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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 presentation will be given at the Annual Thermal Fluids Analysis Workshop (TFAWS 2015, NCTS 21070-15) hosted by the Goddard SpaceFlight Center (GSFC) Thermal Engineering Branch (Code 545). The powerpoint presentation details the process of defining limits throughout the lifecycle of a flight project.
An evaluation of a solar concentrator-based system for producing oxygen from the lunar regolith was performed. The system utilizes a solar concentrator mirror to provide thermal energy for the oxygen production process as well as thermal energy to power a Stirling heat engine for the production of electricity. The electricity produced is utilized to operate the equipment needed in the oxygen production process. The oxygen production method utilized in the analysis was the hydrogen reduction of ilmenite. Utilizing this method of oxygen production a baseline system design was produced. This baseline system had an oxygen production rate of 0.6 kg/hr with a concentrator mirror size of 5 m. Variations were performed on the baseline design to show how changes in the system size and process rate effected the oxygen production rate.
Analytical studies were conducted to investigate in detail the heat balance characteristics of the nuclear light bulb engine. Distributions of energy deposition to all engine components from the fission process, conduction and convection, and thermal radiation were considered. Where uncertainties in basic data or heat transfer characteristics were encountered, ranges of heat loads were calculated and reference values were selected. The influence of these heat loads on engine performance, space radiator requirements, and cooling sequence and cooling circuit designs was determined. The analyses resulted in revisions to the previously reported reference engine characteristics, principally in the heat loads to some engine components and in the cooling sequence. These revisions were incorporated in the engine dynamics digital computer simulation program. No significant changes occurred in the dynamic response of the engine to perturbations in fuel injection rate, reactivity or exhaust nozzle area.
Spacecraft and instruments on space missions are built using a wide variety of carefully-chosen materials. It is common for NASA engineers to propose new candidate materials which have not been totally characterized at cryogenic temperatures. In many cases a material's cryogenic thermal conductivity must be known before selecting it for a specific space-flight application. We developed a test facility in 2004 at NASA's Goddard Space Flight Center to measure the longitudinal thermal conductivity of materials at temperatures between 4 and 300 Kelvin, and we have characterized many candidate materials since then. The measurement technique is not extremely complex, but proper care to details of the setup, data acquisition and data reduction is necessary for high precision and accuracy. We describe the thermal conductivity measurement process and present results for ten engineered materials, including alloys, polymers, composites, and a ceramic.
The thermal management team faces a significant challenge to meet the aggressive thermal loading associated with hypersonic flight. Design strategies require the involvement of many engineering disciplines, as each must design their respective subsystem and then interface with all remaining subsystems to successfully close the vehicle design space. High fidelity thermal solid models will capture the variation in material properties and the effects of chemical reactions associated with hypersonic flight. Selection of the best materials for the mission will be based upon computational fluid dynamics and thermal modeling results. To enhance the probability for success, it is recommended that frequent communication occur between the thermal modeler and the materials scientist regarding design strategies and modeling assumptions. Early in the design process, lower fidelity modeling will be used to narrow the trade space. As promising designs are found, greater fidelity in the modeling process will be required to address more of the flowfield challenges and the material performance under the prescribed flight profile. The end goal is to select the most technically sound and physically advantageous material for the mission while avoiding overdesigning the vehicle due to modeling or material uncertainties. This presentation seeks to give an overview of the key thermal parameters that are affected through materials engineering, the interactions between a thermal engineer and other disciplines, and an example of the thermal design process, the X-43.
A low-cost, high-efficiency dish-Stirling solar thermal-electric power system is being developed for test in 1981. System components are the solar concentrator, receiver, fossil fuel combustor, thermal energy storage (TES), engine-generator, and power processing. System conceptualization is completed and design is in progress. Two receiver alternatives are being evaluated, a direct-coupled receiver-engine configuration with no TES and a heat pipe receiver with TES. System cost projections are being made. Goals for the system development task are (1) to develop an advanced dish-Stirling technology, utilizing a team of industrial contractors, (2) to demonstrate that technology at the system level, and (3) to determine how to achieve low production cost.
The intent of mechanical design is to deliver a hardware product that meets or exceeds customer expectations, while reducing cycle time and cost.
Boiling is an effective mode of heat transfer since high heat flux levels are possible driven by relatively small temperature differences. The high heat transfer coefficients associated with boiling have made the use of these processes increasingly attractive to aerospace engineering. Applications of this type include compact evaporators in the thermal control of aircraft avionics and spacecraft environments, heat pipes, and use of boiling to cool electronic equipment. In spite of its efficiency, cooling based on liquid-vapor phase change processes has not yet found wide application in aerospace engineering due to specific problems associated with the low gravity environment. After a heated surface has reached the superheat required for the initiation of nucleate boiling, bubbles will start forming at nucleation sites along the solid interface by evaporation of the liquid. Bubbles in contact with the wall will continue growing by this mechanism until they detach. In terrestrial conditions, bubble detachment is determined by the competition between body forces (e.g. buoyancy) and surface tension forces that act to anchor the bubble along the three phase contact line. For a given body force potential and a balance of tensions along the three phase contact line, bubbles must reach a critical size before the body force can cause them to detach from the wall. In a low gravity environment the critical bubble size for detachment is much larger than under terrestrial conditions, since buoyancy is a less effective means of bubble removal. Active techniques of heat transfer enhancement in single phase and phase change processes by utilizing electric fields have been the subject of intensive research during recent years. The field of electrohydrodynamics (EHD) deals with the interactions between electric fields, flow fields and temperature fields. Previous studies indicate that in terrestrial applications nucleate boiling heat transfer can be increased by a factor of 50 as compared to values obtained for the same system without electric fields. Imposing an external electric field holds the promise to improve pool boiling heat transfer in low gravity, since a phase separation force other than gravity is introduced. The goal of our research is to experimentally investigate the potential of EHD and the mechanisms responsible for EHD heat transfer enhancement in boiling in low gravity conditions.
The NEXT propulsion system is an advanced ion propulsion system presently under development that is oriented towards robotic exploration of the solar system using solar electric power. The Prototype Model engine PM1 was subjected to qualification-level environmental testing to demonstrate compatibility with environments representative of anticipated mission requirements. Random vibration testing, conducted with the thruster mated to the breadboard gimbal, was executed at 10.0 Grms for 2 minutes in each of three axes. Thermal-vacuum testing included a deep cold soak of the engine to temperatures of -168 C and thermal cycling from -120 to 203 C. Although the testing was largely successful, several issues were identified including the fragmentation of potting cement on the discharge and neutralizer cathode heater terminations during vibration which led to abbreviated thermal testing, and generation of particulate contamination from manufacturing processes and engine materials. Thruster performance was nominal throughout the test program, with minor variations in some engine operating parameters likely caused by facility effects. In general, the NEXT PM1 engine and the breadboard gimbal were found to be well-designed against environmental requirements based on the results reported herein. After resolution of the findings from this test program the hardware environmental qualification program can proceed with confidence.
In order to reduce heat transfer between a hot gas heat source and a metallic engine component, a thermal insulating layer of material is placed between them. This thermal barrier coating is applied by plasma spray processing the thin films. The coating has been successfully employed in aerospace applications for many years. Lewis Research Center, a leader in the development engine components coating technology, has assisted Caterpillar, Inc. in applying ceramic thermal barrier coatings on engines. Because these large engines use heavy fuels containing vanadium, engine valve life is sharply decreased. The barrier coating controls temperatures, extends valve life and reduces operating cost. Additional applications are currently under development.
The technical feasibility of a solar thermal collector to provide process steam in an industrial environment was determined. The form of the experiment was an industrial field test.
This presentation will detail the work done to improve thermal efficiency in the compression process of a gas turbine engine for aircraft applications under NASAs Environmentally Responsible Aviation Project. The talk will present the goals and objectives of the work and show the activity of both Phase 1 and Phase 2 tests and analysis. The summary shows the projected fuel burn savings achieved through system studies.
High thermal gradient casting of PWA 1480 was evaluated as an avenue for reducing the size of casting porosity. Hot isostatic pressing (HIP) was also employed for the elimination of casting pores. An alternate to the standard PWA 1480 coating plus diffusion bonding aging heat treatment cycle was also evaluated for potential improvements in the properties of interest to the Space Shuttle Main Engine (SSME) application. Microstructural changes associated with the high thermal gradient casting process were quantified by measurement of the size and density of the casting porosity, the amount of retained casting eutectic, and dendrite arm spacings. The results of the advanced processing have shown an improvement in material microstructure due to high thermal gradient casting. Improved homogeneity of PWA 1480 is advantageous in providing an improved solution heat treatment window and, potentially, easier HIP. High thermal gradient casting improves fatigue life by reducing casting pore size. The alternate heat treatment improves the balance of strength and ductility which appears to improve low cycle fatigue life, but with a reduction in short time stress rupture life. Based upon these tests, hot isostatic pressing appears to afford further improvements in cyclic life, though additional evaluation is suggested. Development of the alternate heat treatment is not recommended due to the reduced stress rupture capability and the need to develop a new properties data base. High thermal gradient casting and HIP are recommended for application to single crystal castings.
The surface finish found on components manufactured by sinter laser manufacturing (SLM) is rougher (0.013 - 0.0006 inches) than parts made using traditional fabrication methods. Internal features and passages built into SLM components do not readily allow for roughness reduction processes. Alternatively, engineering literature suggests that the roughness of a surface can enhance thermal performance within a pressure drop regime. To further investigate the thermal performance of SLM fabricated pieces, several GRCop-84 SLM single channel components were tested using a thermal conduction rig at MSFC. A 20 kW power source running at 25% duty cycle and 25% power level applied heat to each component while varying water flow rates between 2.1 - 6.2 gallons/min (GPM) at a supply pressure of 550 to 700 psi. Each test was allowed to reach quasi-steady state conditions where pressure, temperature, and thermal imaging data were recorded. Presented in this work are the heat transfer responses compared to a traditional machined OHFC Copper test section. An analytical thermal model was constructed to anchor theoretical models with the empirical data.
The surface finish found on components manufactured by sinter laser manufacturing (SLM) is rougher (0.013 - 0.0006 inches) than parts made using traditional fabrication methods. Internal features and passages built into SLM components do not readily allow for roughness reduction processes. Alternatively, engineering literature suggests that the roughness of a surface can enhance thermal performance within a pressure drop regime. To further investigate the thermal performance of SLM fabricated pieces, several GRCop‐84 SLM single channel components were tested using a thermal conduction rig at MSFC. A 20 kW power source running at 25% duty cycle and 25% power level applied heat to each component while varying water flow rates between 2.1 - 6.2 gallons/min (GPM) at a supply pressure of 500 to 750 psi. Each test was allowed to reach quasi‐steady state conditions where pressure, temperature, and thermal imaging data were recorded. Presented in this work are the heat transfer responses compared to a traditional machined OHFC Copper test section. An analytical thermal model was constructed to anchor theoretical models with the empirical data.
Non-nuclear testing can be a valuable tool in development of a space nuclear power or propulsion system. In a non-nuclear test bed, electric heaters are used to simulate the heat from nuclear fuel. Work at the NASA Marshall Space Flight Center seeks to develop high fidelity thermal simulators that not only match the static power profile that would be observed in an operating, fueled nuclear reactor, but to also match the dynamic fuel pin performance during feasible transients. Comparison between the fuel pins and thermal simulators is made at the fuel clad surface, which corresponds to the sheath surface in the thermal simulator. Static and dynamic fuel pin performance was determined using SINDA-FLUINT analysis, and the performance of conceptual thermal simulator designs was compared to the expected nuclear performance. Through a series of iterative analysis, a conceptual high fidelity design will be developed, followed by engineering design, fabrication, and testing to validate the overall design process. Although the resulting thermal simulator will be designed for a specific reactor concept, establishing this rigorous design process will assist in streamlining the thermal simulator development for other reactor concepts.
Environmental barrier coatings (EBC) and SiCSiC ceramic matrix composites (CMCs) will play a crucial role in future aircraft turbine engine systems, because of their ability to significantly increase engine operating temperatures, reduce engine weight and cooling requirements. This paper presents current NASA EBC-CMC development emphases including: the coating composition and processing improvements, laser high heat flux-thermal gradient thermo-mechanical fatigue - environmental testing methodology development, and property evaluations for next generation EBC-CMC systems. EBCs processed with various deposition techniques including Plasma Spray, Electron Beam - Physical Vapor Deposition, and Plasma Spray Physical Vapor Deposition (PS-PVD) will be particularly discussed. The testing results and demonstrations of advanced EBCs-CMCs in complex simulated engine thermal gradient cyclic fatigue, oxidizing-steam and CMAS environments will help provide insights into the coating development strategies to meet long-term engine component durability goals.
Silicon carbide is of great interest for structural use in aircraft and automobile engines. This ceramic combines high thermal conductivity and low coefficient of thermal expansion, and consequently has good thermal shock resistance. However, like other ceramics, silicon carbide shows strength variability due to processing flaws such as large voids, shrinkage cracks, and inclusions. Agglomerates in the starting powder seem to be the predominant cause of such defects. Improved processing techniques such as slurry pressing and hot isostatic pressing (HIP) were employed to minimize these defects and to improve strength and reliability in the fabricated material. For this purpose 2-inch diameter disks were fabricated by various consolidation techniques. These include: dry pressing and sintering, slurry pressing and sintering, and slurry pressing and HIPing. The results are discussed.