Results for “Exchange” — Page 2

NASA NTRS2017

Design and testing of high-performance mini-channel graphite heat exchangers in thermoelectric energy recovery systems

Recent national energy usage studies by Lawrence Livermore National Laboratory in 2015 [1] show that there is approximately 59 Quads (1015 Btu’s) of waste thermal energy throughout various industrial, residential, power generation, and transportation sectors of the U.S. economy. Thermoelectric energy recovery is one important technology for recovering this waste thermal energy in high-temperature industrial, transportation and military energy systems. Thermoelectric generator (TEG) systems in these applications require high performance hot-side and cold-side heat exchangers to provide the critical temperature differential and transfer the required thermal energy. High performance hot-side heat exchangers in these systems are often metal-based due to requirements for high-temperature operation, strength at temperature, corrosion resistance, and chemical stability. However, the generally selected metal-based hot-side heat exchangers (i.e., Inconels, Stainless Steels) suffer from low thermal conductivity, high thermal expansion, and high density, which degrades their thermal performance, leads to high thermal-expansion-driven stresses, and creates relatively high mass/high volume (i.e., low power density) TEG systems that are then difficult to fabricate and integrate into viable energy recovery systems. This paper describes the design and testing of a new, high-temperature minichannel graphite heat exchanger designed for operation up to 500C that is a critical element of a high-power-density TEG power system for aircraft energy recovery. This high-performance graphite heat exchanger represents a new state-of-the-art standard in high-temperature heat exchangers for TEG systems, which provides higher thermal transport, less thermal expansion at operation, lower system level stresses on TE components, and a lighter weight TEG system. This new heat exchanger creates a new design paradigm in TEG system design for terrestrial energy recovery and potential NASA technology infusion into terrestrial energy system applications. This paper will present and discuss the key heat transfer, pressure drop, pumping power analyses and design tradeoffs that created this unique design. Heat transfer and pressure drop modeling was performed with both empirical models based on known heat transfer and friction factor correlations and COMSOL thermal/fluid dynamic modeling of the graphite heat exchanger structure. We will also discuss resulting thermal transport and heat fluxes predicted at the TEG interface level. Heat exchanger performance testing was performed under simulated operating conditions and correlation with test data at the anticipated operating temperature conditions will be presented and discussed.

Shevade, Abhijit↗

NASA NTRSDate not supplied

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel cells (air supply and thermal management), electric batteries (thermal management), evaporators and recuperators of waste-heat-to-power systems, and rocket engines. Even if the results are more generally applicable, the heat exchangers applications to which this study is more closely related are regeneratively cooled rocket nozzles and chambers, and repressurization systems for the launch vehicles. These components are often thin-walled and contain pressurized fluids, like propellants at cryogenic or elevated temperatures. Given that the environments that these propulsion components must endure are challenging, the manufacturing to meet these specifications often require long lead times due to specialty processes and unique tooling associated with the combined thin-wall integral channel and large-scale structures. Additive manufacturing (AM) offers programmatic advantages for reduction in processing time and cost in addition to various technical advantages, including the possibility to achieve enhanced hardware complexity targeted to superior performance, part consolidation, and the capability of processing of novel alloys. While AM is already being utilized for heat exchanger components in propulsion applications, almost all these AM components are made by means of Laser Powder Bed Fusion (L-PBF). L-PBF allows for fine features but is rather limited with respect to the overall size of the components that can be manufactured. Recent developments are maturing the Laser Powder Directed Energy Deposition (LP-DED) process which may be used, for example, to make integral channel thin-wall regeneratively-cooled rocket nozzles with diameters greater than 1 m. This paper highlights some integral channel heat exchanger demonstrator hardware applications of LP-DED, as well as the characterization of this process in combination with the use of the NASA HR-1 alloy. To properly utilize LP-DED for heat exchanger manufacturing, various aspects are being characterized such as geometry limitations, measurement of surface texture and geometric angled surfaces, surface enhancements for internal channels, and material evaluation. NASA HR-1 (FeNi-Cr) is a high strength hydrogen resistant superalloy developed for use in aerospace applications, such as heat exchangers. Some aspects and considerations about the design of heat exchangers are summarized together with data relevant to LP-DED manufacturing in combination with the NASA HR-1 alloy. Microchannels were successful deposited down to 2.54 mm and 1 mm wall thickness, wall angles of 30°, both with high reproducibility. It was also found that the areal surface roughness is highly dependent on the size of the powder feedstock used for deposition. The characterization of these LP-DED features is critical for fluid flow and heat transfer predictions as it can be exploited to enhance heat transfer at the cost of increased pressure drop.

Additive Manufacturing↗

NASA NTRSDate not supplied

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel cells (air supply and thermal management), electric batteries (thermal management), evaporators and recuperators of waste-heat-to-power systems, and rocket engines. Even if the results are more generally applicable, the heat exchangers applications to which this study is more closely related are regeneratively cooled rocket nozzles and chambers, and repressurization systems for the launch vehicles. These components are often thin-walled and contain pressurized fluids, like propellants at cryogenic or elevated temperatures. Given that the environments that these propulsion components must endure are challenging, the manufacturing to meet these specifications often require long lead times due to specialty processes and unique tooling associated with the combined thin-wall integral channel and large-scale structures. Additive manufacturing (AM) offers programmatic advantages for reduction in processing time and cost in addition to various technical advantages, including the possibility to achieve enhanced hardware complexity targeted to superior performance, part consolidation, and the capability of processing of novel alloys. While AM is already being utilized for heat exchanger components in propulsion applications, almost all these AM components are made by means of Laser Powder Bed Fusion (L-PBF). L-PBF allows for fine features but is rather limited with respect to the overall size of the components that can be manufactured. Recent developments are maturing the Laser Powder Directed Energy Deposition (LP-DED) process which may be used, for example, to make integral channel thin-wall regeneratively-cooled rocket nozzles with diameters greater than 1 m. This paper highlights some integral channel heat exchanger demonstrator hardware applications of LP-DED, as well as the characterization of this process in combination with the use of the NASA HR-1 alloy. To properly utilize LP-DED for heat exchanger manufacturing, various aspects are being characterized such as geometry limitations, measurement of surface texture and geometric angled surfaces, surface enhancements for internal channels, and material evaluation. NASA HR-1 (FeNi-Cr) is a high strength hydrogen resistant superalloy developed for use in aerospace applications, such as heat exchangers. Some aspects and considerations about the design of heat exchangers are summarized together with data relevant to LP-DED manufacturing in combination with the NASA HR-1 alloy. Microchannels were successful deposited down to 2.54 mm and 1 mm wall thickness, wall angles of 30°, both with high reproducibility. It was also found that the areal surface roughness is highly dependent on the size of the powder feedstock used for deposition. The characterization of these LP-DED features is critical for fluid flow and heat transfer predictions as it can be exploited to enhance heat transfer at the cost of increased pressure drop.

additive manufacturing↗

NASA NTRS1993

NASA data exchange standards for computational fluid dynamics

This presentation covers the following topics in viewgraph format: purpose of data exchange standards; data exchange in engineering analysis/CFD; geometry data exchange through existing product data exchange standards, NASA Data Exchange Committee, and NASA-IGES (Initial Graphics Exchange Specification); CFD grid and solution data exchange; and data exchange for multi-disciplinary engineering.

Matthew Blake↗

NASA NTRS2008

Investigation of Condensing Ice Heat Exchangers for MTSA Technology Development

Metabolic heat regenerated Temperature Swing Adsorption (MTSA) technology is being developed for thermal, carbon dioxide (CO2) and humidity control for a Portable Life Support Subsystem (PLSS). Metabolically-produced CO2 present in the ventilation gas of a PLSS is collected using a CO2selective adsorbent via temperature swing adsorption. The temperature swing is initiated through cooling to well below metabolic temperatures. Cooling is achieved with a sublimation heat exchanger using water or liquid carbon dioxide (LCO2) expanded below sublimation temperature when exposed to low pressure or vacuum. Subsequent super heated vapor, as well as additional coolant, is used to further cool the astronaut. The temperature swing on the adsorbent is then completed by warming the adsorbent with a separate condensing ice heat exchanger (CIHX) using metabolic heat from moist ventilation gas. The condensed humidity in the ventilation gas is recycled at the habitat. The water condensation from the ventilation gas is a significant heat transfer mechanism for the warming of the adsorbent bed because it represents as much as half of the energy potential in the moist ventilation gas. Designing a heat exchanger to efficiently transfer this energy to the adsorbent bed and allow the collection of the water is a challenge since the CIHX will operate in a temperature range from 210K to 280K. The ventilation gas moisture will first freeze and then thaw, sometimes existing in three phases simultaneously. A NASA Small Business Innovative Research (SBIR) Phase 1 contract was performed to investigate condensing and icing as applied to MTSA to enable higher fidelity modeling and assess the impact of geometry variables on CIHX performance for future CIHX design optimization. Specifically, a design tool was created using analytical relations to explore the complex, interdependent design space of a condensing ice heat exchanger. Numerous variables were identified as having nontrivial contributions to performance such as hydraulic diameter, heat exchanger effectiveness, ventilation gas mass flow rate and surface roughness. Using this tool, four test articles were designed and manufactured to map to a full MTSA subassembly (the adsorbent bed, the sublimation heat exchanger for cooling and the condensing ice heat exchanger for warming). The design mapping considered impacts due to CIHX geometry as well as subassembly impacts such as thermal mass and thermal resistance through the adsorbent bed. The test articles were tested at simulated PLSS ventilation loop temperature, moisture content and subambient pressure. Ice accumulation and melting were observed. Data and test observations were analyzed to identify drivers of the condensing ice heat exchanger performance. This paper will discuss the analytical models, the test article designs, and testing procedures. Testing issues will be discussed to better describe data and share lessons learned. Data analysis and subsequent conclusions will be presented.

Padilla, Sebastian↗

NASA NTRS2013

Prototype Vent Gas Heat Exchanger for Exploration EVA - Performance and Manufacturing Characteristics

NASA is developing new portable life support system (PLSS) technologies, which it is demonstrating in an unmanned ground based prototype unit called PLSS 2.0. One set of technologies within the PLSS provides suitable ventilation to an astronaut while on an EVA. A new component within the ventilation gas loop is a liquid-to-gas heat exchanger to transfer excess heat from the gas to the thermal control system s liquid coolant loop. A unique bench top prototype heat exchanger was built and tested for use in PLSS 2.0. The heat exchanger was designed as a counter-flow, compact plate fin type using stainless steel. Its design was based on previous compact heat exchangers manufactured by United Technologies Aerospace Systems (UTAS), but was half the size of any previous heat exchanger model and one third the size of previous liquid-to-gas heat exchangers. The prototype heat exchanger was less than 40 cubic inches and weighed 2.57 lb. Performance of the heat exchanger met the requirements and the model predictions. The water side and gas side pressure drops were less 0.8 psid and 0.5 inches of water, respectively, and an effectiveness of 94% was measured at the nominal air side pressure of 4.1 psia.

Quinn, Gregory J.↗

NASA NTRS1972

Gadolinium-hydrogen ion exchange of zirconium phosphate

The Gd(+3)/H(+) ion exchange on a commercial zirconium phosphate ion exchanger was investigated in chloride, sulfate, and phosphate solutions of Gd(+3) at gadolinium concentrations of 0.001 to 1 millimole per cc and in the pH range of 0 to 3.5. Relatively low Gd(+3) capacities, in the range of 0.01 to 0.1 millimole per g of ion exchanger were found at room temperature. A significant difference in Gd(+3) sorption was observed, depending on whether the ion exchanger was converted from initial conditions of greater or lesser Gd(+3) sorption than the specific final conditions. Correlations were found between decrease in Gd(+3) capacity and loss of exchanger phosphate groups due to hydrolysis during washing and between increase in capacity and treatment with H3PO4. Fitting of the experimental data to ideal ion exchange equilibrium expressions indicated that each Gd(+3) ion is sorbed on only one site of the ion exchanger. The selectivity quotient was determined to be 2.5 + or - 0.4 at room temperature on gadolinium desorption in chloride solutions.

Liu, D. C.↗

NASA NTRS1980

Excitation of the b 3 Sigma u + state of H2 by electron impact - Semiclassical exchange potentials at intermediate energies

Integrated and differential cross sections for the excitation of the b 3 Sigma u + state of H2, from the ground state, by electron impact, are presented. The energy range of interest is 10.5 to 40.0 eV. The close-coupling equations for this process are solved in five different exchange approximations: exact two-electron exchange terms, no orthogonality; exact two-electron exchange terms, orthogonality; semiclassical exchange terms, no orthogonality, with barrier term; semiclassical exchange terms, no orthogonality, no barrier term; and semiclassical exchange terms, orthogonality, with barrier term. The purpose is to judge the reliability of the semiclassical exchange approximation for electronic excitation of molecules by electron impact at intermediate energies. The results are compared with recent theoretical estimates for the same process.

Weatherford, C. A.↗

NASA NTRS1981

A heat exchanger computational procedure for temperature-dependent fouling

A novel heat exchanger computational procedure is described which provides a means of rapidly calculating the distributions of fluid and wall temperatures, deposit formation, and pressure loss at various points in a heat exchanger. The procedure is unique in that it is capable of treating wide variations in heat exchanger geometry without recourse to restrictive assumptions concerning heat exchanger type (e.g., co-flow, counterflow, cross flow devices, etc.). The analysis has been used extensively to predict the performance of cross-counterflow heat exchangers in which one fluid behaves as a perfect gas (e.g., air) while the other fluid is assumed to be a distillate fuel. The model has been extended to include the effects on heat exchanger performance of time varying inflow conditions. Heat exchanger performance degradation due to deposit formation with time can be simulated, making this procedure useful in predicting the effects of temperature-dependent fouling.

Chiappetta, L. M.↗

NASA NTRS1987

The effect of wind and currents on gas exchange in an estuarine system

The objectives were to develop a non-volatile tracer to use in gas exchange experiments in laterally unconfined systems and to study applications of deliberate tracers in limnology and oceanography. Progress was made on both fronts but work on the development of the non-volatile tracer proved to be more difficult and labor intensive that anticipated so no field experiments using non-volatile tracers was performed as yet. In the search for a suitable non-volatile tracer for an ocean scale gas exchange experiment a tracer was discovered which does not have the required sensitivity for a large scale experiment, but is very easy to analyze and will be well suited for smaller experiments such as gas exchange determinations on rivers and streams. Sulfur hexafluoride, SF6, was used successfully as a volatile tracer along with tritium as a non-volatile tracer to study gas exchange rates from a primary stream. This is the first gas exchange experiment in which gas exchange rates were determined on a head water stream where significant groundwater input occurs along the reach. In conjunction with SF6, Radon-222 measurements were performed on the groundwater and in the stream. The feasibility of using a combination of SF6 and radon is being studied to determine groundwater inputs and gas exchange of rates in streams with significant groundwater input without using a non-volatile tracer.

Broecker, W. S.↗

NASA NTRS1990

High heat flux single phase heat exchanger

This paper presents the results obtained to date in a program to develop a high heat flux, single-phase heat exchanger for spacecraft thermal management. The intended application is a net generation interface heat exchanger to couple the crew module water thermal bus to the two-phase ammonia main thermal bus in the Space Station Freedom. The large size of the interface heat exchanger is dictated by the relatively poor water-side heat transfer characteristics. The objective of this program is to develop a single-phase heat transfer approach which can achieve heat fluxes and heat transfer coefficients comparable to those of the evaporation ammonia side. A new heat exchanger concept has been developed to meet these objecties. The main feature of this heat exchanger is that it can achieve very high heat fluxes with a pressure drop one to two orders of magnitude lower than those of previous microchannel or jet impingement high heat flux heat exchangers. This paper describes proof-of-concept experiments performed in air and water and presents analytical model of the heat exchanger.

Valenzuela, Javier A.↗

NASA NTRS1992

Biosphere/atmosphere CO2 exchange in tundra ecosystems - Community characteristics and relationships with multispectral surface reflectance

CO2 exchange rates were measured at selected tundra sites near Bethel, Alaska using portable, climate-controlled, instrumented enclosures. The empirically modeled exchange rate for a representative area of vegetated tundra was 1.2 +/- 1.2 g/sq m/d, compared to a tower-measured exchange over the same time period of 1.1 +.0- 1.2 g/sq m/d. Net exchange in response to varying light levels was compared to wet meadow and dry upland tundra, and to the net exchange measured by the micrometeoroidal tower technique. The multispectral reflectance properties of the sites were measured and related to exchange rates in order to provide a quantitative foundation for the use of satellite remote sensing to monitor biosphere/atmosphere CO2 exchange in the tundra biome.

Whiting, Gary J.↗

NASA NTRS2001

Thermal/Fluid Analysis of a Composite Heat Exchanger for Use on the RLV Rocket Engine

As part of efforts to design a regeneratively cooled composite nozzle ramp for use on the reusable vehicle (RLV) rocket engine, a C-SiC composite heat exchanger concept was proposed for thermal performance evaluation. To test the feasibility of the concept, sample heat exchanger panels were made to fit the Glenn Research Center's cell 22 for testing. Operation of the heat exchanger was demonstrated in a combustion environment with high heat fluxes similar to the RLV Aerospike Ramp. Test measurements were reviewed and found to be valuable for the on-going fluid and thermal analysis of the actual RLV composite ramp. Since the cooling fluid for the heat exchanger is water while the RLV Ramp cooling fluid is LH2, fluid and therma models were constructed to correlate to the specific test set-up. The knowledge gained from this work will be helpful for analyzing the thermal response of the actual RLV Composite Ramp. The coolant thermal properties for the models are taken from test data. The heat exchanger's cooling performance was analyzed using the Generalized Fluid System Simulation Program (GFSSP). Temperatures of the heat exchanger's structure were predicted in finite element models using Patran and Sinda. Results from the analytical models and the tests show that RSC's heat exchanger satisfied the combustion environments in a series of 16 tests.

Nguyen, Dalton↗

NASA NTRS2002

Thermal/Fluid Analysis of a Composite Heat Exchanger for Use on the RLV Rocket Engine

As part of efforts to design a regeneratively cooled composite nozzle ramp for use on the reusable vehicle (RLV) rocket engine, an C-SiC composites heat exchanger concept was proposed for thermal performance evaluation. To test the feasibility of the concept, sample heat exchanger panels were made to fit the Glenn Research Center's cell 22 for testing. Operation of the heat exchanger was demonstrated in a combustion environment with high heat fluxes similar to the RLV Aerospike Ramp. Test measurements were reviewed and found to be valuable for the on going fluid and thermal analysis of the actual RLV composite ramp. Since the cooling fluid for the heat exchanger is water while the RLV Ramp cooling fluid is LH2, fluid and thermal models were constructed to correlate to the specific test set-up. The knowledge gained from this work will be helpful for analyzing the thermal response of the actual RLV Composite Ramp. The coolant thermal properties for the models are taken from test data. The heat exchanger's cooling performance was analyzed using the Generalized Fluid System Simulation Program (GFSSP). Temperatures of the heat exchanger's structure were predicted in finite element models using Patran and Sinda. Results from the analytical models and the tests show that RSC's heat exchanger satisfied the combustion environments in a series of 16 tests.

Nguyen, Dalton↗

NASA NTRS2003

Antiferromagnetic Interlayer Exchange Coupling in All-Semiconducting EuS/PbS/EuS Trilayers

A comprehensive experimental study on the antiferromagnetic interlayer exchange coupling in high quality epitaxial all-semiconducting EuSPbSEuS trilayers is reported. The influence of substrates, the thickness of the non-magnetic PbS spacer layer, and of temperature, was investigated by means of SQUID magnetometry. In trilayers with a PbS thickness between 4 and 12 deg A the low temperature hysteresis loops showed the signature of antiferromagnetic coupling. The value of the interlayer exchange coupling energy was determined by simulating the data with a modified Stoner model, including Zeeman, anisotropy, and exchange coupling energies. An important observation was of a strong dependence of the interlayer exchange coupling energy on temperature, consistent with a power law dependence of the exchange coupling constant on the saturation magnetization of the EuS layers. While no theoretical description is readily available, we conjecture that the observed behavior is due to a dependence of the interlayer exchange coupling energy on the exchange splitting of the EuS conduction band.

Smits, C. J. P.↗

NASA NTRS2004

Extratropical Stratosphere-Troposphere Mass Exchange

Understanding the exchange of gases between the stratosphere and the troposphere is important for determining how pollutants enter the stratosphere and how they leave. This study does a global analysis of that the exchange of mass between the stratosphere and the troposphere. While the exchange of mass is not the same as the exchange of constituents, you can t get the constituent exchange right if you have the mass exchange wrong. Thus this kind of calculation is an important test for models which also compute trace gas transport. In this study I computed the mass exchange for two assimilated data sets and a GCM. The models all agree that amount of mass descending from the stratosphere to the troposphere in the Northern Hemisphere extra tropics is approx. 10(exp 10) kg/s averaged over a year. The value for the Southern Hemisphere by about a factor of two. ( 10(exp 10) kg of air is the amount of air in 100 km x 100 km area with a depth of 100 m - roughly the size of the D.C. metro area to a depth of 300 feet.) Most people have the idea that most of the mass enters the stratosphere through the tropics. But this study shows that almost 5 times more mass enters the stratosphere through the extra-tropics. This mass, however, is quickly recycled out again. Thus the lower most stratosphere is a mixture of upper stratospheric air and tropospheric air. This is an important result for understanding the chemistry of the lower stratosphere.

Schoeberl, Mark R.↗

NASA NTRS2010

A Mass Computation Model for Lightweight Brayton Cycle Regenerator Heat Exchangers

Based on a theoretical analysis of convective heat transfer across large internal surface areas, this paper discusses the design implications for generating lightweight gas-gas heat exchanger designs by packaging such areas into compact three-dimensional shapes. Allowances are made for hot and cold inlet and outlet headers for assembly of completed regenerator (or recuperator) heat exchanger units into closed cycle gas turbine flow ducting. Surface area and resulting volume and mass requirements are computed for a range of heat exchanger effectiveness values and internal heat transfer coefficients. Benefit cost curves show the effect of increasing heat exchanger effectiveness on Brayton cycle thermodynamic efficiency on the plus side, while also illustrating the cost in heat exchanger required surface area, volume, and mass requirements as effectiveness is increased. The equations derived for counterflow and crossflow configurations show that as effectiveness values approach unity, or 100 percent, the required surface area, and hence heat exchanger volume and mass tend toward infinity, since the implication is that heat is transferred at a zero temperature difference. To verify the dimensional accuracy of the regenerator mass computational procedure, calculation of a regenerator specific mass, that is, heat exchanger weight per unit working fluid mass flow, is performed in both English and SI units. Identical numerical values for the specific mass parameter, whether expressed in lb/(lb/sec) or kg/(kg/sec), show the dimensional consistency of overall results.

Juhasz, Albert J.↗

NASA NTRS2010

High Performance Non-Dispersive X-Ray Spectrometers for Charge Exchange Measurements

Currently, the only measurements of cosmological charge exchange have been made using low resolution, non-dispersive spectrometers like the PSPC on ROSAT and the CCD instruments on Chandra and XMM/Newton. However, upcoming cryogenic spectrometers on Astro-H and IXO will add vast new capabilities to investigate charge exchange in local objects such as comets and planetary atmospheres. They may also allow us to observe charge exchange in extra-solar objects such as galactic supernova remnants. With low spectral resolution instruments such as CCDs, x-ray emission due to charge exchange recombination really only provides information on the acceptor species, such as the solar wind. With the new breed of x-ray calorimeter instruments, emission from charge exchange becomes highly diagnostic allowing one to uniquely determine the acceptor species, ionization state, donor species and ionization state, and the relative velocity of the interaction. We will describe x-ray calorimeter instrumentation and its potential for charge exchange measurements in the near term. We will also touch on the instrumentation behind a decade of high resolution measurements of charge exchange using an x-ray calorimeter at the Lawrence Livermore National Laboratory.

Porter Frederick↗