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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.

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At least 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Thermal Management for Planar Package Power Electronics (CRADA Final Report)

The National Renewable Energy Laboratory (NREL) and John Deere Electronic Solutions (JDES) collaborated to develop and evaluate computer models and simulations related to the thermal performance of semiconductor device packaging for an inverter of an off-road vehicle ("Semiconductor Packaging"). The objective of the research was for NREL and JDES to develop a two or three-dimensional computer-aided design model of the Semiconductor Packaging ("Computer Model") for thermal performance evaluation in a simulation. The project developed computer models of a Semiconductor Package of silicon-carbide semiconductor devices with appropriate thermal dissipation via one or more of the following thermal features: a double-sided planar cooling configuration, an air-cooled configuration, a liquid-cooled configuration for off-road inverter applications in a relevant simulated operating environment. It is noted that surface area and prototype product embodiment consisting of air-cooled and liquid-cooled configurations may and may not be in direct contact with power semiconductor chips. The idea was to explore and develop packaging and thermal management technology for power semiconductors that was most effective in the performance yet had least burden in overall product cost for a given application.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1988

Computer codes for thermal analysis of a solid rocket motor nozzle

A number of computer codes are available for performing thermal analysis of solid rocket motor nozzles. Aerotherm Chemical Equilibrium (ACE) computer program can be used to perform one-dimensional gas expansion to determine the state of the gas at each location of a nozzle. The ACE outputs can be used as input to a computer program called Momentum/Energy Integral Technique (MEIT) for predicting boundary layer development development, shear, and heating on the surface of the nozzle. The output from MEIT can be used as input to another computer program called Aerotherm Charring Material Thermal Response and Ablation Program (CMA). This program is used to calculate oblation or decomposition response of the nozzle material. A code called Failure Analysis Nonlinear Thermal and Structural Integrated Code (FANTASTIC) is also likely to be used for performing thermal analysis of solid rocket motor nozzles after the program is duly verified. A part of the verification work on FANTASTIC was done by using one and two dimension heat transfer examples with known answers. An attempt was made to prepare input for performing thermal analysis of the CCT nozzle using the FANTASTIC computer code. The CCT nozzle problem will first be solved by using ACE, MEIT, and CMA. The same problem will then be solved using FANTASTIC. These results will then be compared for verification of FANTASTIC.

Chauhan, Rajinder Singh↗
NASA NTRS1996

PICA Forebody Heatshield Qualification for the Stardust Discovery Class Mission

This paper presents the qualification of the light weight Phenolic Impregnated Carbon Ablators (PICA) as the forebody heatshield for the Stardust Discovery Class Mission. The Stardust spacecraft will be launched in early 1999 and fly by Comet Wild-2 to collect cometary and interstellar dust and return them back to earth in the Sample Return Capsule (SRC). This earth re-entry will be the fastest to date, at 12.6 km/s, and therefore requires a heatshield that can withstand very high heating rates and stagnation pressures, as well as provide the necessary insulation to the vehicle structure. The PICA material was developed as part of the Lightweight Ceramic Ablators program at NASA Ames Research Center, and was baselined as the forebody heatshield because of its low density and superior ablation and thermal performance at severe aerothermodynamic conditions. Under a Small Business Innovative Research (SBIR) program with NASA Ames, Fiber Materials, Inc. developed a process to manufacture a single-piece PICA heatshield for the forebody of the SRC, along with witness material for the fabrication of the test models. The test models were fabricated and instrumented by the staff of Lockheed Martin Astronautics in Denver, Colorado. Full body preliminary aerothermal CFD calculations were performed at NASA Ames to determine the heating and stagnation pressure conditions. The Heat shield sizing was also performed at NASA Ames by using a new material response code that accounts for the highly porous characteristics of the PICA material. The ablation and thermal performance of PICA was qualified in the NASA Ames Interaction Heating Arc Jet Facility. A total of 24 models and four test conditions were used to qualify PICA at the predicted peak heat flux, heat load, shear, and stagnation pressure conditions. Surface and in-depth temperatures were measured using optical pyrometers and thermocouples. Surface recession was measured by using a template and a height gage. Several models were tested to evaluate repair procedures, and two models were cold soaked in liquid nitrogen, prior th testing, to investigate the effect of the cold space environment on the performance of the material. In addition, material cored from a demonstration single-piece heatshield was tested to verify that the PICA process can be successfully completed on a large, complex heatshield shape.

Tran, Huy K.↗
NASA NTRS2011

Design and Analysis of Mirror Modules for IXO and Beyond

Advancements in X-ray astronomy demand thin, light, and closely packed thin optics which lend themselves to segmentation of the annular mirrors and, in turn, a modular approach to the mirror design. The functionality requirements of such a mirror module are well understood. A baseline modular concept for the proposed International X-Ray Observatory (IXO) Flight Mirror Assembly (FMA) consisting of 14,000 glass mirror segments divided into 60 modules was developed and extensively analyzed. Through this development, our understanding of module loads, mirror stress, thermal performance, and gravity distortion have greatly progressed. The latest progress in each of these areas is discussed herein. Gravity distortion during horizontal X-ray testing and on-orbit thermal performance have proved especially difficult design challenges. In light of these challenges, fundamental trades in modular X-ray mirror design have been performed. Future directions in module X-ray mirror design are explored including the development of a 1.8 m diameter FMA utilizing smaller mirror modules. The effect of module size on mirror stress, module self-weight distortion, thermal control, and range of segment sizes required is explored with advantages demonstrated from smaller module size in most cases.

McClelland, Ryan S.↗
NASA NTRS2011

Achieving Innovation and Affordability Through Standardization of Materials Development and Testing

The successful expansion of development, innovation, and production within the aeronautics industry during the 20th century was facilitated by collaboration of government agencies with the commercial aviation companies. One of the initial products conceived from the collaboration was the ANC-5 Bulletin, first published in 1937. The ANC-5 Bulletin had intended to standardize the requirements of various government agencies in the design of aircraft structure. The national space policy shift in priority for NASA with an emphasis on transferring the travel to low earth orbit to commercial space providers highlights an opportunity and a need for the national and global space industries. The same collaboration and standardization that is documented and maintained by the industry within MIL-HDBK-5 (MMPDS-01) and MIL-HBDK-17 (nonmetallic mechanical properties) can also be exploited to standardize the thermal performance properties, processing methods, test methods, and analytical methods for use in aircraft and spacecraft design and associated propulsion systems. In addition to the definition of thermal performance description and standardization, the standardization for test methods and analysis for extreme environments (high temperature, cryogenics, deep space radiation, etc) would also be highly valuable to the industry. Its subsequent revisions and conversion to MIL-HDBK-5 and then MMPDS-01 established and then expanded to contain standardized mechanical property design values and other related design information for metallic materials used in aircraft, missiles, and space vehicles. It also includes guidance on standardization of composition, processing, and analytical methods for presentation and inclusion into the handbook. This standardization enabled an expansion of the technologies to provide efficiency and reliability to the consumers. It can be established that many individual programs within the government agencies have been overcome with development costs generated from these nonstandard requirements. Without industry standardization and acceptance, the programs are driven to shoulder the costs of determining design requirements, performance criteria, and then material qualification and certification. A significant investment that the industry could make to both reduce individual program development costs and schedules while expanding commercial space flight capabilities would be to invest in standardizing material performance properties for high temperature, cryogenic, and deep space environments for both metallic and nonmetallic materials.

Bray, M. H.↗
NASA NTRS2015

Thin Aerogel as a Spacer in Multilayer Insulation

Cryogenic fluid management is a critical technical area that is needed for future space exploration. A key challenge is the storability of liquid hydrogen (LH2), liquid methane (LCH4), and liquid oxygen (LOX) propellants for long-duration missions. The storage tanks must be well-insulated to prevent over-pressurization and venting, which can lead to unacceptable propellant losses for long-duration missions to Mars and beyond. Aspen Aerogels had validated the key process step to enable the fabrication of thin, low-density aerogel materials. The multilayer aerogel insulation (MLAI) system prototypes were prepared using sheets of aerogel materials with superior thermal performance exceeding current state-of-the-art insulation for space applications. The exceptional properties of this system include a new breakthrough in high-vacuum cryogenic thermal insulation, providing a durable material with excellent thermal performance at a reduced cost when compared to longstanding state-of-the-art multilayer insulation systems. During the Phase II project, further refinement and qualification/system-level testing of the MLAI system will be performed for use in cryogenic storage applications. Aspen has been in discussions with United Launch Alliance, LLC; NASA's Kennedy Space Center; and Yetispace, Inc., to test the MLAI system on real-world tanks such as Vibro-Acoustic Test Article (VATA) or the Cryogenic Orbital Testbed (CRYOTE).

Moroz, Nancy↗
NASA NTRS2015

Thin Aerogel as a Spacer in Multilayer Insulation

Cryogenic fluid management is a critical technical area that is needed for future space exploration. A key challenge is the storability of liquid hydrogen (LH2), liquid methane (LCH4), and liquid oxygen (LOX) propellants for long-duration missions. The storage tanks must be well-insulated to prevent over-pressurization and venting, which can lead to unacceptable propellant losses for long-duration missions to Mars and beyond. Aspen Aerogels had validated the key process step to enable the fabrication of thin, low-density aerogel materials. The multilayer aerogel insulation (MLAI) system prototypes were prepared using sheets of aerogel materials with superior thermal performance exceeding current state-of-the-art insulation for space applications. The exceptional properties of this system include a new breakthrough in high-vacuum cryogenic thermal insulation, providing a durable material with excellent thermal performance at a reduced cost when compared to longstanding state-of-the-art multilayer insulation systems. During the Phase II project, further refinement and qualification/system-level testing of the MLAI system will be performed for use in cryogenic storage applications. Aspen has been in discussions with United Launch Alliance, LLC; NASA's Kennedy Space Center; and Yetispace, Inc., to test the MLAI system on rea-lworld tanks such as Vibro-Acoustic Test Article (VATA) or the Cryogenic Orbital Testbed (CRYOTE).

Moroz, Nancy↗
NASA NTRS1998

Process for controlling morphology and improving thermal mechanical performance of high performance interpenetrating and semiinterpenetrating polymer networks

In the process of the present invention, a non-polar, aprotic solvent is removed from an oligomer/polymer solution by freeze-drying in order to produce IPNs and semi-IPNs. By thermally quenching the solution to a solid in a short length of time, the size of the minor constituent-rich regions is greatly reduced as they are excluded along with the major constituent from the regions of crystallizing solvent. The use of this process sequence of controlling phase morphology provides IPNs and semi-IPNs with improved fracture toughness, microcracking resistance, and other physical-mechanical properties as compared to IPNs and semi-IPNs formed when the solvent is evaporated rather than sublimed.

Pater, Ruth H.↗
DOE OSTI2025

Design, fabrication, simulation, and testing of additively manufactured lattice-based copper heat sinks

Here, this study investigates the potential advantages of lattice structure-based bound metal material extrusion (MEX) 3D printing for fabricating high-performance copper heat sinks. Copper powder-filled polymer filaments, with a copper content of > 90 wt.%, were developed specifically for the bound metal MEX 3D printing process. Three types of structures—planar, strut, and surface lattices—were 3D printed to facilitate efficient heat transfer pathways within the heat sinks. Subsequent post-processing steps, including polymer removal and sintering, were performed to achieve dense copper parts. Hot isostatic pressing was further employed to enhance the sintered density from 93 to 98%. Finite element analysis (FEA) simulations were conducted to assess the heat transfer efficiency of the designs, and heat transfer experiments were performed using a custom setup to validate the simulation results. Additionally, this research explores the use of extended hold times during pre-sintering and a reduced atmosphere to enhance the %IACS values (electrical conductivity) and thermal performance of the bound metal MEX 3D printed copper heat sinks. The investigation combines experimental analysis, including simulations and heat transfer experiments, to gain insights into the structure-material property relationships and optimize the thermal performance of the printed heat sinks.

Ajjarapu, Kameswara Pavan Kumar [Oak Ridge Nationa↗
NASA NTRS1997

Process for controlling morphology and improving thermal-mechanical performance of high performance interpenetrating and semi-interpenetrating polymer networks

In the process of the present invention, a non-polar, aprotic solvent is removed from an oligomer/polymer solution by freeze-drying in order to produce IPNs and semi-IPNs. By thermally quenching the solution to a solid in a short length of time, the size of the minor constituent-rich regions is greatly reduced as they are excluded along with the major constituent from the regions of crystallizing solvent. The use of this process sequence of controlling phase morphology provides IPNs and semi-IPNs with improved fracture toughness, microcracking resistance, and other physical-mechanical properties as compared to IPNs and semi-IPNs formed when the solvent is evaporated rather than sublimed.

Pater, Ruth H.↗
NASA NTRS2011

Spray-On Foam Insulations for Launch Vehicle Cryogenic Tanks

Spray-on foam insulation (SOFI) has been developed for use on the cryogenic tanks of space launch vehicles beginning in the 1960s with the Apollo program. The use of SOFI was further developed for the Space Shuttle program. The External Tank (ET) of the Space Shuttle, consisting of a forward liquid oxygen tank in line with an aft liquid hydrogen tank, requires thermal insulation over its outer surface to prevent ice formation and avoid in-flight damage to the ceramic tile thermal protection system on the adjacent Orbiter. The insulation also provides system control and stability with throughout the lengthy process of cooldown, loading, and replenishing the tank. There are two main types of SOFI used on the ET: acreage (with the rind) and closeout (machined surface). The thermal performance of the seemingly simple SOFI system is a complex of many variables starting with the large temperature difference of from 200 to 260 K through the typical 25-mm thickness. Environmental factors include air temperature and humidity, wind speed, solar exposure, and aging or weathering history. Additional factors include manufacturing details, launch processing operations, and number of cryogenic thermal cycles. The study of the cryogenic thermal performance of SOFI under large temperature differentials is the subject of this article. The amount of moisture taken into the foam during the cold soak phase, termed Cryogenic Moisture Uptake, must also be considered. The heat leakage rates through these foams were measured under representative conditions using laboratory standard liquid nitrogen boiloff apparatus. Test articles included baseline, aged, and weathered specimens. Testing was performed over the entire pressure range from high vacuum to ambient pressure. Values for apparent thermal conductivity and heat flux were calculated and compared with prior data. As the prior data of record was obtained for small temperature differentials on non-weathered foams, analysis of the different methods is provided. Recent advancements and applications of SOFI systems on future launch vehicles and spacecraft are also addressed.

Fesmire, J. E.↗
NASA NTRS1999

Cryogenic Insulation System for Soft Vacuum

The development of a cryogenic insulation system for operation under soft vacuum is presented in this paper. Conventional insulation materials for cryogenic applications can be divided into three levels of thermal performance, in terms of apparent thermal conductivity [k-value in milliwatt per meter-kelvin (mW/m-K)]. System k-values below 0.1 can be achieved for multilayer insulation operating at a vacuum level below 1 x 10(exp -4) torr. For fiberglass or powder operating below 1 x 10(exp -3) torr, k-values of about 2 are obtained. For foam and other materials at ambient pressure, k-values around 30 are typical. New industry and aerospace applications require a versatile, robust, low-cost thermal insulation with performance in the intermediate range. The target for the new composite insulation system is a k-value below 4.8 mW/m-K (R-30) at a soft vacuum level (from 1 to 10 torr) and boundary temperatures of approximately 77 and 293 kelvin (K). Many combinations of radiation shields, spacers, and composite materials were tested from high vacuum to ambient pressure using cryostat boiloff methods. Significant improvement over conventional systems in the soft vacuum range was demonstrated. The new layered composite insulation system was also shown to provide key benefits for high vacuum applications as well.

Augustynowicz, S. D.↗
NASA NTRSDate not supplied

Validation of Thermodynamic Vent System Performance using Thermal Desktop

Cryogenic fluid management (CFM) for in-space propulsion systems is crucial to enabling future space missions. A means to control the pressure inside a propellant tank is necessary to prevent the venting of liquid propellant in microgravity environments. A thermodynamic vent system (TVS) is one way to regulate the pressure and temperature of the fluid inside a tank. A previous study created a simplified model of a TVS in a two-phase cryogenic heat exchanger. The TVS expands the working fluid across a Joule-Thomson (J-T) device and routes the cooled fluid through the heat exchanger to remove heat from the surrounding fluid. The model was able to predict the TVS heat extraction performance and was validated against experimental data using the same hardware. This study expands the model of the TVS into Thermal Desktop (TD) and recreates the results from both the original model and the experimental data. This new TD model has the potential to be used to predict TVS heat extraction performance in cryogenic propellant tanks for future space missions.

Cryogenic Fluid Management↗
NASA NTRS1989

Integrated Cryogenic Experiment (ICE) microsphere investigation

The main objective is to determine the performance of microsphere insulation in a 0-g environment and compare its performance to reference insulations such as multilayer insulation. The Lockheed Helium Extended-Life Dewar (HELD) is used to provide superfluid-helium cold sink for the experiment. The use of HELD allows the low-g dynamic properties of Passive Orbital Disconnect Struts (PODS) to be characterized and provides a flight demonstration of the PODS system. The thermal performance of microspheres in 1 and 0 g was predicted, a flight experiment was designed to determine microsphere thermal performance, and the interface was also designed between the experimental package and the shuttle through HELD and the Hitchhiker-M carrier. A single test cell was designed and fabricated. The cell was filled with uncoated glass microspheres and tested with a liquid-nitrogen cold sink. The data were found to agree with predictions of microsphere performance in 1 g.

Spradley, I.↗
NASA NTRS2008

Spacesuit Water Membrane Evaporator Development for Lunar Missions

For future lunar extra-vehicular activities (EVA), one method under consideration for rejecting crew and electronics heat involves evaporating water through a hydrophobic, porous Teflon membrane. A Spacesuit Water Membrane Evaporator (SWME) prototype using the Teflon membrane was tested successfully by Ungar and Thomas (2001) with predicted performance matching test data well. The above referenced work laid the foundation for the design of the SWME development unit, which is being considered for service in the Constellation System Spacesuit Element (CSSE) Portable Life Support System (PLSS). Multiple PLSS SWME configurations were considered on the basis of thermal performance, mass, volume, and performance and manufacturing risk. All configurations were a variation of an alternating concentric water and vapor channel configuration or a stack of alternating rectangular water and vapor channels. Supporting thermal performance trades mapped maximum SWME heat rejection as a function of water channel thickness, vapor channel thickness, channel length, number of water channels, porosity of the membrane structural support, and backpressure valve throat area. Preliminary designs of each configuration were developed to determine total mass and volume as well as to understand manufacturing issues. Review of configurations led to the selection of a concentric annulus configuration that meets the requirements of 800 watts (W) of heat rejection. Detailed design of the SWME development unit will be followed by fabrication of a prototype test unit, with thermal testing expected to start in 2008.

Vogel, Matt R.↗
NASA NTRS2000

Thermal Insulation Performance of Textile Structures for Spacesuit Applications at Martian Pressure and Temperature

Protection of astronauts from the extreme temperatures in the space environment has been provided in the past using multi-layer insulation in ultra-high vacuum environments of low earth orbit and the lunar surface. For planetary environments with residual gas atmospheres such as Mars with ambient pressures between 8 to 14 hPa (8 to 14 mbar), new protection techniques are required because of the dominating effect of the ambient gas on heat loss through the insulation. At Mars ambient pressure levels, the heat loss can be excessive at expected suit external temperatures of 172 K with state-of-the-art suit insulation, requiring an active heat source and its accompanying weight and volume penalties. Micro-fibers have been identified as one potential structure to reduce the heat losses, but existing fundamental data on fiber heat transfer at low pressure is lacking for integrated fabric structures. This baseline study presents insulation performance test data at different pressures and fabric loads for selected polyesters and aramids as a function of fiber density, fiber diameter, fabric density, and fabric construction. A set of trend data of thermal conductivity versus ambient pressure is presented for each fiber and fabric construction design to identify the design effects on thermal conductivity at various ambient pressures, and to select a fiber and fabric design for further development as a suit insulation. The trend data also shows the pressure level at which thermal conductivity approaches a minimum, below which no further improvement is possible for a given fiber and fabric design. The pressure levels and resulting thermal conductivities from the trend data can then be compared to the ambient pressure at a planetary surface, Mars for example, to determine if a particular fiber and fabric design has potential as a suit insulation.

Orndoff, Evelyne↗
NASA NTRS1987

Pseudomorphic InGaAs/AlGaAs modulation-doped FET's with reduced low-frequency noise and thermally stable performance

A high-performance MODFET structure grown by MBE with the incorporation of a single quantum well In(0.15)Ga(0.85)As layer for the transport of two-dimensional electron gas has been critically examined for its thermal stability at 80 K and low-frequency noise form 0.01 to 10 to the 8th Hz. Experimental results indicate that the behavior of this device in both these respects is much superior when compared with the same behavior of conventional MODFETs. A maximum low-field carrier mobility of 29,000 sq cm/s at 80 K and an average carrier saturation velocity of 2 x 10 to the 7th cm/s at 300 K in a 1-micron gate device clearly indicate that the quality of the pseudomorphic quantum well (InGaAs) layer is either comparable or better than that of the usual GaAs buffer layer. The deep level spectra, obtained through photo-FET measurements, and the low-frequency noise spectra at different temperatures obtained for the new pseudomorphic and conventional MODFET's have clearly indicated that contributions from various deep levels present in the new structure are significantly reduced.

Liu, Shih-Ming↗