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NASA NTRS2013

NASA Lewis Steady-State Heat Pipe Code Architecture

NASA Glenn Research Center (GRC) has developed the LERCHP code. The PC-based LERCHP code can be used to predict the steady-state performance of heat pipes, including the determination of operating temperature and operating limits which might be encountered under specified conditions. The code contains a vapor flow algorithm which incorporates vapor compressibility and axially varying heat input. For the liquid flow in the wick, Darcy s formula is employed. Thermal boundary conditions and geometric structures can be defined through an interactive input interface. A variety of fluid and material options as well as user defined options can be chosen for the working fluid, wick, and pipe materials. This report documents the current effort at GRC to update the LERCHP code for operating in a Microsoft Windows (Microsoft Corporation) environment. A detailed analysis of the model is presented. The programming architecture for the numerical calculations is explained and flowcharts of the key subroutines are given

Mi, Ye↗

NASA NTRS2015

Multifunctional Cooling Garment for Space Suit Environmental Control

Future manned space exploration missions will require space suits with capabilities beyond the current state of the art. Portable Life Support Systems for these future space suits face daunting challenges, since they must maintain healthy and comfortable conditions inside the suit for long-duration missions while minimizing weight and water venting. We have demonstrated the feasibility of an innovative, multipurpose garment for thermal and humidity control inside a space suit pressure garment that is simple, rugged, compact, and lightweight. The garment is a based on a conventional liquid cooling and ventilation garment (LCVG) that has been modified to directly absorb latent heat as well as sensible heat. This hybrid garment will prevent buildup of condensation inside the pressure garment, prevent loss of water by absorption in regenerable CO2 removal beds, and conserve water through use of advanced lithium chloride absorber/radiator (LCAR) technology for nonventing heat rejection. We have shown the feasibility of this approach by sizing the critical components for the hybrid garment, developing fabrication methods, building and testing a proof-of-concept system, and demonstrating by test that its performance is suitable for use in space suit life support systems.

Izenson, Michael↗

NASA NTRS2015

Primary Dendrite Arm Spacings in Al-7Si Alloy Directionally Solidified on the International Space Station

Samples from directionally solidified Al- 7 wt. % Si have been analyzed for primary dendrite arm spacing (lambda) and radial macrosegregation. The alloy was directionally solidified (DS) aboard the ISS to determine the effect of mitigating convection on lambda and macrosegregation. Samples from terrestrial DS-experiments thermal histories are discussed for comparison. In some experiments, lambda was measured in microstructures that developed during the transition from one speed to another. To represent DS in the presence of no convection, the Hunt-Lu model was used to represent diffusion controlled growth under steady-state conditions. By sectioning cross-sections throughout the entire length of a solidified sample, lambda was measured and calculated using the model. During steady-state, there was reasonable agreement between the measured and calculated lambda's in the space-grown samples. In terrestrial samples, the differences between measured and calculated lambda's indicated that the dendritic growth was influenced by convection.

Angart, Samuel↗

NASA NTRSDate not supplied

Thermal Control in Hypersonic Leading Edges Using Liquid Metal High Temperature Oscillating Heat Pipes

The desire to increase the range and speed of hypersonic vehicles requires sharp, shape-stable Wing Leading Edges (WLE) with performance capabilities well beyond the current state of the art. The concentrated heat flux on sharp leading edges can lead to runaway thermal and mechanical failures. Heat pipes provide a passive solution to minimize the peak temperature, thermal gradients, and resulting thermal stresses near the WLE. Conventional heat pipes have been shown to address these issues at conditions as high as Mach 8. Oscillating heat pipes (OHPs) could be used to extend this benefit to missions with higher Mach numbers since their heat transport capacity typically exceeds that of conventional heat pipes. In the current investigation, several identical liquid metal high-temperature oscillating heat pipes (LMHOHPs) were constructed and tested to demonstrate the concept. The LMHOHPs had six turns, internal diameters of 2 mm, and total lengths of 100 mm. They were additively manufactured from C103 niobium alloy and charged with lithium to reach a fill ratio of approximately 50%. The boundary conditions of the experiment were designed to resemble those of various hypersonic flight profiles. Testing was performed with a system consisting of flow-controlled acetylene torch heating and radiation dominated heat rejection. The LMHOHP’s performance was measured using temperature data from an infrared camera and pyrometer. The experimental results were used to evaluate the capability of C103/lithium LMHOHPs under various flight regimes. A heat transfer model of the LMHOHP was proposed and validated against test data. Insights from the model were then extrapolated to evaluate a Tungsten-RHC/Gallium LMHOHP with anticipated capabilities beyond that of the C103/lithium system.

Max Pawlick↗

NASA NTRS2014

Transient Convection Due to Imposed Heat Flux: Application to Liquid-Acquisition Devices

A model problem is considered that addresses the effect of heat load from an ambient laboratory environment on the temperature rise of liquid nitrogen inside an enclosure. This model has applications to liquid acquisition devices inside the cryogenic storage tanks used to transport vapor-free propellant to the main engine. We show that heat loads from Q = 0.001 to 10 W, with corresponding Rayleigh numbers from Ra = 109 to 1013, yield a range of unsteady convective states and temperature rise in the liquid. The results show that Q = 1 to 10 W (Ra = 1012 to 1013) yield temperature distributions along the enclosure height that are similar in trend to experimental measurements. Unsteady convection, which shows selfsimilarity in its planforms, is predicted for the range of heat-load conditions. The onset of convection occurs from a free-convection-dominated base flow that becomes unstable against convective instability generated at the bottom of the enclosure while the top of the enclosure is convectively stable. A number of modes are generated with small-scale thermals at the bottom of the enclosure in which the flow selforganizes into two symmetric modes prior to the onset of the propagation of the instability. These symmetric vertical modes transition to asymmetric modes that propagate as a traveling-wave-type motion of convective modes and are representative of the asymptotic convective state of the flow field. Intense vorticity production is created in the core of the flow field due to the fact that there is shear instability between the vertical and horizontal modes. For the higher Rayleigh numbers, 1012 to 1013, there is a transition from a stationary to a nonstationary response time signal of the flow and temperature fields with a mean value that increases with time over various time bands and regions of the enclosure.

Duval, Walter M. B.↗

NASA NTRSDate not supplied

Power Hibernation for Low-Cost Solar Powered Lunar Missions

Because the surface of the Moon drops to cryogenic temperatures, no solar-powered lunar spacecraft have reliably operated beyond a single lunar day. Passive thermal control cannot keep a spacecraft sufficiently warm for the 354-hour lunar night, and active thermal control requires a dramatic increase in battery mass at the expense of payload mass. Extreme conditions seen on the lunar surface suggest a radioisotope solution is ideal, but mass, cost, and schedule are inconsistent with low-cost frequent flight intent of the commercial lunar payload services (CLPS) program. To solve the issue of lunar night survivability without radioisotope sources of power and heat, a lunar power hibernation approach is being developed at the Glenn Research Center, which exploits the ability of common 18650 Lithium-ion cells to passively survive cryogenic freeze-thaw cycles and recover without apparent performance degradation. A key aspect of this hibernation approach is the use of cryogenically operable electronics that safely manage the restoration of the battery thermal environment at lunar dawn. A spacecraft utilizing this strategy will operate into the lunar night on batteries until the state of charge or spacecraft temperature reaches a predetermined threshold. At this point, systems are shut down and the battery is isolated from the main bus to prevent charge or discharge during the freezing and thawing transitions. The system remains passive until lunar dawn, where temperatures can reach as low as 50 K. All electronics must be tolerant to these conditions. When the solar arrays are finally illuminated at lunar dawn, the main bus power electronics will initiate a “cold start” and begin regulating array power. The main bus electronics must be designed to operate at cryogenic temperatures. Array power is used to warm the battery and passive electronics back to operational temperatures. Once batteries are returned to normal temperatures, diagnostics and precharging is performed, as needed, and the battery is reconnected. The overall spacecraft system reboots and returns to nominal operations until lunar night returns. To assure that we can develop batteries suited for many hibernation freeze/thaw cycles, STMD Space Technology Research Grant Program (STRG) has selected two principal investigators that will thoroughly characterize of the Li-ion cell through the freeze-thaw process, investigate degradation mechanisms, and identify potential diagnostic techniques. STMD STRG is also funding an investigation of Gallium-Nitride semiconductors for cryogenic power applications. This work includes physics-informed modeling that considers cryogenic conductivity, carrier mobility, and quantum effects that govern semiconductor performance at cryogenic temperatures. These models can enable engineers to develop accurate cryogenic simulation models that assist in the design of power controls stable over the entire lunar surface temperature range. Meanwhile, Glenn is performing cryogenic testing of batteries and electronics, establishing design guidelines for power applications in extreme cold lunar environment, and potentially developing a hibernation technology demonstrator. The hibernation approach will enable low-cost lunar robotic missions to extend their operating lifetime to many months while minimizing development costs and impact on payload capacity. The need for cryogenically operable electronics is restricted to only main bus power and battery controls, as the majority of systems simply need to passively tolerate cryogenic temperatures. This allows developers to continue to exploit the cost savings of legacy and COTS hardware with minimum modification. For these reasons, lunar power hibernation is a viable near-term solution for lunar night survivability for solar powered commercial landers.

Space power↗

NASA NTRS2000

Constituent-Based Life Models Being Developed for SiC/SiC Composites

For the successful utilization of ceramic matrix composites (CMC) as hot-section components in advanced aeropropulsion engines, the CMC constituents will need to be tailored and optimized to meet all the critical property demands of each component. Under the High-Speed Research (HSR) and Advanced High-Temperature Engine Materials Technology (HITEMP) Programs, the NASA Glenn Research Center at Lewis Field initiated research to develop mechanistic models for key CMC thermostructural properties. These models would describe the effects of different constituent factors (composition, geometry, and volume fraction) and of potential application conditions (stress, time, temperature, and environment) on these properties. Particular focus was placed on both analytical and numerical modeling of state-of-the-art SiC/SiC composites where the primary load-bearing constituents are stoichiometric SiC fibers in a complex multiphase SiC matrix produced by chemical vapor infiltration and melt infiltration. Recent studies have resulted in computer-based numerical models for the elastic modulus, thermal expansion, and thermal conductivity properties of the SiC/SiC system. Additional studies have generated analytical and empirical models for the time dependence of composite rupture strength at temperatures above 2200 F (1200 C), where CMC's have an important thermostructural advantage over current nickel-based superalloys. These life models utilize thermal activation theory and fiber stress-rupture results measured at Glenn to generate Larson-Miller (L M) plots of fiber rupture strength versus q, a single time- and temperature-dependent parameter. Assuming a worse case in which the SiC matrix is cracked, rupture is then controlled by the time-dependent fracture characteristics of the fiber bundles bridging the matrix cracks. With this as the controlling mechanism, one can then use simple composite theory and the fiber L M plots to predict CMC rupture strength versus the q parameter. The dashed line shows the predicted rupture strength of a SiC/SiC composite that is reinforced by a state-of-the-art stoichiometric SiC fiber. For the q parameter, time is in hours and temperature in degrees kelvin. To generate these predictions, a two-dimensional 0 /90 composite with approximately 16 percent fiber in the applied stress direction and an air test environment were assumed. As such, it is possible to compare the model predictions against limited stress-rupture data for this CMC as shown by the data points. The good agreement confirms the rupture model at least for the selected CMC and test conditions. Thus for this particular SiC/SiC composite, one can estimate a 1000-hr rupture strength of approximately 12 ksi at 2400 F (T = 1588 K and q = 39 700 K). At lower CMC application stresses, the SiC matrix is typically uncracked, so both the fiber and matrix constituents share the composite load. In this case, CMC rupture is controlled by the constituent with the longest rupture time based on the creep rate of the composite. Measured Monkman-Grant plots of rupture time versus creep rate for the two SiC constituents have been used to develop CMC life models for this important application condition. NASA and DOD are currently using this information to establish application and material goals for more advanced CMC's that can be used at even higher temperatures.

DiCarlo, James A.↗

NASA NTRS1982

High temperature composites for advanced missile and space transportation systems

A study has been conducted to characterize a state-of-the-art graphite/polyimide composite system by determining mechanical and thermophysical properties of selected laminates over a temperature range of -250 F to 600 F. The material studied was Celion 3000/PMR-15. Material property data obtained from testing included tension, compression and shear strengths, and coefficient of thermal expansion. Environmental conditions examined were: as cured/post-cured, isothermal aged at 600 F, thermal cycled from -250 F to 600 F, and moisture conditioned. This study has provided an initial data base on a graphite/polyimide composite system capable of operating in 500/600 F applications.

Mccleskey, S. F.↗

NASA NTRS1983

Thermal Analysis of the X-band 34-meter Antenna Feedcone

A thermal analysis was done to describe feedcone shell temperature profiles and induced thermal stresses in waveguide components. IMP-SS, a steady-state version of the thermal analysis computer program employing the implicit alterating-direction numerical technique documented in a previous report, was used to analyze the two dimensional regions of the feedcone. This portion of the analysis determined the free relative displacement of the feedcone for a worst-case thermal condition.

Hughes, R. D.↗

NASA NTRS1982

Hybrid thermoelectric solar collector design and analysis

A flat-plate solar collector is conceived where energy cascades through thermoelectric power modules generating direct-current electricity. The intent of this work was to choose a collector configuration and to perform a steady-state thermal performance assessment. A set of energy balance equations were written and solved numerically for the purpose of optimizing collector thermal and electrical performance. The collector design involves finned columns of thermoelectric modules imbedded in the absorber plate (hot junction) over a parallel array of vertical tubes. The thermoelectric power output is limited by the small hot-junction/cold-junction temperature difference which can be maintained under steady-state conditions. The electric power per unit tube pass area is found to have a maximum as a function of a geometric parameter, while electric power is maximized with respect to an electric resistance ratio. Although the electric power efficiency is small, results indicate that there is sufficient electric power production to drive a coolant circulator, suggesting the potential for a stand-alone system.

Roberts, A. S., Jr.↗

NASA NTRS1979

TACT 1: A computer program for the transient thermal analysis of a cooled turbine blade or vane equipped with a coolant insert. 2. Programmers manual

A computer program to calculate transient and steady state temperatures, pressures, and coolant flows in a cooled axial flow turbine blade or vane with an impingement insert is described. Coolant-side heat transfer coefficients are calculated internally in the program, with the user specifying either impingement or convection heat transfer at each internal flow station. Spent impingement air flows in a chordwise direction and is discharged through the trailing edge and through film cooling holes. The ability of the program to handle film cooling is limited by the internal flow model. Input to the program includes a description of the blade geometry, coolant-supply conditions, outside thermal boundary conditions, and wheel speed. The blade wall can have two layers of different materials, such as a ceramic thermal barrier coating over a metallic substrate. Program output includes the temperature at each node, the coolant pressures and flow rates, and the coolant-side heat transfer coefficients.

Gaugler, R. E.↗

NASA NTRS1974

Prediction and verification of creep behavior in metallic materials and components, for the space shuttle thermal protection system. Volume 1, phase 1: Cyclic materials creep predictions

Cyclic creep response was investigated and design methods applicable to thermal protection system structures were developed. The steady-state (constant temperature and load) and cyclic creep response characteristics of four alloys were studied. Steady-state creep data were gathered through a literature survey to establish reference data bases. These data bases were used to develop empirical equations describing creep as a function of time, temperature, and stress and as a basis of comparison for test data. Steady-state creep tests and tensile cyclic tests were conducted. The following factors were investigated: material thickness and rolling direction; material cyclic creep response under varying loads and temperatures; constant stress and temperature cycles representing flight conditions; changing stresses present in a creeping beam as a result of stress redistribution; and complex stress and temperature profiles representative of space shuttle orbiter trajectories. A computer program was written, applying creep hardening theories and empirical equations for creep, to aid in analysis of test data. Results are considered applicable to a variety of structures which are cyclicly exposed to creep producing thermal environments.

Davis, J. W.↗

NASA NTRS1991

Integrated flow and structural modeling for rocket engine component test facility propellant systems

A set of PC-based computational Dynamic Fluid Flow Simulation models is presented for modeling facility gas and cryogenic systems. Data obtained provide important information regarding performance envelope parameters for the facility using different engine components; time-dependent valve setting for controlling steady-state, quasi-steady state, and transient profiles; optimum facility pipe and pipe component sizes and parameters; momentum transfer loads; and fluid conditions at critical points. A set of COSMIC NASTRAN-based finite element models is also presented to evaluate the loads and stresses on test facility piping systems from fluid and gaseous effects, thermal chill down, and occasional wind loads. The models are based on Apple Macintosh software which makes it possible to change numerous parameters.

Dequay, L.↗

NASA NTRS1997

Workshop on Parent-Body and Nebular Modification of Chondritic Materials

The purpose of the workshop was to advance our understanding of solar nebula and asteroidal processes from studies of modification features in chondrites and interplanetary dust particles. As reflected in the program contained in this volume, the workshop included five regular sessions, a summary session, and a poster session. Twenty-three posters and 42 invited and contributed talks were presented. Part 1 of this report contains the abstracts of these presentations. The focus of the workshop included: (1) mineralogical, petrologic, chemical, and isotopic observations of the alteration mineralogy in interplanetary dust particles, ordinary and carbonaceous chondrites, and their components (Ca-Al-rich inclusions, chondrules, and matrix) to constrain the conditions and place of alteration; (2) sources of water in chondrites; (3) the relationship between aqueous alteration and thermal metamorphism; (4) short-lived radionuclides, AI-26, Mn-53, and I-129, as isotopic constraints on timing of alteration; (5) experimental and theoretical modeling of alteration reactions; and (6) the oxidation state of the solar nebula. There were approximately 140 participants at the workshop, probably due in part to the timeliness of the workshop goals and the workshop location. In the end few new agreements were achieved between warring factions, but new research efforts were forged and areas of fruitful future exploration were highlighted. Judged by these results, the workshop was successful.

Krot, A. N.↗

NASA NTRS2012

Wavefront Compensation Segmented Mirror Sensing and Control

The primary mirror of very large submillimeter-wave telescopes will necessarily be segmented into many separate mirror panels. These panels must be continuously co-phased to keep the telescope wavefront error less than a small fraction of a wavelength, to ten microns RMS (root mean square) or less. This performance must be maintained continuously across the full aperture of the telescope, in all pointing conditions, and in a variable thermal environment. A wavefront compensation segmented mirror sensing and control system, consisting of optical edge sensors, Wavefront Compensation Estimator/Controller Soft ware, and segment position actuators is proposed. Optical edge sensors are placed two per each segment-to-segment edge to continuously measure changes in segment state. Segment position actuators (three per segment) are used to move the panels. A computer control system uses the edge sensor measurements to estimate the state of all of the segments and to predict the wavefront error; segment actuator commands are computed that minimize the wavefront error. Translational or rotational motions of one segment relative to the other cause lateral displacement of the light beam, which is measured by the imaging sensor. For high accuracy, the collimator uses a shaped mask, such as one or more slits, so that the light beam forms a pattern on the sensor that permits sensing accuracy of better than 0.1 micron in two axes: in the z or local surface normal direction, and in the y direction parallel to the mirror surface and perpendicular to the beam direction. Using a co-aligned pair of sensors, with the location of the detector and collimated light source interchanged, four degrees of freedom can be sensed: transverse x and y displacements, as well as two bending angles (pitch and yaw). In this approach, each optical edge sensor head has a collimator and an imager, placing one sensor head on each side of a segment gap, with two parallel light beams crossing the gap. Two sets of optical edge sensors are used per segment-to-segment edge, separated by a finite distance along the segment edge, for four optical heads, each with an imager and a collimator. By orienting the beam direction of one edge sensor pair to be +45 away from the segment edge direction, and the other sensor pair to be oriented -45 away from the segment edge direction, all six degrees of freedom of relative motion between the segments can be measured with some redundancy. The software resides in a computer that receives each of the optical edge sensor signals, as well as telescope pointing commands. It feeds back the edge sensor signals to keep the primary mirror figure within specification. It uses a feed-forward control to compensate for global effects such as decollimation of the primary and secondary mirrors due to gravity sag as the telescope pointing changes to track science objects. Three segment position actuators will be provided per segment to enable controlled motions in the piston, tip, and tilt degrees of freedom. These actuators are driven by the software, providing the optical changes needed to keep the telescope phased.

Redding, David C.↗

NASA NTRS2012

Nuclear Thermal Rocket Element Environmental Simulator (NTREES) Upgrade Activities

To support the on-going nuclear thermal propulsion effort, a state-of-the-art non nuclear experimental test setup has been constructed to evaluate the performance characteristics of candidate fuel element materials and geometries in representative environments. The facility to perform this testing is referred to as the Nuclear Thermal Rocket Element Environment Simulator (NTREES). This device can simulate the environmental conditions (minus the radiation) to which nuclear rocket fuel components will be subjected during reactor operation. Test articles mounted in the simulator are inductively heated in such a manner so as to accurately reproduce the temperatures and heat fluxes which would normally occur as a result of nuclear fission and would be exposed to flowing hydrogen. Initial testing of a somewhat prototypical fuel element has been successfully performed in NTREES and the facility has now been shutdown to allow for an extensive reconfiguration of the facility which will result in a significant upgrade in its capabilities

Emrich, William J. Jr.↗

NASA NTRS2013

Nuclear Thermal Rocket Element Environmental Simulator (NTREES) Phase II Upgrade Activities

Emrich, William J.↗

NASA NTRS2014

Initial Operation and Shakedown of the Nuclear Thermal Rocket Element Environmental Simulator (NTREES)

To support the on-going nuclear thermal propulsion effort, a state-of-the-art non nuclear experimental test setup has been constructed to evaluate the performance characteristics of candidate fuel element materials and geometries in representative environments. The facility to perform this testing is referred to as the Nuclear Thermal Rocket Element Environment Simulator (NTREES). This device can simulate the environmental conditions (minus the radiation) to which nuclear rocket fuel components will be subjected during reactor operation. Prototypical fuel elements mounted in the simulator are inductively heated in such a manner so as to accurately reproduce the temperatures and heat fluxes which would normally occur as a result of nuclear fission in addition to being exposed to flowing hydrogen. Recent upgrades to NTREES now allow power levels 24 times greater than those achievable in the previous facility configuration. This higher power operation will allow near prototypical power densities and flows to finally be achieved in most prototypical fuel elements.

Emrich, William J., Jr.↗