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NASA NTRS1994

Development of Lightweight Radiators for Lunar Based Power Systems

This report discusses application of a new lightweight carbon-carbon (C-C) space radiator technology developed under the NASA Civil-Space Technology Initiative (CSTI) High Capacity Power Program to a 20 kWe lunar based power system. This system comprises a nuclear (SP-100 derivative) heat source, a Closed Brayton Cycle (CBC) power conversion unit with heat rejection by means of a plane radiator. The new radiator concept is based on a C-C composite heat pipe with integrally woven fins and a thin walled metallic liner for containment of the working fluid. Using measured areal specific mass values (1.5 kg/m2) for flat plate radiators, comparative CBC power system mass and performance calculations show significant advantages if conventional heat pipes for space radiators are replaced by the new C-C heat pipe technology.

Juhasz, Albert J.↗

NASA NTRS1995

Analysis of shadowing effects on MIR photovoltaic and solar dynamic power systems

The NASA Lewis Research Center is currently working with RSC-Energia, the Russian Space Agency, and Allied Signal in developing a flight demonstration solar dynamic power system. This type of power system is dependent upon solar flux that is reflected and concentrated into a thermal storage system to provide the thermal energy input to a closed-cycle Brayton heat engine. The solar dynamic unit will be flown on the Russian Mir space station in anticipation of use on the International Space Station Alpha. By the time the power system is launched, the Mir will be a spatially complex configuration which will have, in addition to the three-gimbaled solar dynamic unit, eleven solar array wings that are either fixed or track the Sun along one axis and a variety or repositionable habitation and experiment modules. The proximity of arrays to modules creates a situation which makes it highly probable that there will be varying solar flux due to shadowing on the solar dynamic unit and some of the arrays throughout the orbit. Shadowing causes fluctuations in the power output from the arrays and the solar dynamic power system, thus reducing the energy capabilities of the spacecraft. An assessment of the capabilities of the power system under these conditions is an important part in influencing the design and operations of the spacecraft and predicting its energy performance. This paper describes the results obtained from using the Orbiting Spacecraft Shadowing Analysis Station program that was integrated into the Station Power Analysis for Capability Evaluation (SPACE) electrical power system computer program. OSSA allows one to consider the numerous complex factors for analyzing the shadowing effects on the electrical power system including the variety of spacecraft hardware geometric configurations, yearly and daily orbital variations in the vehicle attitude and orbital maneuvers (for communications coverage, payload pointing requirements and rendezvous/docking with other vehicles). The geometric models of the MIR with a solar dynamic power unit that were used in performing shadowing analyses are described. Also presented in this paper are results for individual orbits for several flight attitude cases which include assessments of the shadowing impacts upon the solar dynamic unit and the solar arrays. These cases depict typical MIR flight attitudes likely to have shadowing impact. Because of the time varying nature of the Mir orientation with respect to the Sun and the lack of knowledge of the precise timing of the attitude changes, strategies must be devised to assess and depict the shadowing impacts on power generation throughout the year. To address this, the best, nominal and worst impacts of shadowing considering a wide possible range of parameter changes for typical mission operation period are shown.

Fincannon, James↗

NASA NTRS1990

Improved boundary layer heat transfer calculations near a stagnation point

A thermal design of a solar receiver has been developed for the solutions of problems involving phase-change thermal energy storage and natural convection loss. Two dimensional axisymmetrical solidification and melting of materials contained between two concentric cylinders of finite length has been studied for thermal energy storage analysis. For calculation of free convection loss inside receiver cavity, two dimensional axisymmetrical, laminar, transient free convection including radiation effects has been studied using integral/finite difference method. Finite difference equations are derived for the above analysis subject to constant or variable material properties, initial conditions, and boundary conditions. The validity of the analyses has been substantiated by comparing results of the present general method with available analytic solutions or numerical results reported in the literature. Both explicit and implicit schemes are tested in phase change analysis with different number of nodes ranging from 4 to 18. The above numerical methods have been applied to the existing solar receiver analyzing computer code as additional subroutines. The results were computed for one of the proposed Brayton cycle solar receiver models running under the actual environmental conditions. Effect of thermal energy storage on the thermal behavior of the receiver has been estimated. Due to the thermal energy storage, about 65% reduction on working gas outlet temperature fluctuation has been obtained; however, maximum temperature of thermal energy storage containment has been increased about 18%. Also, effect of natural convection inside a receiver cavity on the receiver heat transfer has been analyzed. The finding indicated that thermal stratification occurs during the sun time resulting in higher receiver temperatures at the outlet section of the gas tube, and lower temperatures at the inlet section of the gas tube when compared with the results with no natural convection. Due to heat supply from the air during the shade time, minimum temperature has been increased, while maximum temperature has been reduced due to convection loss to air. Consequently, cyclic temperature fluctuation has been reduced 29% for working gas and 16% for thermal energy storage containment. On the other hand, despite the presence of the natural convection the time-averaged temperatures for receiver components were found to be similar for two cases with/without natural convection (maximum difference was 1.8%).

Ahn, Kyung Hwan↗

NASA NTRS1995

Human Exploration and Settlement of the Moon Using LUNOX-Augmented NTR Propulsion

An innovative trimodal nuclear thermal rocket (NTR) concept is described which combines conventional liquid hydrogen (LH2)-cooled NTR, Brayton cycle power generation and supersonic combustion ramjet (scramjet) technologies. Known as the liquid oxygen (LOX) augmented NTR (LANTR), this concept utilizes the large divergent section of the NTR nozzle as an 'afterburner' into which LOX is injected and supersonically combusted with nuclear preheated hydrogen emerging from the LANTR's choked sonic throat--'scramjet propulsion in reverse.' By varying the oxygen-to-hydrogen mixture ratio (MR), the LANTR can operate over a wide range of thrust and specific impulse (Isp) values while the reactor core power level remains relatively constant. As the MR varies from zero to seven, the thrust-to-weight ratio for a 15 thousand pound force (klbf) NTR increases by approximately 440%--from 3 to 13--while the Isp decreases by only approximately 45%--from 940 to 515 seconds. This thrust augmentation feature of the LANTR means that 'big engine' performance can be obtained using smaller more affordable, easier to test NTR engines. 'Reoxidizing' the bipropellant LANTR system in low lunar orbit (LLO) with high density 'lunar-derived' LOX (LUNOX) enables a reusable, reduced size and mass lunar transfer vehicle (LTV) which can be deployed and resupplied using two 66 t-class Shuttle-derived launch vehicles. The reusable LANTR can also transport 200 to 300% more payload on each piloted round trip mission than an expendable 'all LH2' NTR system. As initial outposts grow to eventual lunar settlements and LUNOX production capacity increases, the LANTR concept can also enable a rapid 'commuter' shuttle capable of 36 to 24 hour 'one way' trips to the Moon and back with reasonable size vehicles and initial mass in low Earth orbit (IMLEO) requirements.

Borowski, Stanley K.↗

NASA NTRS1996

Design of the Heat Receiver for the U.S./Russia Solar Dynamic Power Joint Flight Demonstration

A joint U.S./Russia program is being conducted to develop, fabricate, launch, and operate a solar dynamic demonstration system on Space Station Mir. The goal of the program is to demonstrate and confirm that solar dynamic power systems are viable for future space applications such as the International Space Station Alpha The major components of the system include a heat receiver, a closed Brayton cycle power conversion unit, a power conditioning and control unit, a concentrator, a radiator, a thermal control system, and a Space Shuttle Carrier. This paper discusses the design of the heat receiver component. The receiver comprises a cylindrical cavity, the walls of which are lined with a series of tubes running the length of the cavity. The engine working fluid, a mixture of xenon and helium, is heated by the concentrated sunlight incident on these tubes. The receiver incorporates integral thermal storage, using a eutectic mixture of lithium fluoride and calcium difluoride as the thermal storage solid-to-liquid phase change materiaL This thermal storage is required to enable power production during eclipse. The phase change material is contained in a series of individual containment canisters.

Strumpf, Hal J.↗

NASA NTRS1997

Design and Analysis of the Aperture Shield Assembly for a Space Solar Receiver

A joint U.S./Russia program has been conducted to design, develop, fabricate, launch, and operate the world's first space solar dynamic power system on the Russian Space Station Mir. The goal of the program was to demonstrate and confirm that solar dynamic power systems are viable for future space applications such as the International Space Station (ISS). The major components of the system include a solar receiver, a closed Brayton cycle power conversion unit, a power conditioning and control unit, a solar concentrator, a radiator, a thermal control system, and a Space Shuttle carrier. Unfortunately, the mission was demanifested from the ISS Phase 1 Space Shuttle Program in 1996. However, NASA Lewis is proposing to use the fabricated flight hardware as part of an all-American flight demonstration on the ISS in 2002. The present paper concerns the design and analysis of the solar receiver aperture shield assembly. The aperture shield assembly comprises the front face of the cylindrical receiver and is located at the focal plane of the solar concentrator. The aperture shield assembly is a critical component that protects the solar receiver structure from highly concentrated solar fluxes during concentrator off-pointing events. A full-size aperture shield assembly was fabricated. This unit was essentially identical to the flight configuration, with the exception of materials substitution. In addition, a thermal shock test aperture shield assembly was fabricated. This test article utilized the flight materials and was used for high-flux testing in the solar simulator test rig at NASA Lewis. This testing is described in a companion paper.

Strumpf, Hal J.↗

NASA NTRS1999

Flight Test Results for the HST Orbital Systems Test (HOST) Capillary Pump Loop Cooling System

The Near Infrared Camera and Multi Object Spectrometer (NICMOS) was installed in the Hubble Space Telescope (MST) in February 1997. Shortly thereafter, the instrument experienced a thermal short in its solid nitrogen dewar system which will significantly shorten the instrument's useful life. A reverse Brayton cycle mechanical refrigerator will be installed during the Third Servicing Mission (SM3) to provide cooling for the instrument, and thereby extend its operations. A Capillary Pump Loop (CPL) and radiator system was designed, built and tested to remove up to 500 watts of heat from the mechanical cryocooler and its associated electronics. The HST Orbital Systems Test (HOST) platform was flown on the Space Shuttle Discovery (STS-95) as a flight demonstration of the cryocooler system, CPL control electronics, and the CPL/Radiator. This paper will present the flight test results and thermal performance of the CPL system in detail.

Buchko, M.↗

NASA NTRS2002

Cryo Cooler Induced Micro-Vibration Disturbances to the Hubble Space Telescope

This paper presents an overview of the Hubble Space Telescope (HST) Near Infrared Camera and Multi-Object Spectrometer (NICMOS) Cryo Cooler (MCC) system, a description of the micro-vibration characterization testing performed, and a discussion of the simulated performance. The NCC is a reverse Brayton cycle system that employs micro turbo-machinery to provide cooling to the NICMOS instrument. Extensive testing was conducted to quantify the expected on-orbit disturbances caused by the micro turbo-machinery and provide input to a flexible-body dynamic simulation to demonstrate compliance with the HST 7 milli-arcsecond root mean square jitter requirement.

Jedrich, Nick↗

NASA NTRS2002

A Mechanical Cryogenic Cooler for the Hubble Space Telescope

This paper presents a description of the Hubble Space Telescope (HST) Near-Infrared Camera and Multi-Object Spectrometer (NICMOS) Cryo Cooler (NCC), the cutting edge technology involved, its evolution, performance, and future space applications. The NCC is the primary hardware component of the NICMOS Cooling System comprised of the NCC, an Electronics Support Module, a Capillary Pumped Loop/Radiator, and associated interface harnessing. The system will be installed during extravehicular activities on HST during Servicing Mission 3B scheduled for launch in February 2002. The NCC will be used to revive the NICMOS instrument, which experienced a reduced operational lifetime due to an internal thermal short in its dewar structure, and restore HST scientific infrared capability to operational status. The NCC is a state-of-the-art reverse Turbo-Brayton cycle cooler employing gas bearing micro turbo machinery, driven by advanced power conversion electronics, operating at speeds up to 7300 revolutions per second (rps) to remove heat from the NICMOS instrument.

Jedrich, Nicholas↗

NASA NTRS2005

Two Dimensional Viscoelastic Stress Analysis of a Prototypical JIMO Turbine Wheel

The designers of the Jupiter Icy Moons Orbiter (JIMO) are investigating the potential of nuclear powered-electric propulsion technology to provide deep space propulsion. In one design scenario a closed-Brayton-cycle power converter is used to convert thermal energy from a nuclear reactor to electrical power for the spacecraft utilizing an inert gas as the working fluid to run a turboalternator as described in L.S. Mason, "A Power Conversion for the Jupiter Icy Moons Orbiter," Journal of Propulsion and Power, vol. 20, no. 5, pp. 902-910. A key component in the turboalternator is the radial flow turbine wheel which may be fabricated from a cast superalloy. This turbine wheel is envisioned to run continuously over the life of the mission, which is anticipated to be about ten years. This scenario places unusual material requirements on the turbine wheel. Unlike the case of terrestrial turbine engines, fatigue, associated with start-up and shut-down of the engine, foreign-object damage, and corrosion issues are insignificant and thus creep issues become dominate. The purpose of this paper is to present estimates for creep growth of a prototypical JIMO turbine wheel over a ten year life. Since an actual design and bill of materials does not exist, the results presented in this paper are based on preliminary concepts which are likely to evolve over time. For this reason, as well as computational efficiency, a simplified 2-D, in lieu of a 3-D, viscoelastic, finite element model of a prototypical turbine wheel will be utilized employing material properties for the cast superalloy MAR-M247. The creep data employed in this analysis are based on preliminary data being generated at NASA Glenn Research Center.

Gayda, John↗

NASA NTRS2004

Consideration of Alternate Working Fluid Properties in Gas Lubricated Foil Journal Bearings

The Oil-Free Turbomachinery Program at the NASA Glenn Research center is committed to, revolutionary improvements in performance, efficiency and reliability of turbomachinery propulsion systems. One of the key breakthroughs by which this goal is being achieved is the maturation of air lubricated foil bearing technology. Through experimental testing, foil bearings have demonstrated a variety of exceptional qualities that show them to have an important role in the future of rotordynamic lubrication. Most of the work done with foil bearings thus far has considered ambient air at atmospheric pressure as the working fluid or lubricating fluid in the bearing. However, special applications of oil-free technology require the use of air at non- standard ambient conditions or completely different working fluids altogether. The NASA Jupiter Icy Moon Orbiter program presents power generation needs far beyond that of any previous space exploration effort. The proposed spacecraft will require significant power generation to provide the propulsion necessary to reach the moons of Jupiter and navigate between them. Once there, extensive scientific research will be conducted that will also present significant power requirements. Such extreme needs require exploring a new method for power generation in space. A proposed solution involves a Brayton cycle nuclear fission reactor. The nature of this application requires reliable performance of all reactor components for many years of operation under demanding conditions. This includes the bearings which will be operating with an alternative working fluid that is a combination of Helium and Xenon gases commonly known as HeXe. This fluid has transport and thermal properties that vary significantly from that of air and the effect of these property differences on bearing performance must be considered. One of the most promising applications of oil-free technology is in aircraft turbine engines. Eliminating the oil supply systems from aircraft engines will lead to significant weight and maintenance reduction. In such applications, the lubricating fluid will be high altitude air. This air will be at much lower pressure than that at sea level. Again this property change will result in a change in bearing performance, and analysis is required to quantify this effect. The study of these alternate working fluid properties will be conducted in two ways: analytically and experimentally. Analytical research will include the use of a mathematical code that can predict film thickness profiles for various ambient conditions. Estimations of load capacity can be made based upon the film thickness trends. These values will then be compared to those obtained from classical rigid bearing analysis. Experimental Research will include testing a foil bearing at a variety of ambient air pressures. The analytical and experimental data will be compared to draw conclusions on bearing performance under alternate working fluid properties.

Smith, Matthew J.↗

NASA NTRS1999

Power System Optimization Codes Modified

A major modification of and addition to existing Closed Brayton Cycle (CBC) space power system optimization codes was completed. These modifications relate to the global minimum mass search driver programs containing three nested iteration loops comprising iterations on cycle temperature ratio, and three separate pressure ratio iteration loops--one loop for maximizing thermodynamic efficiency, one for minimizing radiator area, and a final loop for minimizing overall power system mass. Using the method of steepest ascent, the code sweeps through the pressure ratio space repeatedly, each time with smaller iteration step sizes, so that the three optimum pressure ratios can be obtained to any desired accuracy for each of the objective functions referred to above (i.e., maximum thermodynamic efficiency, minimum radiator area, and minimum system mass). Two separate options for the power system heat source are available: 1. A nuclear fission reactor can be used. It is provided with a radiation shield 1. (composed of a lithium hydride (LiH) neutron shield and tungsten (W) gamma shield). Suboptions can be used to select the type of reactor (i.e., fast spectrum liquid metal cooled or epithermal high-temperature gas reactor (HTGR)). 2. A solar heat source can be used. This option includes a parabolic concentrator and heat receiver for raising the temperature of the recirculating working fluid. A useful feature of the code modifications is that key cycle parameters are displayed, including the overall system specific mass in kilograms per kilowatt and the system specific power in watts per kilogram, as the results for each temperature ratio are computed. As the minimum mass temperature ratio is encountered, a message is printed out. Several levels of detailed information on cycle state points, subsystem mass results, and radiator temperature profiles are stored for this temperature ratio condition and can be displayed or printed by users.

Juhasz, Albert J.↗

NASA NTRS2004

High Temperature Heat Rejection System for Large Heat Loads; Architecture and Trade Study Results

To investigate space nuclear reactor technologies, NASA has awarded several contracts under Project Prometheus, the Nuclear Systems Program. The effort described in this paper was performed under one of those contracts (the Brayton NRA) . Like all power conversion systems, nuclear power conversion systems operate at efficiencies less than 100% resulting in the need to reject waste heat to space. Several different HRSs (Heat Rejection Systems) potential designs have been identified for rejecting NEP (Nuclear Electric Power) waste heat and several of them for a CBC (Closed Brayton Cycle) power conversion system are described herein and the results of their initial analyses presented. The analyses presented were performed as part of an initial trade study to recommend a promising HRS for advancement of its TRL.

Nilitkin, Michael N.↗

NASA NTRS1999

Turbofan engine with a low pressure turbine driven supercharger in a bypass duct operated by a fuel rich combustor and an afterburner

A multiple bypass turbofan engine includes a core Brayton Cycle gas generator with a fuel rich burning combustor and is provided with a variable supercharged bypass duct around the gas generator with a supercharging means in the supercharged bypass duct powered by a turbine not mechanically connected to the gas generator. The engine further includes a low pressure turbine driven forward fan upstream and forward of an aft fan and drivingly connected to a low pressure turbine by a low pressure shaft, the low pressure turbine being aft of and in serial flow communication with the core gas generator. A fan bypass duct is disposed radially outward of the core engine assembly and has first and second inlets disposed between the forward and aft fans. An inlet duct having an annular duct wall is disposed radially inward of the bypass duct and connects the second inlet to the bypass duct. A supercharger means for compressing air is drivingly connected to the low pressure turbine and is disposed in the inlet duct. A secondary combustor or augmentor is disposed in an exhaust duct downstream of and in fluid flow communication with the bypass duct and the gas generator.

Bartos, James W.↗

NASA NTRS2008

Gas Foil Bearing Misalignment and Unbalance Effects

The effects of misalignment and unbalance on gas foil bearings are presented. The future of U.S. space exploration includes plans to conduct science missions aboard space vehicles, return humans to the Moon, and place humans on Mars. All of these endeavors are of long duration, and require high amounts of electrical power for propulsion, life support, mission operations, etc. One potential source of electrical power of sufficient magnitude and duration is a nuclear-fission-based system. The system architecture would consist of a nuclear reactor heat source with the resulting thermal energy converted to electrical energy through a dynamic power conversion and heat rejection system. Various types of power conversion systems can be utilized, but the Closed Brayton Cycle (CBC) turboalternator is one of the leading candidates. In the CBC, an inert gas heated by the reactor drives a turboalternator, rejects excess heat to space through a heat exchanger, and returns to the reactor in a closed loop configuration. The use of the CBC for space power and propulsion is described in more detail in the literature (Mason, 2003). In the CBC system just described, the process fluid is a high pressure inert gas such as argon, krypton, or a helium-xenon mixture. Due to the closed loop nature of the system and the associated potential for damage to components in the system, contamination of the working fluid is intolerable. Since a potential source of contamination is the lubricant used in conventional turbomachinery bearings, Gas Foil Bearings (GFB) have high potential for the rotor support system. GFBs are compliant, hydrodynamic journal and thrust bearings that use a gas, such as the CBC working fluid, as their lubricant. Thus, GFBs eliminate the possibility of contamination due to lubricant leaks into the closed loop system. Gas foil bearings are currently used in many commercial applications, both terrestrial and aerospace. Aircraft Air Cycle Machines (ACMs) and ground-based microturbines have demonstrated histories of successful long-term operation using GFBs (Heshmat et al., 2000). Small aircraft propulsion engines, helicopter gas turbines, and high-speed electric motors are potential future applications.

Howard, Samuel A.↗

NASA NTRS2009

Windage Power Loss in Gas Foil Bearings and the Rotor-Stator Clearance of High Speed Generators Operating in High Pressure Environments

Closed Brayton Cycle (CBC) and Closed Supercritical Cycle (CSC) engines are prime candidates to convert heat from a reactor into electric power for robotic space exploration and habitation. These engine concepts incorporate a permanent magnet starter/generator mounted on the engine shaft along with the requisite turbomachinery. Successful completion of the long-duration missions currently anticipated for these engines will require designs that adequately address all losses within the machine. The preliminary thermal management concept for these engine types is to use the cycle working fluid to provide the required cooling. In addition to providing cooling, the working fluid will also serve as the bearing lubricant. Additional requirements, due to the unique application of these microturbines, are zero contamination of the working fluid and entirely maintenance-free operation for many years. Losses in the gas foil bearings and within the rotor-stator gap of the generator become increasingly important as both rotational speed and mean operating pressure are increased. This paper presents the results of an experimental study, which obtained direct torque measurements on gas foil bearings and generator rotor-stator gaps. Test conditions for these measurements included rotational speeds up to 42,000 revolutions per minute, pressures up to 45 atmospheres, and test gases of nitrogen, helium, and carbon dioxide. These conditions provided a maximum test Taylor number of nearly one million. The results show an exponential rise in power loss as mean operating density is increased for both the gas foil bearing and generator windage. These typical "secondary" losses can become larger than the total system output power if conventional design paradigms are followed. A nondimensional analysis is presented to extend the experimental results into the CSC range for the generator windage.

Bruckner, Robert J.↗

NASA NTRS2010

Numerical Comparison of NASA's Dual Brayton Power Generation System Performance Using CO2 or N2 as the Working Fluid

A Dual Brayton Power Conversion System (DBPCS) has been tested at the NASA Glenn Research Center using Nitrogen (N2) as the working fluid. This system uses two closed Brayton cycle systems that share a common heat source and working fluid but are otherwise independent. This system has been modeled using the Numerical Propulsion System Simulation (NPSS) environment. This paper presents the results of a numerical study that investigated system performance changes resulting when the working fluid is changed from gaseous (N2) to gaseous carbon dioxide (CO2).

Ownens, Albert K.↗

NASA NTRS2013

Oil-Free Turbomachinery Technologies for Long-Life, Maintenance-Free Power Generation Applications

Turbines have long been used to convert thermal energy to shaft work for power generation. Conventional turbines rely upon oil-lubricated rotor supports (bearings, seals, etc.) to achieve low wear, high efficiency and reliability. Emerging Oil-Free technologies such as gas foil bearings and magnetic bearings offer a path for reduced weight and complexity and truly maintenance free systems. Oil-Free gas turbines, using gaseous and liquid fuels are commercially available in power outputs to at least 250kWe and are gaining acceptance for remote power generation where maintenance is a challenge. Closed Brayton Cycle (CBC) turbines are an approach to power generation that is well suited for long life space missions. In these systems, a recirculating gas is heated by nuclear, solar or other heat energy source then fed into a high-speed turbine that drives an electrical generator. For closed cycle systems such as these, the working fluid also passes through the bearing compartments thus serving as a lubricant and bearing coolant. Compliant surface foil gas bearings are well suited for the rotor support systems of these advanced turbines. Foil bearings develop a thin hydrodynamic gas film that separates the rotating shaft from the bearing preventing wear. During start-up and shut down when speeds are low, rubbing occurs. Solid lubricants are used to reduce starting torque and minimize wear. Other emerging technologies such as magnetic bearings can also contribute to robust and reliable Oil-Free turbomachinery. In this presentation, Oil-Free technologies for advanced rotor support systems will be reviewed as will the integration and development processes recommended for implementation.

turbomachinery↗