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NASA NTRS1985

A mixed pseudospectral/finite difference method for a thermally driven fluid in a nonuniform gravitational field

A numerical study of the steady, axisymmetric flow in a heated, rotating spherical shell is conducted to model the Atmospheric General Circulation Experiment (AGCE) proposed to run aboard a later shuttle mission. The AGCE will consist of concentric rotating spheres confining a dielectric fluid. By imposing a dielectric field across the fluid a radial body force will be created. The numerical solution technique is based on the incompressible Navier-Stokes equations. In the method a pseudospectral technique is based on the incompressible Navier-Stokes equations. In the method a pseudospectral technique is used in the latitudinal direction, and a second-order accurate finite difference scheme discretizes time and radial derivatives. This paper discusses the development and performance of this numerical scheme for the AGCE which has been modelled in the past only by pure FD formulations. In addition, previous models have not investigated the effect of using a dielectric force to simulate terrestrial gravity. The effect of this dielectric force on the flow field is investigated as well as a parameter study of varying rotation rates and boundary temperatures. Among the effects noted are the production of larger velocities and enhanced reversals of radial temperature gradients for a body force generated by the electric field.

Macaraeg, M. G.↗

DOE OSTI2024

Power Electronics Thermal Management

The 2017 Electrical and Electronics Technical Team Roadmap [11] proposes aggressive research and development targets aimed at improving power electronics technology to enable the mass-market penetration of electric-drive vehicles. Achieving these aggressive targets will require a decrease in cost (year 2025 cost target: $2.70/kW) and an increase in power density (year 2025 power density target: 100 kW/L) as compared with current on-road technology. Replacing traditional silicon device-based components with more efficient and higher-temperature wide-bandgap (WBG) semiconductor device-based components will enable increased power density. However, meeting the power density target will also require innovative thermal management solutions to increase the heat fluxes dissipated and allow for compact electronics packaging. This project evaluates, designs, and develops thermal management strategies that use dielectric fluid (single-phase heat transfer) as coolants.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

Multiphysics Co-Optimization Design and Analysis of Double-Side Cooled Silicon Carbide-Based Power Module: Preprint

With the rapid growth of Electric Vehicles (EVs) and Hybrid Electric Vehicles (HEVs), much more rigorous design targets have been set for automotive power electronics, including high power density, high reliability, and low cost. Novel power module and inverter technologies based on wide bandgap (WEG) semiconductors have been developed to meet these design targets, while providing optimal power semiconductor operating temperature and promising thermomechanical performance. Compared with conventional cooling techniques which are normally applied only on one side of power module, double-side cooling approach is now believed to be the solution to enable high power density and low thermal resistance of WEG semiconductor-based power electronics. In this work, we develop a three-phase power module that is double-sided cooled using dielectric fluid jet impingement. In each phase, four silicon carbide (SiC) power semiconductors are bonded to copper busbars without electrical insulation layers. A finite element analysis (FEA) model is created for thermal and thermomechanical analysis. Based on FEA modeling results, we select particular dimensions for a parametric study to optimize thermal and mechanical performance. Using a multi-objective genetic algorithm (MOGA)-based optimization method, we have minimized the maximum junction temperature and thermal stresses within the power module. The multiphysics co-optimization approach has enabled an efficient design process of power modules with greatly reduced computational cost, as compared to conventional processes that rely on exhaustive numerical simulations and iterations.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

Electric-Drive Vehicle Power Electronics Thermal Management: Current Status, Challenges, and Future Directions

Effective thermal management of traction-drive power electronics is critical to the advancement of electric-drive vehicles and is necessary for increasing power density and improving reliability. Replacing traditional silicon devices with more efficient, higher temperature, higher voltage, and higher frequency wide-bandgap (WBG) devices will enable increased power density but will result in higher device heat fluxes. Compact packaging of high-temperature WBG devices near low-temperature-rated components creates thermal management challenges that need to be addressed for future power-dense systems. This paper summarizes the thermal performance of on-road automotive power electronics thermal management systems and provides thermal performance and pumping-power metrics for select vehicles. Thermal analyses reveal that the package/conduction resistance dominates the total thermal resistance (for existing automotive systems). We model advanced packaging concepts and compare the results with existing packaging designs to quantify their thermal performance enhancements. Double-side-cooled configurations that do not use thermal interface materials are package concepts predicted to provide a low junction-to-fluid thermal resistance (compared to current packages). Dielectric-fluid-cooled concepts enable a redesign of the package to reduce the package resistance, can be implemented in single- and two-phase cooling approaches, and allow for cooling of passive components (e.g., capacitors) and bus bars.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

Surface Tension of Dielectric–Air Interfaces

Analytical and semianalytical expressions for the surface tension of dielectric–air interfaces are presented after considering local and nonlocal dielectric effects near interfaces. It is shown that the nonlocal effects of dielectrics are significant for highly polar dielectric fluids such as water. Far from the interface, nonlocal dielectric effects are shown to cause not only the oscillatory potential of the mean force but also a reversal of sign at intermediate distances.

42 ENGINEERING↗

NASA NTRS2004

Controllable Sonar Lenses and Prisms Based on ERFs

Sonar-beam-steering devices of the proposed type would contain no moving parts and would be considerably smaller and less power-hungry, relative to conventional multiple-beam sonar arrays. The proposed devices are under consideration for installation on future small autonomous underwater vehicles because the sizes and power demands of conventional multiple-beam arrays are excessive, and motors used in single-beam mechanically scanned systems are also not reliable. The proposed devices would include a variety of electrically controllable acoustic prisms, lenses, and prism/lens combinations both simple and compound. These devices would contain electrorheological fluids (ERFs) between electrodes. An ERF typically consists of dielectric particles floating in a dielectric fluid. When an electric field is applied to the fluid, the particles become grouped into fibrils aligned in rows, with a consequent increase in the viscosity of the fluid and a corresponding increase in the speed of sound in the fluid. The change in the speed of sound increases with an increase in the applied electric field. By thus varying the speed of sound, one varies the acoustic index of refraction, analogously to varying the index of refraction of an optical lens or prism. In the proposed acoustic devices, this effect would be exploited to control the angles of refraction of acoustic beams, thereby steering the beams and, in the case of lenses, controlling focal lengths.

Bar-Cohen, Yoseph↗

NASA NTRS1985

The effect of power law body forces on a thermally-driven flow between concentric rotating spheres

A numerical study is conducted to determine the effect of power-law body forces on a thermally-driven axisymmetric flow field confined between concentric co-rotating spheres. This study is motivated by Spacelab geophysical fluid-flow experiments, which use an electrostatic force on a dielectric fluid to simulate gravity; this force exhibits a (1/r)sup 5 distribution. Meridional velocity is found to increase when the electrostatic body force is imposed, relative to when the body force is uniform. Correlation among flow fields with uniform, inverse-square, and inverse-quintic force fields is obtained using a modified Grashof number.

Macaraeg, M. G.↗

NASA NTRS1986

The effect of power-law body forces on a thermally driven flow between concentric rotating spheres

Macaraeg, M. G.↗

NASA NTRS1976

Studies of earth simulation experiments

The low gravity environment of earth orbit offers the potential for performing experiments involving baroclinic Geophysical Fluid Dynamics (GFD) on spherical surfaces. These experiments in turn have the potential for providing deeper understanding of large scale planetary and solar circulations. However, to perform these experiments, one requires an experimental technique whereby a radially directed body force can be generated to simulate a radial gravitational force field. One viable technique is the use of dielectric fluids with temperature dependent dielectric permittivity in a radially directed electric field. Application of the Boussinesq approximation to the equations of motion for this system and restrictions on the size of certain electrodynamic terms in the energy equations yields a set of equations which are analogous to the equations of motions of geophysical systems like the earth's atmosphere on term by term basis. The theoretical design of GFD experiments for performance in earth orbit are described along with results of preliminary tests of a prototype.

Hart, J. E.↗

NASA NTRS1971

Dielectric siphons.

The normally weak polarization force density, exerted on insulating dielectric liquids by a nonuniform electric field, is enhanced if high pressures are used. The nonuniform electric field acts as an elastic ?wall' to contain and guide the dielectric fluid. A general theory for these electrohydrodynamic (EHD) conduits has been developed. An illustrative example of the EHD conduits is the dielectric siphon consisting of two U-shaped electrodes held adjacent to each other by insulating nylon screws.

Jones, T. B.↗

DOE OSTI2022

Experimental and analytical study of the hydrodynamic and single and two-phase convective heat transfer performance of flexible PDMS microchannels with micropillar arrays

Various copper and silicon based thermal management systems are used in the cooling of electronics. However, the rigid nature of these materials along with their high thermal and electrical conductivity pose a difficulty in developing direct contact embedded flexible cooling systems that can offer robust cooling performance. The low density, thermal stability, chemical inertness, and electrical insulation of Polydimethylsiloxane (PDMS) make it an ideal material to develop lightweight direct contact thermal management systems for electronics. Its ease of fabrication with tunable flexibility provides the opportunity to go beyond traditional electronics and develop advanced active and passive thermal management systems for a wide–range of applications in foldable and wearable electronics, liquid cooling garments, microgravity, and electric motors. In this study, a flexible PDMS based microchannel with micropillar arrays, which enhance the thermal performance of the device through capillary-assisted flow, has been developed. The hydrodynamic and convection heat transfer performance of three PDMS wick pillar geometries, ranging from a porosity of 0.8–0.91, are investigated and compared under single-phase and two-phase conditions. Dielectric coolant FC-3283 is employed and permeability measurements are made for mass fluxes ranging from 53 kg/m 2 s to 369 kg/m 2 s. Given its conformability, the device demonstrates a deviation from Darcy’s Law, within the laminar regime, with an increasing permeability with mass flux at the rate of ~0.5–0.8 Darcy/(kg/m 2 s). A semi-analytical model has been developed and reported to quantify the conformability of the device. The heat transfer performance is experimentally evaluated using the same dielectric fluid for mass flux ranging from 105 kg/m 2 s to 420 kg/m 2 s with heat fluxes ranging from 1.5 W/cm 2 to 16 W/cm 2 . Heat transfer coefficients of up to 7000 W/m 2 K are observed, which are comparable to copper and silicon microchannels. The effect of porosity on the single phase thermal performance has been evaluated against the pumping power to provide a basis for thermal management system design. Finally, high-speed imaging is performed to study the two-phase flow characteristics to provide insight into the vapor formation and removal.

42 ENGINEERING↗

DOE OSTI2022

A remarkable CHF of 345W/cm 2 is achieved in a wicked-microchannel using HFE-7100

Boiling heat transfer of dielectric fluids is a promising cooling technique for thermal management of microelectronic systems. However, the critical heat flux achievable is generally low, because of the poor thermophysical properties of these fluids. Here, to address this dilemma, we propose a new cooling concept to substantially enhance global liquid supply during phase-change process using enhanced capillary-driven force. Additionally, dedicated vapor pathways are designed among a bank of micro-pillars to facilitate vapor removal. In this work, new wicks comprised of silicon micro-pinfin arrays are explored to significantly enhance the flow boiling heat transfer performance. To examine the functionalities of this wick, experiments on HFE-7100 were carried out with mass velocities varying from 247 to 3,465 kg/m 2 s. To explore the enhancement mechanisms and to analyze the capillary-assisted flow boiling process, visualization studies were conducted. The results indicate that sustainable evaporation induced by wick microstructures and efficient liquid supply are the enhancement mechanisms compared to parallel microchannels with solid walls. It is found that the overall heat transfer coefficient is substantially increased up to 75%. Remarkably, a high critical heat flux (CHF) of approximately 345 W/cm 2 is recorded at G = 3,465 kg/m 2 s at coolant inlet temperature of ~20 °C. Equally importantly, this noticeable enhancement of CHF value is associated with drastically decreased pressure drops compared to microchannels decorated with μ-pinfin fences.

36 MATERIALS SCIENCE↗

NASA NTRS1965

Three-dimensional wire-mesh capacitor system measures fluid density

Gaging system automatically measures the bulk density of a stored, electrically nonconductive fluid containing varying portions of liquid and vapor. The system employs a three-dimensional wire-mesh capacitor whose capacitance varies with the bulk density of the fluid dielectric medium between the capacitor plates.

Source record↗

NASA NTRS1965

Electromagnetic flowmeter.

Transducer and electronic detector of electromagnetic flow meter for volumetric flow measurement for both electrically conducting and dielectric fluids

FLOW METER↗

NASA NTRS1973

Electrohydrodynamically coupled Kelvin-Helmholtz instability

An inviscid model of the surface dynamics at the interface between two parallel-flowing insulating dielectric fluids, subject to a tangential electric field with a weak gradient, is developed. The two flows are oppositely directed, resulting in an electrohydrodynamically coupled Kelvin-Hemholtz instability. A simple stability criterion is used successfully to correlate experimental data obtained with a test configuration.

Perry, M. P.↗

NASA NTRS1974

RF gauging efforts with liquid hydrogen and liquid oxygen as applicable to subcritical space vehicle systems

The RF gauging concept is based on the interaction between a fluid dielectric medium in an enclosed metallic cavity and electromagnetic fields set up within that cavity. In RF gauging systems, the fundamental measurement relies on the interpretation of changes in the resonant RF frequencies of an enclosed tank as the mass of the propellant contained in the tank is changed. In addition to a discussion of the basic principles of operation of these systems, the study presents a description of the current breadboard implementation with typical test arrangements, along with supporting test data. The experimental testing of the RF gauging technique for liquid cryogen mass gauging indicates that this technique is a feasible approach to liquid oxygen and liquid hydrogen gauging under all attitude or reduced gravity environments.

Thompson, H. E.↗

NASA NTRS1984

Electroformed Electrodes for Electrical-Discharge Machining

Copper electrodes replace graphite electrodes in many instances of electrical-discharge machining (EDM) of complex shapes. Copper electrodes wear longer and cause less contamination of EDM dielectric fluid than do graphite electrodes.

Werner, A.↗

NASA NTRS1985

Computation of flow regimes in parameter space for the AGCE

This report describes the results of a small study program in support of the design studies for NASA's proposed Atmospheric General Circulation Experiment (AGCE). The proposed experiment will model the atmosphere using a hemispherical layer of a dielectric fluid such as silicone oil, heated at the equator, and with a large radial AC electric field producing a temperature-dependent radial body force similar to radial gravity. The effect of terrestrial gravity on the experiment can be eliminated by doing the experiment in space flight. The author developed a series of three computer models to support these design studies. The first two calculate axisymmetric solutions and their stability to small non-axisymmetric perturbations. The third computes three-dimensional solutions. These codes allow the option of solving problems in a cylindrical geometry as well as a rather generally defined spherical layer.

Roberts, G. O.↗