radiators, will be developed. A miniature cryogenic cooler will be integrated with this system to form a two-stage thermal control system. Key components will be miniaturized by using advanced additive manufacturing techniques resulting in a thermal testbed for proving out these technologies. Previous CubeSat missions have not tackled the problem of active thermal control systems nor have any past or current CubeSat missions included cryogenic instrumentation. This Active CryoCubeSat development effort will provide completely new capacities for CubeSats and constitutes a major advancement over the state-of-the-art in CubeSat thermal control.

CubeSat↗
NASA NTRS1989

Environmental loading effects on structures

The environment in which a structure vibrates influences its modal characteristics. Presented herein is experimental modal survey test results on splitter vanes under liquid nitrogen mass-pressure-thermal loading. In particular, shifts in modal frequencies are studied via frequency response functions, power spectral densities, isoplots, quadrature or imaginary plots, and vibration mode shape characteristics generated from strain and acceleration measurements. Analyses have shown that while mass loading lowers the frequencies, increased pressure and lower temperature have opposite effect. Thus, pressurization and cooling of a liquid causes the modal frequencies of the structure in which it is contained to shift upward.

Panossian, H. V.↗
NASA NTRS1994

Finite Element Analysis of the Random Response Suppression of Composite Panels at Elevated Temperatures using Shape Memory Alloy Fibers

A feasibility study on the use of shape memory alloys (SMA) for suppression of the random response of composite panels due to acoustic loads at elevated temperatures is presented. The constitutive relations for a composite lamina with embedded SMA fibers are developed. The finite element governing equations and the solution procedures for a composite plate subjected to combined acoustic and thermal loads are presented. Solutions include: 1) Critical buckling temperature; 2) Flat panel random response; 3) Thermal postbuckling deflection; 4) Random response of a thermally buckled panel. The preliminary results demonstrate that the SMA fibers can completely eliminate the thermal postbuckling deflection and significantly reduce the random response at elevated temperatures.

Turner, Travis L.↗