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At least 523 records · Page 29

Analysis of cure in composites processing

Finite element analysis is a general numerical tool for solving the field equations of engineering practice, and this paper demonstrates its use in modeling the nonisothermal cure of pultruded composite material. A very simple grid is used in this case to model a narrow strip of material, and this grid is then solved using a time-stepping transient algorithm to simulate the passage of the strip along the pultruder die. As time proceeds, heat is conducted into the strip from the heated boundaries at the die walls, and cure proceeds at a rate dependent on the local temperature. The computer model can be used to minimize the time needed for sufficient cure, and helps avoid such processing errors as undercure or thermal degradation.

Aylward, L.↗

A Modular Conjugate Heat Transfer Optimization Framework for Thermal Management of Electric Aircraft

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.

heat transfer↗

Environmental Loss Characterization of an Advanced Stirling Convertor (ASC-E2) Insulation Package Using a Mock Heater Head

The U.S. Department of Energy (DOE) and Lockheed Martin Space Systems Company (LMSSC) have been developing the Advanced Stirling Radioisotope Generator (ASRG) for use as a power system for space science missions. This generator would use two highefficiency Advanced Stirling Convertors (ASCs), developed by Sunpower Inc. and NASA Glenn Research Center (GRC). As part of ground testing of these ASCs, different operating conditions are used to simulate expected mission conditions. These conditions require achieving a specified electrical power output for a given net heat input. While electrical power output can be precisely quantified, thermal power input to the Stirling cycle cannot be directly measured. In an effort to improve net heat input predictions, the Mock Heater Head was developed with the same relative thermal paths as a convertor using a conducting rod to represent the Stirling cycle and tested to provide a direct comparison to numerical and empirical models used to predict convertor net heat input. The Mock Heater Head also served as the pathfinder for a higher fidelity version of validation test hardware, known as the Thermal Standard. This paper describes how the Mock Heater Head was tested and utilized to validate a process for the Thermal Standard.

Schifer, Nicholas A.↗

Boundary-Layer Transition on Hollow Cylinders in Supersonic Free Flight as Affected by Mach Number and a Screwthread Type of Surface Roughness

The effects of Mach number and surface-roughness variation on boundary-layer transition were studied using fin-stabilized hollow-tube models in free flight. The tests were conducted over the Mach number range from 2.8 to 7 at a nominally constant unit Reynolds number of 3 million per inch, and with heat transfer to the model surface. A screwthread type of distributed two-dimensional roughness was used. Nominal thread heights varied from 100 microinches to 2100 microinches. Transition Reynolds number was found to increase with increasing Mach number at a rate depending simultaneously on Mach number and roughness height. The laminar boundary layer was found to tolerate increasing amounts of roughness as Mach number increased. For a given Mach number an optimum roughness height was found which gave a maximum laminar run greater than was obtained with a smooth surface.

James, Carlton S.↗

Numerical Prediction of Heat Transfer Coefficients during Xenon Tank Fill in Microgravity

NASA’s Gateway will serve as an orbital outpost to enable sustained human lunar exploration and facilitate access to destinations beyond the Moon. To maintain sustainable deep space missions, on-orbit propellant transfer and refueling must be realized. One of Gateway’s critical components, the Power and Propulsion Element (PPE), will use solar electric propulsion to perform attitude control maneuvers and orbit transfers. Xenon will be used as the propellant for the PPE and stored in a composite overwrapped pressure vessel (COPV). During the propellant refueling process, xenon will compress causing the fluid and tank walls to warm. There is concern that the bond between the tank liner and composite may degrade at elevated temperatures, along with the possibility of the tank exceeding design pressure. While on-orbit testing is being proposed, numerical models are being used to predict the thermal response and reduce risk during a refueling operation in microgravity where natural convection is diminished. Accurate numerical models may be used to inform decisions for follow-on testing, or design and operation of refueling architectures. Challenges of modeling xenon tank fill in microgravity include non-ideal gas behavior, operating near the fluid’s critical point, and lack of experimental flight data. This study presents a computational fluid dynamics (CFD) model with conjugate heat transfer that is used to predict averaged heat transfer coefficients during tank filling. At the anticipated injection flow rates, the CFD results showed that forced convection dominates in microgravity. Initial results from a multi-node Thermal Desktop model that assumed a purely conducting fluid (Nu=1) over-predicted the CFD fluid temperature and pressure, while a similar model allowing for natural convection under-predicted. The heat transfer coefficients predicted by CFD were implemented into the multi-node model, and the COPV thermal response from the two computational approaches were compared with good agreement.

Heat Transfer↗

Hall Thruster Thermal Modeling and Test Data Correlation

The life of Hall Effect thrusters are primarily limited by plasma erosion and thermal related failures. NASA Glenn Research Center (GRC) in cooperation with the Jet Propulsion Laboratory (JPL) have recently completed development of a Hall thruster with specific emphasis to mitigate these limitations. Extending the operational life of Hall thursters makes them more suitable for some of NASA's longer duration interplanetary missions. This paper documents the thermal model development, refinement and correlation of results with thruster test data. Correlation was achieved by minimizing uncertainties in model input and recognizing the relevant parameters for effective model tuning. Throughout the thruster design phase the model was used to evaluate design options and systematically reduce component temperatures. Hall thrusters are inherently complex assemblies of high temperature components relying on internal conduction and external radiation for heat dispersion and rejection. System solutions are necessary in most cases to fully assess the benefits and/or consequences of any potential design change. Thermal model correlation is critical since thruster operational parameters can push some components/materials beyond their temperature limits. This thruster incorporates a state-of-the-art magnetic shielding system to reduce plasma erosion and to a lesser extend power/heat deposition. Additionally a comprehensive thermal design strategy was employed to reduce temperatures of critical thruster components (primarily the magnet coils and the discharge channel). Long term wear testing is currently underway to assess the effectiveness of these systems and consequently thruster longevity.

Hall thruster↗

Numerical simulations of loops heated to solar flare temperatures. III - Asymmetrical heating

A numerical model is defined for asymmetric full solar flare loop heating and comparisons are made with observational data. The Dynamic Flux Tube Model is used to describe the heating process in terms of one-dimensional, two fluid conservation equations of mass, energy and momentum. An adaptive grid allows for the downward movement of the transition region caused by an advancing conduction front. A loop 20,000 km long is considered, along with a flare heating system and the hydrodynamic evolution of the loop. The model was applied to generating line profiles and spatial X-ray and UV line distributions, which were compared with SMM, P78-1 and Hintori data for Fe, Ca and Mg spectra. Little agreement was obtained, and it is suggested that flares be treated as multi-loop phenomena. Finally, it is concluded that chromospheric evaporation is not an effective mechanism for generating the soft X-ray bursts associated with flares.

Cheng, C.-C.↗

A Warm Garage for a Lunar Rover

Approach: One approach to heating a rover during the lunar night is the so-called thermal wadis concept [1]. This involves heating the regolith with solar concentrators and placing the rover on the heated surface for the night. Since the regolith is heated by a relatively weak heat flux, a high thermal conductivity is required for heating a sufficiently large mass of regolith. However, lunar regolith has a low thermal conductivity. Therefore, the concept involves increasing the conductivity by sintering the regolith, which requires a significant energy input and complex procedures. Here we propose an alternative approach where the low thermal conductivity of regolith is an advantage. Specifically, we propose to use a highly exothermic combustible mixture for heat generation. The mixture pellets are placed in the surface layer of regolith and ignited. The combustion forms condensed products and releases heat, which then slowly spreads to the surrounding regolith. Heat can also be transferred, for example, by heat pipes, into radiant heating surfaces installed on the ground. A greenhouse that transmits sunlight during the day and decreases the radiative heat losses during the night can also be installed. Selection of the Heat-generating Mixture: The reactive mixture should have a high specific energy and generate only condensed products since gases could disturb the regolith layer, carry enthalpy out of the system, and lead to an explosion. There are mixtures, (sometimes called pyrolants) that possess very high specific energies. One example is magnesium-Teflon-Viton mixtures used in flares. However, they produce gases and may cause explosions. Other mixtures that include magnesium cannot be used either because of the high vapor pressure of Mg at temperatures well below the combustion temperature. Recently, mixtures that involve lithium peroxide (Li2O2) have been proposedfor using in space power systems [2]. However, they produce lithium oxide (Li2O), which boils at 2800 K at 1 atm and hence at a lower temperature in vacuum. Fortunately, there exist many mixtures that release a lot of heat and form only condensed products during the combustion. Many such mixtures have been used for self-propagating high-temperature synthesis (SHS) of various materials [3, 4]. For the application discussed here, t itanium/boron (1:2 mole ratio) mixture appears to be particularly promising. The specific energy is 4.0 MJ/kg (1.1 kWh/kg), the adiabatic flame temperature is about 3200 K, and the reaction forms solid titanium diboride (TiB2, melting point: 3500 K). The mixture can be ignited easily with a heated tungsten wire, and it has been used widely as a booster to ignite the main mixture in the SHS process.Estimates: Assuming that specific heat of regolith is 500 J/(kg∙K) [5] and all generated heat is transferred to regolith, 12.5 kg of the Ti/B mixture would increase the temperature of 1000 kg of regolith by 100 K. To evaluate the rate of heat transfer in the regolith, a spherical model was analyzed where the heat released by a 12.5 kg Ti/B core propagates by thermal conduction through a 1000 kg regolith shell with no heat loss from its outer surface. At a bulk density of 1500 kg/m3 [5], the radius of the shell was 54 cm, while the radius of the core was about 11 cm. The calculations were conducted using Thermal Desktop SINDA/FLUINT (Cullimore and Ring Technologies) software at two constant values of bulk thermal conductivityk of the regolith: 0.001 and 0.01 W/(m∙K). The results show that after 14.5 days the core lost 31% of the released heat at the lower k and 77% at the higher k. At a distance of 20 cm from the core surface, the temperature of the regolith increased by only 1 K at the lower k and by 132 K at the higher k. In reality, the regolith near the heat source will be melted, so its thermal conductivity will increase significantly. Nevertheless, the conducted estimates indicate that combustion-based heat generators, placed directly in the regolith, could provide heat during a rather long period such as the lunar night.Conclusion: Heat generators based on gasless combustion of highly energetic reactive mixtures could be installed directly in the surface layer of lunar regolith. Because of the low thermal conductivity of the regolith, such generators would keep thermal energy for days and gradually supply heat to a rover/lander.Acknowledgment: The material presented in this work is based upon the work supported by National Aeronautics and Space Administration (NASA) under Grant #80NSSC20K0293.References: [1] Balasubramaniam R. et al. (2011) J. Thermophys. Heat Trans., 25,130−139. [2] Blair R.G. and Vasu S.S. (2022) Conf. Advanced Power Systems for Deep Space Exploration. [3] Varma A. et al. (1998) Adv. Chem. Eng., 24,79−226. [4] Levashov E.A. et al. (2017) Int. Mater. Rev., 62,203−239. [5] Wood-Robinson R. et al. (2019) J. Geophys. Res. Planets, 124, 1989−2011.

lunar↗

The effects of Reynolds number, rotor incidence angle and surface roughness on the heat transfer distribution in a large-scale turbine rotor passage

A combined experimental and computational program was conducted to examine the heat transfer distribution in a turbine rotor passage geometrically similar to the Space Shuttle Main Engine (SSME) High Pressure Fuel Turbopump (HPFTP). Heat transfer was measured and computed for both the full span suction and pressure surfaces of the rotor airfoil as well as for the hub endwall surface. The objective of the program was to provide a benchmark-quality database for the assessment of rotor heat transfer computational techniques. The experimental portion of the study was conducted in a large scale, ambient temperature, rotating turbine model. The computational portion consisted of the application of a well-posed parabolized Navier-Stokes analysis of the calculation of the three-dimensional viscous flow through ducts simulating a gas turbine package. The results of this assessment indicate that the procedure has the potential to predict the aerodynamics and the heat transfer in a gas turbine passage and can be used to develop detailed three dimensional turbulence models for the prediction of skin friction and heat transfer in complex three dimensional flow passages.

Blair, M. F.↗

Frequency-Domain Analysis of Diffusion-Cooled Hot-Electron Bolometer Mixers

A new theoretical model is introduced to describe heterodyne mixer conversion efficiency and noise (from thermal fluctuation effects) in diffusion-cooled superconducting hot-electron bolometers. The model takes into account the non-uniform internal electron temperature distribution generated by Wiedemann-Franz heat conduction, and accepts for input an arbitrary (analytical or experimental) superconducting resistance-versus- temperature curve. A non-linear large-signal solution is solved iteratively to calculate the temperature distribution, and a linear frequency-domain small-signal formulation is used to calculate conversion efficiency and noise. In the small-signal solution the device is discretized into segments, and matrix algebra is used to relate the heating modulation in the segments to temperature and resistance modulations. Matrix expressions are derived that allow single-sideband mixer conversion efficiency and coupled noise power to be directly calculated. The model accounts for self-heating and electrothermal feedback from the surrounding bias circuit.

Skalare, A.↗

Extinction of the Stagnation Point Diffusion Flame: Effect of Conductive Heat Loss into Solid Interior

The flammability boundary of a solid is U-shaped with the ordinate as ambient oxygen percentage (or total pressure) and the abscissa represents flow velocity, gravity level, stretch rate, etc. The left side of the flammability boundary is the quenching branch, and the right side is the blow-off branch. Quenching is due to a weak flame whose heat release from combustion cannot overcome the excessive heat losses from, for example, radiation. Blow-off is due to a short gas residence time that is smaller than the chemical reaction time (traditionally referred to as the small Damköhler number effect). For thick solids, the heat conduction into the solid interior has a long transient after ignition before the solid temperature reaches the steady state. During this slow transient, there is excessive (i.e. more than that at the steady state) gas phase heat conduction into the solid interior. From the viewpoint of the quasi-static gaseous flame, this is an additional heat loss that will affect the gas flame's flammability. In this work, a previously developed one-dimensional axisymmetric stagnation-point diffusion flame model is extended to account for the excessive heat loss into the solid beyond the steady burning state. A non-dimensional excessive conductive heat loss parameter Ψ is defined in the paper to account for the transient solid effect. For each Ψ, the gas phase is considered reaching a quasi-steady state. Extensive numerical computations have been performed to determine the extinction boundary and the characteristics of near-limit flames. The U-shaped flammability boundary is now a series of boundaries with Ψ as a parameter. Flame structures under the same environment condition but with different Ψ are compared. For a given oxygen ambient, the extinction boundary Ψ vs stretch rate is an inverted U-shape. The boundary consists of a blowoff branch and a radiative quenching branch. Extensive computed data including flame and pyrolysis temperatures, burning rate, flame standoff distance, species concentration, and reaction rate are presented along the extinction boundaries. Heat balance analysis is performed for both the gas phase and the gas-solid interface. Along the extinction boundary, the relative importance of conduction, convection, radiation, and chemical reaction are analyzed in detail.

Stagnation point diffusion flame↗

Safe Affordable Fission Engine (SAFE 30) Module Conductivity Test Thermal Model Correlation

Two SAFE 30 modules were tested to determinate the thermal conductivity efficiency of the tri-cusps filled between the heat pipe and the heater cores. The modules consisted of four one-inch diameter tubes with heaters joined to an empty 1 inch diam. tube. The test was conducted on a vacuum chamber with 4 configurations: tri-cusps filled with and without radiation shielding and non-filled tri-cusps with and without radiation shielding. The tri-cusps material helps the bonding of the heat pipe to the four electric heater cores, filling the gap between the pipes. The baseline configuration is a brazed joint between the pipe. The test consisted of controlling the power applied to the heaters until a set surface temperature is reach. The temperatures varied between a max. of 800 C to 500 C. Test data, input energy and chamber surface temperature from each individual test, was used as boundary conditions for the model. Nodes located on the same location as the test thermocouples were plotted again test data to determinate the accuracy of the analysis. The unknown n variables on the analysis are the radiation emissivity of the pipe and chamber and the radiation view factor between the module and the chamber. A correlation was determined using a parametric analysis varying the surface emissivity and view factor until a good match was reach.

Roman, Jose↗

Polymer Matrix Composites Fabrication and Testing

This project involves two separate processes for fabricating carbon fiber composite parts using Hexcel’s RTM6 resin system and Kaneka’s IR-6070 toughened resin system to impregnate carbon fiber tow and weave. These two resins were chosen to model microcracking in parts using RTM6 compared to parts using IR-6070. Plies of the composites were made by painting resin onto 8 harness satin weave or impregnating IM7 12k tow in a prepregging machine. Plies were consolidated using an out-of-autoclave oven or a heat press. Fabrication of the composite parts were conducted with the end goal of sending the composites to be tested and modeled for microcracking. The data will be used for computer modeling in the future.

Miller, Sandi↗

The effect of entrance radius and film injection on wall heating in scramjet nozzles

An experimental study has been performed with a scramjet combustor and nozzle model to determine the effect of nozzle radii on relaminarization, and the effectiveness of film injection in reducing wall heat flux. The nozzle model was installed downstream of a swept-ramp scramjet combustor model, operated at Mach 2.7 with vitiated air, simulating Mach 6-7 flight enthalpies. Results from tests conducted with three nozzle radii, varying in curvature from a sharp Prandtl-Meyer expansion to a radius of two scramjet combustor exit heights, showed little or no effect on the downstream wall heat flux, which is not in agreement with both subsonic and supersonic relaminarization correlations in the available literature. In contrast, film injection upstream of all three radii produced reductions of 70 percent in the entire nozzle model heating rate, for the nominal film-to-free stream pressure matched condition. Results from film injection, with and without pressure gradient, but without wall curvature, show that the gradients appear to stabilize the film, with the resulting reductions in wall heat transfer rates apparent far downstream of the point of injection.

Baker, N. R.↗

Frost formation on an airfoil: A mathematical model 1

A computer model to predict the frost formation process on a flat plate was developed for application to most environmental conditions under which frost occurs. The model was analytically based on a generalized frost thermal conductivity expression, on frost density and thickness rate equations, and on modified heat and mass transfer coefficients designed to fit the available experimental data. The broad experimental ranges reflected by the extremes in ambient humidities, wall temperatures, and convective flow properties in the various publications which were examined served to severely test the flexibility of the model. An efficient numerical integration scheme was developed to solve for the frost surface temperature, density, and thickness under the changing environmental conditions. The comparison of results with experimental data was very encouraging.

Dietenberger, M.↗

A model of the planetary boundary layer over a snow surface

A model of the planetary boundary layer over a snow surface has been developed. It contains the vertical heat exchange processes due to radiation, conduction, and atmospheric turbulence. Parametrization of the boundary layer is based on similarity functions developed by Hoffert and Sud (1976), which involve a dimensionless variable, dependent on boundary-layer height and a localized Monin-Obukhov length. The model also contains the atmospheric surface layer and the snowpack itself, where snowmelt and snow evaporation are calculated. The results indicate a strong dependence of surface temperatures, especially at night, on the bursts of turbulence which result from the frictional damping of surface-layer winds during periods of high stability, as described by Businger (1973). The model also shows the cooling and drying effect of the snow on the atmosphere, which may be the mechanism for air mass transformation in sub-Arctic regions.

Halberstam, I.↗

Experimental Aerothermodynamics In Support Of The Columbia Accident Investigation

The technical foundation for the most probable damage scenario reported in the Columbia Accident Investigation Board's final report was largely derived from synergistic aerodynamic/aerothermodynamic wind tunnel measurements and inviscid predictions made at NASA Langley Research Center and later corroborated with engineering analysis, high fidelity numerical viscous simulations, and foam impact testing near the close of the investigation. This report provides an overview of the hypersonic aerothermodynamic wind tunnel program conducted at NASA Langley and illustrates how the ground-based heating measurements provided early insight that guided the direction and utilization of agency resources in support of the investigation. Global surface heat transfer mappings, surface streamline patterns, and shock shapes were measured on 0.0075 scale models of the Orbiter configuration with and without postulated damage to the thermal protection system. Test parametrics include angle of attack from 38 to 42 degs, sideslip angles of 38 to 42 degs, sideslip angles of plus or minus 1 deg, Reynolds numbers based upon model length from 0.05 x 10(exp 6) to 6.5 x 10(exp 6), and normal shock density ratios of 5 (Mach 6 Air) and 12 (Mach 6 CF4). The primary objective of the testing was to provide surface heating characteristics on scaled Orbiter models with outer mold line perturbations to simulate various forms of localized surface damage to the thermal protection system. Initial experimental testing conducted within two weeks of the accident simulated a broad spectrum of thermal protection system damage to the Orbiter windward surface and was used to refute several hypothesized forms of thermal protection system damage, which included gouges in the windward thermal protection system tiles, breaches through the wing new the main landing gear door, and protuberances along the wing leading edge that produced asymmetric boundary layer transition. As the forensic phase of the investigation developed and the condition of recovered debris was examined, increasing emphasis was placed on identifying wing leading edge damage (partially and fully missing reinforced carbon-carbon panels, and eventually holes in the wing leading edge with venting to the wing upper surface) that produced off-nominal heating trends consistent with extracted Orbiter flight recorder temperature data.

Horvath, Thomas J.↗

Energy Transport in the Thermosphere During the Solar Storms of April 2002

The dramatic solar storm events of April 2002 deposited a large amount of energy into the Earth's upper atmosphere, substantially altering the thermal structure, the chemical composition, the dynamics, and the radiative environment. We examine the flow of energy within the thermosphere during this storm period from the perspective of infrared radiation transport and heat conduction. Observations from the SABER instrument on the TIMED satellite are coupled with computations based on the ASPEN thermospheric general circulation model to assess the energy flow. The dominant radiative response is associated with dramatically enhanced infrared emission from nitric oxide at 5.3 microns from which a total of approx. 7.7 x 10(exp 23) ergs of energy are radiated during the storm. Energy loss rates due to NO emission exceed 2200 Kelvin per day. In contrast, energy loss from carbon dioxide emission at 15 microns is only approx. 2.3% that of nitric oxide. Atomic oxygen emission at 63 microns is essentially constant during the storm. Energy loss from molecular heat conduction may be as large as 3.8% of the NO emission. These results confirm the "natural thermostat" effect of nitric oxide emission as the primary mechanism by which storm energy is lost from the thermosphere below 210 km.

SOLAR STORMS↗