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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 451 records · Page 25

GIOTTO's antenna de-spin mechanism: Ots lubrication and thermal vacuum performance

Except in the near Earth phase of GIOTTO's mission to Comet Halley, the HGA (high gain antenna) on board GIOTTO was the only designed means of up/down communications. The spacecraft spin stabilization required that the HGA be despun at the same rotational rate of nominally 15 rpm in order to keep the HGA pointing accurately to a Earth. A dual servomotor despin mechanism was designed and built by SEP of France for this purpose. The expected thermal environment suggested that dry lubrication was preferable to wet for the ball bearings but there existed no relevant data on the torque noise spectrum of candidate solid lubricants. Therefore ad hoc torque noise tests were run with two solid lubricants: ion plated lead film plus lead bronze cage (retainer) and a PTFE composite cage only. The lead lubrication showed the better spectrum up to the mission lifetime point so it was selected for continued test over some 20 times the Halley mission life, with periodic torque spectrum monitoring. The spectrum remained well within the pointing error budget over the 100 million revolutions covered.

Todd, M. J.↗

Multi-cell, triple pane, vacuum insulated glazing

A novel Triple Pane Vacuum Insulated Glazing (TPVIG) architecture consisting of three panes of glass separated by two offset grids is described. The grids are made of frit-coated fibers fused with the glass panes in a vacuum to create many independent hermetic cells. Unlike traditional VIGs, which are separated by support pillars, these cells significantly increase the redundancy in sealing, and the additional bonds formed by the grid lines reduce the stresses on the edge bonds thereby increasing VIG reliability. A numerical thermal analysis was conducted to determine the thermal performance of the VIG and suggested U-values below 0.5 W/m 2 -K (greater than R=11.4 hr-ft 2 -°F/Btu) can be obtained. A prototype of the VIG unit consisting of three glass panes (5.7 mm, 1.1 mm and 5.7 mm thick with low-e coating on two surfaces) was fabricated and tested for thermal performance using the hot box method. The experimental center of glass U-value for the VIG was found to be 0.42 W/m 2 K (R=13.2 hr-ft 2 -°F/Btu). Furthermore, this U-value is about four times lower than a typical Argon filled double pane window.

14 SOLAR ENERGY↗

Method of Generating Transient Equivalent Sink and Test Target Temperatures for Swift BAT

The NASA Swift mission has a 600-km altitude and a 22 degrees maximum inclination. The sun angle varies from 45 degrees to 180 degrees in normal operation. As a result, environmental heat fluxes absorbed by the Burst Alert Telescope (BAT) radiator and loop heat pipe (LHP) compensation chambers (CCs) vary transiently. Therefore the equivalent sink temperatures for the radiator and CCs varies transiently. In thermal performance verification testing in vacuum, the radiator and CCs radiated heat to sink targets. This paper presents an analytical technique for generating orbit transient equivalent sink temperatures and a technique for generating transient sink target temperatures for the radiator and LHP CCs. Using these techniques, transient target temperatures for the radiator and LHP CCs were generated for three thermal environmental cases: worst hot case, worst cold case, and cooldown and warmup between worst hot case in sunlight and worst cold case in the eclipse, and three different heat transport values: 128 W, 255 W, and 382 W. The 128 W case assumed that the two LHPs transport 255 W equally to the radiator. The 255 W case assumed that one LHP fails so that the remaining LHP transports all the waste heat from the detector array to the radiator. The 382 W case assumed that one LHP fails so that the remaining LHP transports all the waste heat from the detector array to the radiator, and has a 50% design margin. All these transient target temperatures were successfully implemented in the engineering test unit (ETU) LHP and flight LHP thermal performance verification tests in vacuum.

Choi, Michael K.↗

Development & Experimental Validation of a Generalized Resistance-Capacitance Model for Numerical Simulation of Phase-Change Material Embedded Heat Exchangers

Latent heat thermal energy storage (LHTES) using phase change material (PCM) has attracted increased attention as a viable solution for overcoming the mismatch between energy supply and demand for renewable energy-based systems. PCM-embedded heat exchangers (PCM-HX) have the potential to significantly improve thermal performance due to high storage capacity and low temperature variation during the phase change process. Most models for simulating LHTES heat transfer use Computational Fluid Dynamics (CFD) simulations, which have high computational costs resulting from considering the complex and time-dependent physics relevant to PCM-HXs. In this paper, a Generalized Resistance Capacitance-based Model (GRCM) was developed to predict the thermal performance of arbitrary PCM-HXs in a computationally efficient manner without compromising modeling accuracy. The GRCM is exercised for three case studies: (i) verification for a single-slabbed finned PCM-HX, (ii) verification and validation for a copper foam/paraffin composite PCM-HX, and (iii) validation for a straight tube annular finned PCM-HX. The copper foam PCM-HX uses an electric heater at the top of HX, while the other two configurations utilize water as heat transfer fluid. For the single-slabbed finned PCM-HX melting case, the mean deviation in average PCM temperature predicted by the GRCM compared to the CFD model was between 0.56 – 0.73 K, with maximum temperature deviation of 2.68 K. For the HTF outlet temperature, the validation results showed that GRCM prediction matches very well with experimental data, with mean temperature deviation of 0.24 K during melting case, while for solidification case was 0.34 K. These results showcase the GRCM’s capability for accurately reproducing the thermal characteristics of PCM-HXs with considerably lower computational effort.

42 ENGINEERING↗

Study of a heat rejection system for the Nuclear Electric Propulsion (NEP) spacecraft

Two different heat pipe radiator elements, one intended for use with the power conversion subsystem of the NASA funded nuclear electric propulsion (NEP) spacecraft, and one intended for use with the DOE funded space power advanced reactor (SPAR) system were tested and evaluated. The NEP stainless steel/sodium heat pipe was 4.42 meters long and had a 1 cm diameter. Thermal performance testing at 920 K showed a non-limited power level of 3560 watts, well in excess of the design power of 2600 watts. This test verified the applicability of screen arteries for use in long radiator heat pipes. The SPAR titanium/potassium heat pipe was 5.5 meters long and had a semicircular crossection with a 4 cm diameter. Thermal performance testing at 775 K showed a maximum power level of 1.86 kW, somewhat short of the desired 2.6 kW beginning of life design requirement. The reduced performance was shown to be the result of the inability of the evaporator wall wick (shot blasted evaporator wall) to handle the required liquid flow.

Ernest, D. M.↗

Characterization of Hollow Cathode Performance and Thermal Behavior

Hollow cathodes are one of the main life-limiting components in ion engines and Hall thrusters. Although state-of-the-art hollow cathodes have demonstrated up to 30,352 hours of operation in ground tests with careful handling, future missions are likely to require longer life, more margin and greater resistance to reactive contaminant gases. Three alternate hollow cathode technologies that exploit different emitter materials or geometries to address some of the limitations of state-of-the-art cathodes are being investigated. Performance measurements of impregnated tungsten-iridium dispenser cathodes at discharge currents of 4 to 15 A demonstrated that they have the same operating range and ion production efficiency as conventional tungsten dispenser cathodes. Temperature measurements indicated that tungsten-iridium cathodes also operate at the same emitter temperatures. They did not exhibit the expected reduction in work function at the current densities tested. Hollow cathodes with lanthanum hexaboride emitters operated over a wide current range, but suffered from lower ion production efficiency at currents below about 12.4 A because of higher insert heating requirements. Differences in operating voltages and ion production rates are explained with a simple model of the effect of cathode parameters on discharge behavior.

ion engines↗

Ultra-clear Aerogels for Insulated Glass in Refrigeration Doors (CRADA Final Report)

Display refrigerators commonly employ glass doors to provide product visibility; however, these doors exhibit significantly poorer thermal insulation than solid doors, resulting in increased heat transfer and higher energy consumption. To address this limitation, this project investigated the use of silica aerogel as a transparent insulating medium for refrigerator glass doors, with the objective of enhancing thermal performance without compromising visual clarity. In Phase I of the project, we assessed the feasibility of silica aerogel insulation through laboratory and full-scale studies, including material characterization, durability testing, and heat transfer measurements, along with the development and performance evaluation of prototype glass doors under realistic operating conditions. In Phase II, the project focused on scaling the technology toward practical deployment. This included scaling up the manufacturing process to achieve a surface area roughly 20 times larger for commercial applications, developing full-scale prototypes that integrated silica aerogel into standard display refrigerator doors, and conducting field evaluations to assess thermal performance, energy savings, and operational durability under real-world conditions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Are Deep Energy Retrofits in Commercial Buildings Including Window Upgrades?

U.S. Commercial buildings account for about 20% of total U.S. energy consumption. Because the thermal performance of windows significantly affects building energy efficiency and HVAC system performance, best practice guidance often includes window and envelope improvements in conjunction with HVAC upgrades to optimize energy use and improve occupant comfort. It is an open question, however, regarding how often these best practices are implemented in the field. This paper aims to address that gap by conducting a literature review and a series of interviews with commercial building auditing and management professionals to explore the factors that drive window retrofits in commercial buildings. The paper explores a range of case studies from deep energy retrofits across the globe, comparing projects with and without window retrofits. The primary goals of this review are to: (1) provide data from real-world case studies illustrating the role of windows in deep energy renovations and HVAC upgrades, (2) conduct retrofit cost analyses for windows and high-performance HVAC systems and (3) offer insights into how window upgrade decisions are made and when they are implemented as part of deep energy retrofits. Most of the retrofit studies focused exclusively on high performance HVAC upgrades without considering how window upgrades might further enhance the overall energy efficiency of commercial buildings. Interviews with building industry experts shed light on the key factors influencing deep energy retrofit decisions and what factors tip the scales in favor of including window measures with more comprehensive retrofit projects.

Cort, Katherine↗

Technoeconomic Benefits of Film-Forming Amine Products Applied to Steam Surface Condensers

In a conventional Rankine cycle, the majority of power plants employ surface condensers that use pumped cooling water to reject heat from the cycle. In such cases, heat rejection occurs in a shell and tube heat exchanger by film-wise condensation of low-pressure steam on stainless steel, titanium, brass, or copper-nickel tubing. To improve the thermal performance of steam surface condensers, a replenishable film-forming substance (FFS) can be ap-plied to the condenser tubing to promote efficient dropwise condensation. Conventionally, film-forming amine prod-uct (FFAP) coatings protect boiler surfaces from oxidative corrosion, which substantially reduces the operation and maintenance costs. To quantify the technical and economic benefits of FFAP coatings applied to condenser tubing due to the promotion of dropwise condensation, a thermal resistance network model was established. Using a rep-resentative steam surface condenser, the improvements in thermal performance (overall heat transfer coefficient) and process parameters (net plant efficiency, cooling water flowrate, and turbine backpressure) were determined due to the enhancement in the condensation heat transfer coefficient. Experimentally measured condensation heat transfer coefficients for common condenser materials were compared with the modeling results and were found to be within attainable bounds. Lastly, the trend in total heat exchanger cost reduction is generalized to understand the trade-off between reduced surface area for heat rejection and increase in coating application costs for a re-plenishable coating system.

20 FOSSIL-FUELED POWER PLANTS↗

SR19021 Tritium Aging of Regenerated LANA.75 (Final Project Report)

The Savannah River Tritium Enterprise (SRTE) has used the metal hydride LaNi 4.25 Al 0.75 (LANA.75) in the Tritium Facilities for over two decades. LANA.75 beds store significant quantities of tritium but have a limited service life due to the radiolytic decay of tritium to He-3 within the metal matrix. It has been shown that heating tritium-aged LANA.75 under vacuum can reverse tritium aging effects, eliminating the heel of trapped hydrogen, and restoring the reversible capacity. Additional investigation is needed to ensure there are no unexpected changes to the hydride before this restoration technique is employed in full scale beds in the Tritium Facilities. This project was to be comprised of three distinct scopes: obtain tritium aging data on the sample regenerated in 2018, regenerate a tritium-aged sample at 600 °C, and perform thermal stability testing on a non-tritiated sample. Isotherms were collected on the previously regenerated sample after approximately two years of tritium aging. Isotherms were collected at 80, 100, and 120 °C. As expected, there was a decrease in the plateau pressure, an increase in plateau slope, and a portion of the “heel” of tritium trapped in the metal had been reestablished. Unexpectedly, it appeared that the plateau had shortened at the higher tritium to metal ratios as well. This is typically seen in older samples. The second scope, to regenerate a second tritium-aged LANA.75 sample, was not completed. A Task Technical and Quality Assurance Plan was written and approved, a high temperature test cell was fabricated, several pre-job briefs were held, and the hydride sample was passivated with air. Despite these successes, the hydride sample was not recovered from the legacy test cell. The third scope was to perform thermal stability testing on a “cold” LANA.75 sample. A non-tritiated sample of LANA.75 was held at 750 °C under vacuum for 200 hours to simulate exposure to multiple regeneration evolutions. Hydride isotherm performance, chemical composition, crystallinity, particle size, and morphology are compared between the pre- and post-regeneration samples. No significant changes were observed in composition, crystallinity, or particle size. Comparison of before and after isotherms showed that performance improved rather than deteriorated during the evolution. Scanning Electron Microscopy (SEM) analysis showed small growths on the particle surface after exposure to regeneration conditions. Additional testing will be required to determine the cause of these growths.

07 ISOTOPE AND RADIATION SOURCES↗

Evaluation of the Energy, Hygrothermal, and Thermal Capacity Performance of Cross-Laminated Timber

Cross-laminated timber (CLT) construction is gaining momentum in the US because it offers multiple advantages over traditional construction methods. Benefits that have received the most attention focus on constructability, the environment, and protection (e.g., blast resistance), although CLT construction is likely to offer other benefits, as well. Still, these have not been studied at length because such evaluations are costly, requiring long-term assessments in an actual building and specialized technical knowledge. Among the possible benefits, CLT construction likely provides a higher-performing building envelope. Using CLT panels to enclose a building means fewer joints in the opaque envelope than what is required in traditional stick-framed construction. Fewer joints mean fewer locations where the air- and water-resistive barrier (WRB) could be compromised; thus, a CLT building enclosure may require less maintenance and have a longer lifespan than a traditionally built structure because of fewer air and water leaks. In addition, CLT’s thermal mass moderates indoor temperatures, allowing the heating, ventilation, and air conditioning (HVAC) system to operate more efficiently during peak hours, reducing operational energy consumption throughout the lifetime of the CLT building (Salonvaara et al., 2022). Furthermore, more stable indoor temperatures can increase occupant comfort. The CLT’s thermal mass can also reduce energy costs by adjusting to utility time-of-use pricing without affecting occupant comfort. The ability of CLT buildings to bridge periods without HVAC operation prepares them for future grid interaction and provides a certain level of resilience against power outages. Researchers have attempted to quantify these benefits; however, their work is based on simplified simulations with numerous assumptions. To correctly understand the benefits, an actual building must be monitored. Therefore, information needs to be gathered on indoor and outdoor temperatures, HVAC energy consumption, thermostat setpoints, temperatures, and thermal transport in CLT components to comprehend how these parameters are affected by the CLT’s thermal mass. These data are needed to reduce the number of assumptions and calibrate simulation models to optimize HVAC controls to minimize overall energy consumption, reduce energy use and higher fees during peak demand, and maintain occupant comfort. Additionally, the calibrated simulation model allows the optimization exercise to be repeated in various US climates. Potential benefits can be tailored to buildings in various locations, and decisions can be made on where CLT construction could be most advantageous. Furthermore, monitoring and simulation results are needed to evaluate the durability of the CLT structures in different climates. This project’s researchers gathered information to help understand and quantify the benefits of CLT buildings concerning operational energy, moderated indoor temperatures, and comfort; the dynamic operation to provide grid services; and resilience in times of power outage. Through the corroboration of simulation models with real-world measurements, this study paves the way for extrapolating findings to other climatic zones and building typologies, thereby broadening the understanding of CLT’s multifaceted benefits and reinforcing its position as a material of choice in sustainable construction.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Cryogenic Testing of Different Seam Concepts for Multilayer Insulation Systems

Recent testing in a cylindrical, comparative cryostat at the Cryogenics Test Laboratory has focused on various seam concepts for multilayer insulation systems. Three main types of seams were investigated: straight overlap, fold-over, and roll wrapped. Each blanket was comprised of 40 layer pairs of reflector and spacer materials. The total thickness was approximately 12.5-mm, giving an average layer density of 32 layers per centimeter. The blankets were tested at high vacuum, soft vacuum, and no vacuum using liquid nitrogen to maintain the cold boundary temperature at 77 K. Test results show that all three seam concepts are all close in thermal performance; however the fold-over method provides the lowest heat flux. For the first series of tests, seams were located 120 degrees around the circumference of the cryostat from the previous seam. This technique appears to have lessened the degradation of the blanket due to the seams. In a follow-on test, a 20 layer blanket was tested in a roll wrapped configuration and then cut down the side of the cylinder, taped together, and re-tested. This test result shows the thermal performance impact of having the seams all in one location versus having the seams clocked around the vessel. This experimental investigation indicates that the method of joining the seams in multilayer insulation systems is not as critical as the quality of the installation process.

Johnson, Wesley L.↗

NASA’s Quiet Electric ENgines (QUEEN): Summary of the QUEEN V2 Test

A liquid-cooled electric ducted fan system was designed, built, and tested at the NASA Glenn Research Center. Main components of the system include a Commercial-Off- the-Shelf (COTS) fan and motor, and a custom-designed heat exchanger integrated into the fan duct. Fan speed, thrust, and cooling system thermal performance was measured in this static ground test of the propulsor. This propulsor prototype is one of NASA’s Quiet Electric ENgines (QUEENs) and is designated the ‘QUEEN V2.’ The Quiet Electric Engines are being developed for the 25% scale model of the Subsonic Aft Engine (SUSAN) Flight Research Vehicle and are intended to explore the potential of distributed electric propulsion for regional single-aisle aircraft. This test demonstrated the functionality of the QUEEN V2, quantified the thrust produced by the electrofan, and characterized the electrical and thermal performance of the system. Lessons learned will be used to guide development of future QUEEN prototypes.

Aerodynamics↗

NASA’s Quiet Electric ENgines (QUEEN): Summary of the QUEEN V2 Test

A liquid-cooled electric ducted fan system was designed, built, and tested at the NASA Glenn Research Center. Main components of the system include a Commercial-Off- the-Shelf (COTS) fan and motor, and a custom-designed heat exchanger integrated into the fan duct. Fan speed, thrust, and cooling system thermal performance was measured in this static ground test of the propulsor. This propulsor prototype is one of NASA’s Quiet Electric ENgines (QUEENs) and is designated the ‘QUEEN V2.’ The Quiet Electric Engines are being developed for the 25% scale model of the Subsonic Aft Engine (SUSAN) Flight Research Vehicle and are intended to explore the potential of distributed electric propulsion for regional single-aisle aircraft. This test demonstrated the functionality of the QUEEN V2, quantified the thrust produced by the electrofan, and characterized the electrical and thermal performance of the system. Lessons learned will be used to guide development of future QUEEN prototypes.

Aeronautics-General↗

Guarded Hot Cylinder Apparatus for Characterization of Thermal Insulation Systems and Materials at Liquid Hydrogen Temperatures

As interest in liquid hydrogen (LH2) continues to grow within the energy and mobility sectors, so does the demand for testing capabilities at deep cryogenics temperatures. However, cost-, complexity-, and safety-related challenges associated with handling LH2 effectively limit the landscape of possible options. As an alternative, LH2 temperatures can be accessed via a helium-based cryogenic refrigerator, or “cryocooler”. Recently, NASA and its partners CB&I and Shell began the development of a cryocooler-based calorimeter to characterize the thermal performance of insulations and other materials down to 20 K. Deemed the Guarded Hot Cylinder (GHC), the apparatus utilizes a small vacuum chamber in conjunction with a GM cryocooler and trim heater to control the cold boundary temperature. A sealed, cylindrical copper cup bolts to the cryocooler and houses the material specimen, with an internal, cylindrical test heater assembly to maintain the warm boundary. The steady-state heat load, traveling radially through the specimen, is measured via the electrical input power to the test heater and then used to evaluate the material’s absolute thermal performance. Initial checkout and validation of the GHC using a common bulk-fill insulation material showed close agreement with published data from standardized LN2 boiloff calorimetry testing. The instrument is now considered a lab standard, with the goal of incorporating it into the ASTM C1774 standard in the future, and it is in continuous use, examining insulation materials for next-generation LH2 applications.

Swanger, Adam (ORCID:000000021487592X)↗

Bioinspired Dry‐Steam Superinsulation Straw Foam

Abstract Cellulosic materials offer sustainable advantages for building energy conservation. However, their development has been hindered by reduced thermal performance, often caused by structural collapse during the transition from solution to solid. Inspired by natural goose down, a bio‐based, lightweight insulation foam derived from agricultural waste straw is presented. Through in situ synthesis, bio‐silica fibers with branched structures capable of supporting hollow silica microspheres are fabricated. After steam‐mediated processing, the resulting foam exhibit low density (95 mg cm − 3 ), high porosity (95.5%), low thermal conductivity (0.03 ± 0.003 W mK −1 ), and a cyclic compressive strength of 90 kPa at 50% strain. Owing to the synergistic microstructure formed by branched bio‐fibers and hollow silica spheres, the bio‐silica foam exhibit outstanding thermal insulation performance relative to other bio‐based foams prepared by ambient drying. A passivated insulation panel is further developed by incorporating this material as the core component, achieving a thermal conductivity of 0.0275 W mk −1 and flexural strength of 6.85 MPa. The panel demonstrated durability with stable thermal performance throughout a 60‐day outdoor test. Moreover, the bio‐silica foam shows a carbon footprint of 7.50 kgCO₂ kg −1 at 70.2 wt.% silica, highlighting its promise as a sustainable insulation solution for green buildings.

Chemistry↗

Experimental testing of particle attrition in CSP systems at high temperature

An alternate and sustainable form of energy is CSP systems, which capture and store the sun’s energy in the form of heat. Increasing the operational temperature of CSP systems will increase the efficiency of electricity production while operating at temperatures exceeding 700 degrees Celsius also creates novel operational problems. One approach for high-temperature CSP systems is to utilize solid particles as the primary heat transfer medium. As particles flow through this system, the movement of particles creates erosion in the forms of impact, abrasion, and attrition erosion. In the real world, while all three forms of erosion will occur simultaneously, it is imperative to understand the individual effect of each erosion over the lifetime of the powerplant. Besides material erosion and long-term durability concerns, thermal cycling of the particles could also introduce changes in particle thermal performance due to alterations in particle morphology. Current research on the issue of erosion has been limited to industrial applications and does not necessarily coincide with the operating conditions in CSP systems. We focus on attrition erosion resulting from particle-to-wall and particle-to-particle interactions. Research has shown that besides material hardness affecting how fast particles break down, attrition erosion increased as the size of the particles increased due to a higher chance of collision between the particles. Particle attrition is relevant to the CSP community as it may result in material loss, change the system's thermal performance, and generation of fines which could pose an environmental hazard. In this work, we focus on developing a test set up that can isolate and measure particle attrition when subjected to conditions relevant to Gen3 CSP systems.

14 SOLAR ENERGY↗