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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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The development and integration of 16 payload bay liner filters into the existing shuttle/payload contamination evaluation (SPACE) computer program is discussed as well as an initial mission profile model. As part of the mission profile model, a thermal conversion program, a temperature cycling routine, a flexible plot routine and a mission simulation of orbital flight test 3 are presented.
Constructed specimens for tranverse tensile testing of unidirectional graphite/epoxy tape is tested more accurately than earlier samples. Specimens are made using unsupported adhesive and commercially-available (e.g., Nomex, or equivalent) honeycomb core. Flexible adhesive and dimensionally stable core eliminate uneven thermal expansion. Tensile strength of tape at various temperatures becomes direct function of applied mechanical stress.
Composite flexible multilayer insulation systems (MLI) were evaluated for thermal performance and compared with the currently used fibrous silica (baseline) insulation system. The systems described are multilayer insulations consisting of alternating layers of metal foil and scrim ceramic cloth or vacuum metallized polymeric films quilted together using ceramic thread. A silicon carbide thread for use in the quilting and the method of making it are also described. These systems are useful in providing lightweight insulation for a variety of uses, particularly on the surface of aerospace vehicles subject to very high temperatures during flight.
Composite flexible multilayer insulation systems (MLI) were evaluated for thermal performance and compared with currently used fibrous silica (baseline) insulation system. The systems described are multilayer insulations consisting of alternating layers of metal foil and scrim ceramic cloth or vacuum metallized polymeric films quilted together using ceramic thread. A silicon carbide thread for use in the quilting and the method of making it are also described. These systems provide lightweight thermal insulation for a variety of uses, particularly on the surface of aerospace vehicles subject to very high temperatures during flight.
Thermal losses are a key factor in the successful application of high temperature superconducting (HTS) power cables. Existing concepts and prototypes rely on the use of multilayer insulation (MLI) systems that are subject to large variations in actual performance. The small space available for the thermal insulation materials makes the application even more difficult because of bending considerations, mechanical loading, and the arrangement between the inner and outer piping. Each of these mechanical variables affects the heat leak rate. These factors of bending and spacing are examined in this study. Furthermore, a maintenance-free insulation system (high vacuum level for 20 years or longer) is a practical requirement. A thermal insulation system simulating a section of a flexible FITS power cable was constructed for test and evaluation on a research cryostat. This paper gives experimental data for the comparison of ideal MLI, MLI on rigid piping, and MLI between flexible piping. A section of insulated flexible piping was tested under cryogenic vacuum conditions including simulated bending and spacers.
Early NASA missions (Gemini, Apollo, Mars Viking) employed new ablative TPS that were tailored for the entry environment. After 40 years, heritage ablative TPS materials using Viking or Pathfinder era materials are at or near their performance limits and will be inadequate for future exploration missions. Significant advances in TPS materials technology are needed in order to enable any subsequent human exploration missions beyond Low Earth Orbit. This poster summarizes some recent progress at NASA in developing families of advanced rigid/conformable and flexible ablators that could potentially be used for thermal protection in planetary entry missions. In particular the effort focuses technologies required to land heavy (approx.40 metric ton) masses on Mars to facilitate future exploration plans.
Efficient and reliable RF power couplers in accelerating cavities require precise impedance matching and mechanical stability to ensure optimal beam energy transfer. In radio-frequency quadrupole (RFQ) accelerators, power is commonly delivered using waveguide iris or coaxial loop couplers. Iris couplers can handle high RF power but lack tunability, while coaxial loop couplers offer tuning flexibility but are limited in power handling and thermal performance. We propose a new RFQ power coupling concept utilizing a single input coaxial center-fed double-loop antenna built into a vane in an RFQ structure . The design integrates back-to-back loops into the RFQ vanes, fed by a TEM coaxial transmission line with standard 50-Ω characteristic impedance. The configuration can allow straightforward and easy ceramic window replacement without retuning, and coupling strength is adjusted with protruding tuning rods. Numerical simulations, performed with both a simplified RFQ model and the Spallation Neutron Source RFQ, demonstrate improved RF performance and reduced dipole mode excitation. The results establish the coaxial double-loop coupler as a practical alternative for high-power RFQ coupling applications.
Advanced nuclear power plants (NPPs) will potentially need to operate in environments where power generation flexibility is more highly valued than the stability or baseload generation capability for conventional demand curves. Thermal energy storage (TES) systems would enable NPPs to respond nimbly to market variability and could also position advanced NPPs to participate differently in restructured markets, thus further enhancing their economic competitiveness. TES systems could also benefit the electric grid by eliminating the need for peaking plants, as well as by improving the economic performance of baseload NPPs. While TES technologies afford a unique opportunity to address many of these challenges, the applicability of these systems is also complicated by the fact that various advanced NPPs are designed differently, each with its own temperature range, size, operating fluids, and operating conditions. Hence, TES systems face significant barriers to investment, as more information on their compatibility and performance metrics is needed to quantify the advantages provided by each, as well as the challenges these technologies might face if coupled with a particular type of advanced NPP. This study explores the possibility of integrating a wide variety of TES technologies with various categories of advanced NPPs, based on their operating characteristics. To help decision makers, users and developers decide which TES technology is best suited to a particular category of advanced NPPs, this research present a Phenomena Identification and Ranking Table (PIRT) analysis of 10 TES systems that could potentially be coupled with advanced NPPs, which themselves are divided into nine categories based on their operating conditions. Then, each advanced NPP category is evaluated for compatibility with the 10 TES systems by assembling and discussing a database of information concerning 10 engineering questions, defined herein in as figures of merit (FOMs), such as: technology readiness level (TRL), temperature compatibility, energy density, size, cycle frequency, ramp time, realignment frequency, geographic needs, environmental impact, and interventions. By assembling a database of information concerning the TES technologies' compatibility with various advanced NPP systems, this study can help developers acquaint themselves with a particular TES technology before choosing to build a new integrated installation.
One of the advantages of using a Radioisotope Power System (RPS) for deep space or planetary surface missions is the readily available waste heat, which can be used to maintain electronic components within a controlled temperature range, to warm propulsion tanks and mobility actuators, and to gasify liquid propellants. Previous missions using Radioisotope Thermoelectric Generators (RTGs) dissipated a very large quantity of waste heat due to the relatively low efficiency of the thermoelectric conversion technology. The next generation RPSs, such as the 110-watt Stirling Radioisotope Generator (SRG110) will have much higher conversion efficiencies than their predecessors and therefore may require alternate approaches to transferring waste heat to the spacecraft. RTGs, with efficiencies of approx. 6 to 7% and 200 C housing surface temperatures, would need to use large and heavy radiator heat exchangers to transfer the waste heat to the internal spacecraft components. At the same time, sensitive spacecraft instruments must be shielded from the thermal radiation by using the heat exchangers or additional shields. The SRG110, with an efficiency around 22% and 50 C nominal housing surface temperature, can use the available waste heat more efficiently by more direct heat transfer methods such as heat pipes, thermal straps, or fluid loops. The lower temperatures allow the SRG110 much more flexibility to the spacecraft designers in configuring the generator without concern of overheating nearby scientific instruments, thereby eliminating the need for thermal shields. This paper will investigate using a high efficiency SRG110 for spacecraft thermal management and outline potential methods in several conceptual missions (Lunar Rover, Mars Rover, and Titan Lander) to illustrate the advantages with regard to ease of assembly, less complex interfaces, and overall mass savings.
Conjugate heat transfer (CHT) analysis and optimization is a powerful method for improving thermal management, as it simultaneously resolves the temperature distribution in both fluid and solid domains. This paper presents a modular, discrete adjoint-based CHT optimization capability integrated within the OpenMDAO/MPhys framework. A unique feature of the proposed framework is its flexibility to extend to multidisciplinary optimization, including aero-structural-thermal applications. The fluid domain is modeled using a finite-volume Computational Fluid Dynamics (CFD) solver, and the solid domain with a conduction heat transfer solver. A mixed Neumann-Dirichlet boundary condition is developed to enable full submersion of the solid geometry within the fluid domain, while ensuring consistent temperature and heat flux coupling at the CHT interface. Gradient-based optimization is performed; the gradients are efficiently computed using the discrete adjoint solvers implemented in DAFoam. To demonstrate the method, this paper considers two cases related to electric aircraft thermal management: a U-bend heat exchanger and an actively cooled battery pack. The U-bend case aims to minimize pressure loss while maximizing heat flux by changing the pipe geometry. The optimized design reduces pressure loss by 52.7% and increases total heat flux by 2.3%. In the battery pack case, a 3-by-3 cell configuration is cooled by ambient airflow, with constant heat generation prescribed in the cells. The battery casing shape serves as the design variable, and the objective function is a weighted sum of pressure loss and pack weight, subject to a maximum temperature constraint. The optimized design achieves a 44.6% reduction in pressure loss and a 1.5% reduction in weight, while satisfying the thermal constraint. To ensure the reliability of the optimized designs, this study validates coarse-mesh, steady-state predictions against fine-mesh unsteady simulations, demonstrating consistency within acceptable errors. This work demonstrates the potential of the developed framework to enable rapid, high-fidelity design of thermal management systems for electric aircraft.
A system for non-venting thermal control for spacesuits was built by integrating two previously developed technologies, namely NASA s Spacesuit Water Membrane Evaporator (SWME), and Creare s flexible version of the Lithium Chloride Absorber Radiator (LCAR). This SEAR system was tested in relevant thermal vacuum conditions. These tests show that a 1 m2 radiator having about three times as much absorption media as in the test article would be required to support a 7 hour spacewalk. The serial flow arrangement of the LCAR of the flexible version proved to be inefficient for venting non-condensable gas (NCG). A different LCAR packaging arrangement was conceived wherein the Portable Life Support System (PLSS) housing would be made with a high-strength carbon fiber composite honeycomb, the cells of which would be filled with the chemical absorption media. This new packaging reduces the mass and volume impact of the SEAR on the Portable Life Support System (PLSS) compared to the flexible design. A 0.2 sq m panel with flight-like honeycomb geometry is being constructed and will be tested in thermal and thermal vacuum conditions. Design analyses forecast improved system performance and improved NCG control. A flight-like regeneration system also is also being built and tested. Design analyses for the structurally integrated prototype as well as the earlier test data show that SEAR is not only practical for spacesuits but also has useful applications in spacecraft thermal control.
A system for non-venting thermal control for spacesuits was built by integrating two previously developed technologies, namely NASA's Spacesuit Water Membrane Evaporator (SWME), and Creare's flexible version of the Lithium Chloride Absorber Radiator (LCAR). This SEAR system was tested in relevant thermal vacuum conditions. These tests show that a 1 sq m radiator having about three times as much absorption media as in the test article would be required to support a 7 hour spacewalk. The serial flow arrangement of the LCAR of the flexible version proved to be inefficient for venting non-condensable gas (NCG). A different LCAR packaging arrangement was conceived wherein the Portable Life Support System (PLSS) housing would be made with a high-strength carbon fiber composite honeycomb, the cells of which would be filled with the chemical absorption media. This new packaging reduce the mass and volume impact of the SEAR on the Portable Life Support System (PLSS) compared to the flexible design. A 0.2 sq m panel with flight-like honeycomb geometry is being constructed and will be tested in thermal and thermal vacuum conditions. Design analyses forecast improved system performance and improved NCG control. A flight-like regeneration system also is also being built and tested. Design analyses for the structurally integrated prototype as well as the earlier test data show that SEAR is not only practical for spacesuits but also has useful applications in spacecraft thermal control.
A flexible aperture cover and latch were developed for the Thermal Ion Detection Experiment (TIDE). The latch utilized a high-output paraffin (HOP) linear motor to supply the force to operate the latch. The initial approach for the cover was to use a heat-treated, coiled strip of 0.05 mm (.002-inch)-thick beryllium-copper as the cover. Development test results showed that one end of the cover developed a trajectory during release that threatened to impact against adjacent instruments. An alternative design utilizing constant force springs and a flexible, metallized Kapton cover was then tested. Results from development tests, microgravity tests, and lessons learned during the development of the aperture cover are discussed.
Composites have excellent properties for strength, thermal stability, and weight. However, they are traditionally highly rigid, and when used in deployable structures require hinges bonded to the composite material, which increases complexity and opportunities for failure. Recent research in composites has found by adding an elastomeric soft matrix, often silicone instead of an epoxy, the composite becomes flexible. This work explores the deployment repeatability of silicone matrix composite hinges which join rigid composite beams. The hinges were found to have sub-millimeter deployment repeatability. Also, an interesting creep effect was discovered, that a hinges deployment error would decrease with time.
Composites have excellent properties for strength, thermal stability, and weight. However, they are traditionally highly rigid, and when used in deployable structures require hinges bonded to the composite material, which increases complexity and opportunities for failure. Recent research in composites has found by adding an elastomeric soft matrix, often silicone instead of an epoxy, the composite becomes flexible. This work explores the deployment repeatability of silicone matrix composite hinges which join rigid composite beams. The hinges were found to have sub-millimeter linear deployment repeatability, and sub-degree angular deployment repeatability. Also, an interesting relaxation effect was discovered, as a hinges deployment error would decrease with time.
Highly crosslinked polymers, commonly utilized in spacecraft component fabrication, especially for heatshields, have historically encountered challenges due to their inherent brittleness. To overcome this issue, researchers have explored the incorporation of additives into the polymer backbone to enhance flexibility and durability. This study aims to improve the flexibility and durability of highly crosslinked polymers by introducing long-chain aliphatic silicon-based additives with varying molecular weights into the polymer backbone. By increasing the flexibility of these brittle polymers, they can be effectively employed in constructing intricate curvatures for heatshields, eliminating the need for gap fillers. In this study, we investigated six different additives, comparing them to a highly crosslinked high-temperature polymer used as a baseline. Various characterization techniques, including thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), dilatometry, dynamic mechanical analysis (DMA), nuclear magnetic resonance (NMR), and Fourier transform infrared spectroscopy (FTIR), were employed to assess the properties of the materials. The FTIR and NMR results indicated the successful incorporation of the silicon-based additives into the polymer backbone. Furthermore, thermal characterization results demonstrated that certain additives exhibited superior flexibility and lower densities compared to the baseline polymer.
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The analytical methods, thermal model, and user's instructions for the Skylab Extravehicular Mobility Unit (SEMU) routine are presented. This digital computer program was developed for detailed thermal performance predictions of the SEMU on the NASA-JSC Univac 1108 computer system. It accounts for conductive, convective, and radiant heat transfer as well as fluid flow and special component characterization. The program provides thermal performance predictions for a 967 node thermal model in one thirty-sixth (1/36) of mission time when operated at a calculating interval of three minutes (mission time). The program has the operational flexibility to: (1) accept card or magnetic tape data input for the thermal model describing the SEMU structure, fluid systems, crewman and component performance, (2) accept card and/or magnetic tape input of internally generated heat and heat influx from the space environment, and (3) output tabular or plotted histories of temperature, flow rates, and other parameters describing system operating modes.