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All sources NASA NTRS DOE OSTI

NASA NTRS2010

Custom Unit Pump Development for the EVA PLSS

Schuller, Michael↗

NASA NTRS2019

Rewet Temperature Correlations for Liquid-Nitrogen Boiling Pipe Flows Across Varying Flow Conditions and Orientations

In many convective liquid-vapor phase change heat transfer engineering applications, cryogenic fluids are widely used in industrial processes, spacecraft and cryosurgery systems, and so on. For example, cryogens are usually used as liquid fuels such as liquid hydrogen and oxygen in the rocket industry, liquid nitrogen (LN2) and helium are frequently used to cool superconducting magnetic device for medical applications. In these systems, proper transport, handling, and storage of cryogenic fluids are of extreme importance. Among all the cryogenic transport processes performed in room temperatures, quenching, also termed chilldown, is a unavoidable initial, transient phase-change heat transfer process that brings the system down to the cryogenic condition. The Leidenfrost temperature or rewet temperature that signals the end of film boiling is practically considered the completion point of a quenching process. Therefore, rewet temperature has been considered the most important parameter for the engineering design of cryogenic thermal management systems. As most of the previous correlations for predicting the Leidenfrost temperature and the rewet temperature have been basically developed for water, they are shown to disagree with recent liquid nitrogen pipe chilldown experiments in upward and downward flow directions over a wide range of flow rates, pressures, and degrees of inlet subcooling. In addition to a complete review of the literature, two new correlations are presented in this work, one based on bubble growth and another based on the theoretical maximum limit of superheat. Each correlation performs well over the entire data set.

liquid nitrogen↗

NASA NTRS2012

Supercritical CO2 Cleaning System for Planetary Protection and Contamination Control Applications

Current spacecraft-compatible cleaning protocols involve a vapor degreaser, liquid sonication, and alcohol wiping. These methods are not very effective in removing live and dead microbes from spacecraft piece parts of slightly complicated geometry, such as tubing and loosely fitted nuts and bolts. Contamination control practices are traditionally focused on cleaning and monitoring of particulate and oily residual. Vapor degreaser and outgassing bakeout have not been proven to be effective in removing some less volatile, hydrophilic biomolecules of significant relevance to life detection. A precision cleaning technology was developed using supercritical CO2 (SCC). SCC is used as both solvent and carrier for removing organic and particulate contaminants. Supercritical fluid, like SCC, is characterized by physical and thermal properties that are between those of the pure liquid and gas phases. The fluid density is a function of the temperature and pressure. Its solvating power can be adjusted by changing the pressure or temperature, or adding a secondary solvent such as alcohol or water. Unlike a regular organic solvent, SCC has higher diffusivities, lower viscosity, and lower surface tension. It readily penetrates porous and fibrous solids and can reach hard-to-reach surfaces of the parts with complex geometry. Importantly, the CO2 solvent does not leave any residue. The results using this new cleaning device demonstrated that both supercritical CO2 with 5% water as a co-solvent can achieve cleanliness levels of 0.01 mg/cm2 or less for contaminants of a wide range of hydrophobicities. Experiments under the same conditions using compressed Martian air mix, which consists of 95% CO2, produced similar cleaning effectiveness on the hydrophobic compounds. The main components of the SCC cleaning system are a high-pressure cleaning vessel, a boil-off vessel located downstream from the cleaning vessel, a syringe-type high-pressure pump, a heat exchanger, and a back pressure regulator (BPR). After soaking the parts to be cleaned in the clean vessel for a period, the CO2 with contaminants is flushed out of the cleaning vessel using fresh CO2 in a first-in-first-out (FIFO) method. The contaminants are either precipitating out in the boil-off container or being trapped in a filter subsystem. The parts to be cleaned are secured in a basket inside and can be rotated up to 1,400 rpm by a magnetic drive. The fluid flows within the vessel generate tangential forces on the parts surfaces, enhancing the cleaning effectiveness and shortening the soaking time. During the FIFO flushing, the pump subsystem pushes fresh CO2 into the cleaning vessel at a constant flow rate between 0.01 and 200 mL/min, while the BPR regulates the pressure in the cleaning vessel to within 0.1 bar by controlling the needle position in an outlet valve. The fresh CO2 gas flows through the heat exchanger at a given temperature before entering the cleaning vessel. A platinum resistance thermometer (PRT) reads the cleaning vessel interior temperature that can be controlled to within 0.1 K. As a result, cleaning vessel temperature remains constant during the FIFO flushing. There is no change in solvent power during FIFO flushing since both temperature and pressure inside the cleaning vessel remain unchanged, thus minimizing contaminants left behind. During decompression, both temperature and pressure are strictly controlled to prevent bubbles from generating in the cleaning vessel that could stir up the contaminants that sank to the bottom by gravity.

Lin, Ying↗

DOE OSTI2024

Demonstration of a multi-channel fluidized bed particle–supercritical carbon dioxide heat exchanger for concentrating solar applications

High-temperature thermal energy storage in oxide particles at temperatures above 600°C can couple concentrated solar energy with high-efficiency thermal power cycles to provide dispatchable solar-driven electricity. Challenges remain in developing cost-effective primary heat exchangers, which require expensive alloys, to extract the high-temperature thermal energy from the particles to power cycle fluids, such as supercritical CO 2 (sCO 2 ) in recuperated Brayton cycles. To explore one pathway for cost-effective, high-temperature particle heat exchangers, the current study demonstrates a shell-and-plate, particle–sCO 2 heat exchanger with narrow- channel fluidized beds coupled with micro-channel sCO 2 flows in the heat exchanger walls. This study evaluates the feasibility of multiple parallel, narrow-channel fluidized beds in shell-and-plate particle–sCO 2 HXs, to achieve high bed-wall heat fluxes at elevated temperatures. A reduced-order model simulates the narrow- channel, fluidized-bed particle–sCO 2 heat exchanger to design the fluidized bed geometry, in terms of depth, height, and number of channels,for a nominal 40-kWth heat exchanger at particle and sCO 2 inlet temperatures up to 600 °C and 400 °C respectively. The resulting shell-and-plate heat exchanger design operates with bubbling fluidization of the downward-flowing oxide particles to enhance bed-wall heat transfer. The heat exchanger core is fabricated with etched sCO 2 micro-channels in thin wall plates that are diffusion bonded to spacer frames to form the shell-and-plate structure with 12 parallel, fluidized bed channels, 10.4 mm deep. The heat exchanger is tested at the National Solar Thermal Test Facility at Sandia National Laboratories with CARBOBEAD HSP particles at design particle flow rates of 0.20 kg s –1 and inlet temperatures up to 525 °C. Results show that fluidization across multiple parallel channel beds can maintain uniform particle inventory with a common freeboard zone above the heat exchanger core. Bubbling fluidization improves particle–wall heat transfer coefficients but also increases axial dispersion of particle thermal energy, which lowers the log- mean temperature difference such that total heat transfer remains relatively constant to within ±10% over a broad range of fluidization gas velocities. The axial dispersion required particle and sCO 2 flow rates to be increased by 25% over model-designed conditions to achieve the targeted 40 kWth, which indicates the importance of incorporating axial dispersion into heat exchanger design models and of deploying bed structures to suppress it. Furthermore, this study demonstrates the feasibility and preferred fluidizing gas conditions for particle heat exchangers for releasing high-temperature thermal energy storage systems.

14 SOLAR ENERGY↗

NASA NTRS1990

Design and test of a compact optics system for the pool boiling experiment

The experiment described seeks to improve the understanding of the fundamental mechanisms that constitute nucleate pool boiling. The vehicle for accomplishing this is an investigation, including tests to be conducted in microgravity and coupled with appropriate analyses, of the heat transfer and vapor bubble dynamics associated with nucleation, bubble growth/collapse and subsequent motion, considering the interrelations between buoyancy, momentum and surface tension which will govern the motion of the vapor and surrounding liquid, as a function of the heating rate at the heat transfer surface and the temperature level and distribution in the bulk liquid. The experiment is designed to be contained within the confines of a Get-Away-Special Canister (GAS Can) installed in the bay of the space shuttle. When the shuttle reaches orbit, the experiment will be turned on and testing will proceed automatically. In the proposed Pool Boiling Experiment a pool of liquid, initially at a precisely defined pressure and temperature, will be subjected to a step imposed heat flux from a semitransparent thin-film heater forming part of one wall of the container such that boiling is initiated and maintained for a defined period of time at a constant pressure level. Transient measurements of the heater surface and fluid temperatures near the surface will be made, noting especially the conditions at the onset of boiling, along with motion photography of the boiling process in two simultaneous views, from beneath the heating surface and from the side. The conduct of the experiment and the data acquisition will be completely automated and self-contained. For the initial flight, a total of nine tests are proposed, with three levels of heat flux and three levels of subcooling. The design process used in the development and check-out of the compact photographic/optics system for the Pool Boiling Experiment is documented.

Ling, Jerri S.↗

NASA NTRS2014

An RF Sensor for Gauging Screen-Channel Liquid Acquisition Devices for Cryogenic Propellants

A key requirement of a low-gravity screen-channel liquid acquisition device (LAD) is the need to retain 100% liquid in the channel in response to propellant outflow and spacecraft maneuvers. The point at which a screen-channel LAD ingests vapor is known as breakdown, and can be measured several different ways such as: visual observation of bubbles in the LAD channel outflow; a sudden change in pressure drop between the propellant tank and LAD sump outlet; or, an indication by wet-dry sensors placed in the LAD channel or outflow stream. Here we describe a new type of sensor for gauging a screen-channel LAD, the Radio Frequency Mass Gauge (RFMG). The RFMG measures the natural electromagnetic modes of the screen-channel LAD, which is very similar to an RF waveguide, to determine the amount of propellant in the channel. By monitoring several of the RF modes, we show that the RFMG acts as a global sensor of the LAD channel propellant fill level, and enables detection of LAD breakdown even in the absence of outflow. This paper presents the theory behind the RFMG-LAD sensor, measurements and simulations of the RF modes of a LAD channel, and RFMG detection of LAD breakdown in a channel using a simulant fluid during inverted outflow and long-term stability tests.

microwave sensor↗

DOE OSTI2021

Computational Fluid Dynamics Simulations to Support Efficiency Improvements in Aluminum Smelting Process

Smelting is broadly described as the extraction of a metal from its ore. In the United States, aluminum is commonly produced by smelting alumina in bauxite using the Hall-Héroult process. Optimization of equipment and processes in conventional smelting is crucial to enhancing process efficiency and productivity, is necessary for improving the techno-economic feasibility, which directly manifests as the growth of the American economy. To achieve optima, insightful data on the multiphysics phenomena that are inherent to the process must be obtained through physical investigation or high-fidelity numerical simulations. The resolution of relevant scales in time and space for smelting operations requires intensive, high-performance computing (HPC) simulations. Hostile operating conditions limit physical data acquisition to specific techniques; therefore, these data do not describe the multiscale interaction of simultaneous effects. Fortunately, in recent decades, significant advancements in computing hardware and computational methods have made the numerical resolution of such a complex process possible. In this study, a high-fidelity simulation of aluminum smelting was performed using an open-source tool, OpenFOAM, which analyzed many parameters characteristic to underlying phenomena. A multiphysics model based on the Eulerian-Eulerian multifluid approach was adopted. This model can resolve critical issues in the electrolytic smelting of aluminum, such as bubbling of carbon dioxide from the anode(s), magnetohydrodynamics from electromagnetic effects, ionic dissolution of the alumina in the electrolyte, and the evolution of thermal profiles. This study provides valuable connectivity for characteristic data that can direct the future designs of efficient smelters. A basic framework to model and simulate the smelting process using OpenFOAM is presented for user modification in keeping with process development. Of relevance to the flow field, a detailed investigation of vortices produced by bubble motion and electromagnetics is discussed, along with their impact on the evolution of thermal profiles. The predictions show small-scale vortices in the clearance between the anode and cathode caused by magnetic forces. Predictions also indicate relatively large-scale vortices in the inter-anode space resulting from carbon dioxide rising through the electrolytic flow field. The formation of vortices at the edges of anodes was shown to direct alumina charged by the feeder to the bottom of the anodes, thus preventing the entrapment of gas bubbles in the periphery of the bottom of the anode. Symmetry was observed in the location of cold spots in the electrolytic mixture in the vicinity of the feeder. Cold spots were also observed in the clearance between the anode and cathode due to the flow’s transmission of unconverted alumina to this region.

36 MATERIALS SCIENCE↗

NASA NTRS2018

Steady and Unsteady Excitation of Separated Flow over the NASA Hump Model

Separated flow and its control over the NASA hump model were investigated at subsonic speeds. Three-dimensional, unsteady fluid dynamic simulations were supplemented by wind tunnel measurements. Flow control was implemented by means of spatially distributed discrete jets operating in steady and unsteady modes. The effects of excitation amplitude and frequency were studied numerically and experimentally. Several integral parameters were explored as quality metrics. In addition to the existing ones, two new integral parameters, which are slightly modified versions of the normal force and moment coefficients, were introduced. These two parameters together with pressure drag coefficient were found to be well correlated with the flow control and used in the performance evaluation of different flow control methods including, zero net mass flux actuators, steady suction, sweeping jet actuators, and the currently studied steady and unsteady excitations. For the cases tested, it was found that the unsteady excitation is superior to the steady excitation and slightly better than the sweeping jet actuators whereas the steady suction was found to be the most effective. Although the numerical simulations overpredict the separation bubble, these simulations capture the salient features of flow separation control and hence help us to understand the effect of steady/unsteady excitation on the separated flow.

Koklu, Mehti↗

NASA NTRS2023

Experimental Investigation of Flow Orientation Effects on Cryogenic Flow Boiling

Cryogenic flow boiling physics is of paramount importance for future cryogenic space applications employing Cryogenic Fluid Management (CFM) technologies. This experimental study investigates the two-phase flow and heat transfer performance of LN 2 flow boiling across five distinct flow orientations: vertical upflow, vertical downflow, horizontal flow, 45° inclined upflow, and 45° inclined downflow. The study employed the steady- state heating method within a circular heated tube featuring an 8.5-mm inner diameter and a 680-mm heated length. High-speed video recordings were utilized to capture two-phase flow patterns and interfacial behaviors across various flow orientations. The experiments covered a wide range of operating conditions, including mass velocities ranging from 351.80 to 1572.77 kg/m 2 s and inlet pressures from 297.14 to 1032.97 kPa, primarily with near-saturated inlet subcooling. Distinct two-phase flow patterns and regime transitions were identified for each flow orientation. Symmetrical flow patterns were evident in vertical orientations, whereas non-vertical orientations exhibited asymmetric flow stratifications, primarily influenced by the buoyancy force in a terrestrial gravity environment. Bubble dynamic parameters were quantified, and bubble collision and dispersion phenomena were visualized. Analyzing heat transfer performance based on local flow boiling curves and variations in heat transfer coefficients (HTCs), it was observed that vertical upflow demonstrated the most enhanced heat transfer performance, while vertical downflow exhibited the lowest. As mass velocity exceeded 830 kg/ m 2 s, the differences in heat transfer among orientations became less distinct, emphasizing the role of flow inertia in mitigating the influence of flow orientation. A direct comparison of microgravity HTC data from a recent study by the authors against the 1-𝘨 e HTC data indicated enhanced heat transfer performance in microgravity for flow orientation configurations in terrestrial gravity. However, this enhancement progressively diminished as the heat flux increased. Distinct HTC trends were observed as mass velocity increased for different flow orientations and gravity levels.

Cryogens↗

DOE OSTI2024

Onset of kinetic effects on Rayleigh–Taylor instability: Advective–diffusive asymmetry

In nature and engineering applications, the Rayleigh–Taylor instability (RTI) occurs over a wide range of Atwood, Reynolds, Mach, and Knudsen numbers. At low Atwood, Mach, and Knudsen numbers, the classic advective instability causes quasi-symmetric bubble and spike growth on the two sides of the interface. However, recent findings suggest that at high degrees of rarefaction, advective effects are suppressed and molecular diffusion leads to planar growth of the density fronts on either side of the interface. This study aims to investigate the flow physics of the transition from advective to diffusive behavior, focusing on the onset of the kinetic effects. Using the gas kinetic methodology, RTI is simulated over a range of Knudsen and Mach numbers in the transition regime. The simulation results reveal the various stages of transformation from advective instability to diffusive transport. For the first time, the study demonstrates the existence of a Knudsen–Mach parameter regime where the bubble side exhibits advective instability, while the other side shows a planar density front due to molecular diffusion, rather than the canonical advective spike shape. The dominance of different mechanisms on the two sides of the interface leads to the advective–diffusive asymmetry. In conclusion, the findings of this study can lead to a more comprehensive understanding of RTI over a wide range of Mach and Knudsen numbers.

42 ENGINEERING↗

NASA NTRS2000

Measurement of the Surface Dilatational Viscosity of an Insoluble Surfactant Monolayer at the Air/Water Interface Using a Pendant Drop Apparatus

When a fluid interface with surfactants is at rest, the interfacial stress is isotropic (as given by the equilibrium interfacial tension), and is described by the equation of state which relates the surface tension to the surfactant surface concentration. When surfactants are subjected to shear and dilatational flows, flow induced interaction of the surfactants; can create interfacial stresses apart from the equilibrium surface tension. The simplest relationship between surface strain rate and surface stress is the Boussinesq-Scriven constitutive equation completely characterized by three coefficients: equilibrium interfacial tension, surface shear viscosity, and surface dilatational viscosity Equilibrium interfacial tension and surface shear viscosity measurements are very well established. On the other hand, surface dilatational viscosity measurements are difficult because a flow which change the surface area also changes the surfactant surface concentration creating changes in the equilibrium interfacial tension that must be also taken into account. Surface dilatational viscosity measurements of existing techniques differ by five orders of magnitude and use spatially damped surface waves and rapidly expanding bubbles. In this presentation we introduce a new technique for measuring the surface dilatational viscosity by contracting an aqueous pendant drop attached to a needle tip and having and insoluble surfactant monolayer at the air-water interface. The isotropic total tension on the surface consists of the equilibrium surface tension and the tension due to the dilation. Compression rates are undertaken slow enough so that bulk hydrodynamic stresses are small compared to the surface tension force. Under these conditions we show that the total tension is uniform along the surface and that the Young-Laplace equation governs the drop shape with the equilibrium surface tension replaced by the constant surface isotropic stress. We illustrate this technique using DPPC as the insoluble surfacant monolayer and measured for it a surface dilatational viscosity in the LE phase that is 20 surface poise.

Lorenzo, Jose↗

NASA NTRS2002

Acoustically Enhanced Electroplating Being Developed

In cooperation with the NASA Glenn Research Center, Alchemitron Corp. is developing the Acoustically Enhanced Electroplating Process (AEEP), a new technique of employing nonlinear ultrasonics to enhance electroplating. The applications range from electroplating full-panel electronic circuit boards to electroplating microelectronics and microelectromechanical systems (MEMS) devices. In a conventional plating process, the surface area to be plated is separated from the nonplated areas by a temporary mask. The mask may take many forms, from a cured liquid coating to a simple tape. Generally, the mask is discarded when the plating is complete, creating a solid waste product that is often an environmental hazard. The labor and materials involved with the layout, fabrication, and tooling of masks is a primary source of recurring and nonrecurring production costs. The objective of this joint effort, therefore, is to reduce or eliminate the need for masks. AEEP improves selective plating processes by using directed beams of high-intensity acoustic waves to create nonlinear effects that alter the fluid dynamic and thermodynamic behavior of the plating process. It relies on two effects: acoustic streaming and acoustic heating. Acoustic streaming is observed when a high-intensity acoustic beam creates a liquid current within the beam. The liquid current can be directed as the beam is directed and, thus, users can move liquid around as desired without using pumps and nozzles. The current of the electroplating electrolyte, therefore, can be directed at distinct target areas where electroplating is desired. The current delivers fresh electrolyte to the target area while flushing away the spent electrolyte. This dramatically increases the plating rate in the target area. In addition, acoustic heating of both the liquid in the beam and the target surface increases the chemical reaction rate, which further increases the plating rate. The combined effects of acoustic streaming and heating accelerate the deposition of plating in that area and, thus, provide an effect similar to a mask but without the costs of masking. AEEP further improves the plating process by clearing debris and bubbles from the surface by acoustic radiation pressure and acoustic streaming.

Oeftering, Richard C.↗

NASA NTRS2013

Electrical Capacitance Volume Tomography for the Packed Bed Reactor ISS Flight Experiment

Fixed packed bed reactors are compact, require minimum power and maintenance to operate, and are highly reliable. These features make this technology a highly desirable unit operation for long duration life support systems in space. NASA is developing an ISS experiment to address this technology with particular focus on water reclamation and air revitalization. Earlier research and development efforts funded by NASA have resulted in two hydrodynamic models which require validation with appropriate instrumentation in an extended microgravity environment. To validate these models, the instantaneous distribution of the gas and liquid phases must be measured.Electrical Capacitance Volume Tomography (ECVT) is a non-invasive imaging technology recently developed for multi-phase flow applications. It is based on distributing flexible capacitance plates on the peripheral of a flow column and collecting real-time measurements of inter-electrode capacitances. Capacitance measurements here are directly related to dielectric constant distribution, a physical property that is also related to material distribution in the imaging domain. Reconstruction algorithms are employed to map volume images of dielectric distribution in the imaging domain, which is in turn related to phase distribution. ECVT is suitable for imaging interacting materials of different dielectric constants, typical in multi-phase flow systems. ECVT is being used extensively for measuring flow variables in various gas-liquid and gas-solid flow systems. Recent application of ECVT include flows in risers and exit regions of circulating fluidized beds, gas-liquid and gas-solid bubble columns, trickle beds, and slurry bubble columns. ECVT is also used to validate flow models and CFD simulations. The technology is uniquely qualified for imaging phase concentrations in packed bed reactors for the ISS flight experiments as it exhibits favorable features of compact size, low profile sensors, high imaging speed, and flexibility to fit around columns of various shapes and sizes. ECVT is also safer than other commonly used imaging modalities as it operates in the range of low frequencies (1 MHz) and does not radiate radioactive energy. In this effort, ECVT is being used to image flow parameters in a packed bed reactor for an ISS flight experiment.

Tomography↗

DOE OSTI2022

Very small-scale, segregating-fluidized-bed experiments: A dataset for CFD-DEM validation and uncertainty quantification

IWe report fluidization experiments were conducted on a small scale and with a rapid response (short duration) to enable corresponding simulations at low-computational cost. Rise times are reported for four or fewer polyethylene particles (intruders) in an air-fluidized bed of ~5000 group D glass beads. Experimental inputs were completely characterized—particle properties, system dimensions and operating conditions—which is necessary for validating computational fluid mechanics (CFD)-discrete element method (DEM) including a comprehensive uncertainty quantification (UQ) analysis. Input uncertainties are reported as bounds or cumulative distribution functions of measured values. The staggering number of simulations required to complete a UQ analysis (~O[10 4 ] simulations corresponding to ~5 uncertain inputs) motivates this study. These segregating-bed experiments are designed to permit analogous CFD-DEM simulations to complete in less than a day on a single (~2.5 GHz) computational processor unit (CPU). Segregation times are reported for several operating conditions, intruder sizes, and initial configurations, providing a rich dataset for numerical model testing, validation and UQ.

42 ENGINEERING↗

DOE OSTI2022

Speed of Sound Measurements of Binary Mixtures of Hydrofluorocarbons [Pentafluoroethane (R-125), 1,1-Difluoroethane (R-152a), or 1,1,1,2,3,3,3-Heptafluoropropane (R-227ea)] with Hydrofluoroolefins [2,3,3,3-Tetrafluoropropene (R-1234yf) or trans-1,3,3,3-Tetrafluoropropene (R-1234ze(E))]

In this article, speed of sound data measured using a dual-path pulse-echo instrument are reported for three binary refrigerant mixtures, R-125/1234yf, R-1234yf/152a, and R-1234ze(E)/227ea, at compositions of (0.33/0.67) and (0.67/0.33) mole fraction. The speed of sound was studied at temperatures ranging from 230 K to 345 K from pressures slightly above the bubble point curve up to 20 MPa for the mixtures containing R-1234yf and 49 MPa for the R-1234ze(E)/227ea mixtures. The relative combined expanded speed of sound uncertainty ranged from 0.039 % to 0.317 % with a mean uncertainty over all state points of less than 0.10 %. The reported data are compared to the most recent mixture models in REFPROP for each blend studied. Comparisons of available mixture models for the R-125/1234yf and R-1234yf/152a blends exhibit average absolute deviation values ranging from 0.10 % to 0.27 %, and the average absolute deviations for R-1234ze(E)/227ea blends range from 0.62 % to 0.94 %. The comparisons show that only minor adjustments are required to the R-125/1234yf and R-1234yf/152a mixture models to represent the speed of sound data within its uncertainty. However, significant adjustments are needed to improve the current mixture models for the R-1234ze(E)/227ea blend. Deficiencies with the R-1234ze(E)/227ea mixture model are not unexpected since it (1) utilizes a pure-fluid EOS R-1234ze(E) that has been shown to inaccurately represent R-1234ze(E) speed of sound values and (2) uses binary interaction parameters for the chemically similar mixture of R-1234yf/227ea.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2009

Custom Unit Pump Design and Testing for the EVA PLSS

This paper describes the effort by the Texas Engineering Experiment Station (TEES) and Honeywell for NASA to design and test a pre-flight prototype pump for use in the Extra-vehicular activity (EVA) portable life support subsystem (PLSS). Major design decisions were driven by the need to reduce the pump s mass, power, and volume compared to the existing PLSS pump. In addition, the pump must accommodate a much wider range of abnormal conditions than the existing pump, including vapor/gas bubbles and increased pressure drop when employed to cool two suits simultaneously. A positive displacement, external gear type pump was selected because it offers the most compact and highest efficiency solution over the required range of flow rates and pressure drops. An additional benefit of selecting a gear pump design is that it is self priming and capable of ingesting non-condensable gas without becoming air locked. The chosen pump design consists of a 28 V DC, brushless, sealless, permanent magnet motor driven, external gear pump that utilizes a Honeywell development that eliminates the need for magnetic coupling. Although the planned flight unit will use a sensorless motor with custom designed controller, the pre-flight prototype to be provided for this project incorporates Hall effect sensors, allowing an interface with a readily available commercial motor controller. This design approach reduced the cost of this project and gives NASA more flexibility in future PLSS laboratory testing. The pump design was based on existing Honeywell designs, but incorporated features specifically for the PLSS application, including all of the key features of the flight pump. Testing at TEES verified that the pump meets the design requirements for range of flow rates, pressure drop, power consumption, working fluid temperature, operating time, gas ingestion , and restart capability under both ambient and vacuum conditions. The pump operated between 40 and 240 lbm/hr flowrate, 35 to 100 F pump temperature range, and 5 to 10 psid pressure rise. Power consumption of the pump controller at the nominal operating point in both ambient and vacuum conditions was 9.5 W, which was less than the 12 W predicted. Gas ingestion capabilities were tested by injecting 100 cc of air into the fluid line; the pump operated normally throughout this test. The test results contained a number of anomalies, specifically power increases and a few flow stoppages, that prompted TEES and Honeywell to disassemble and inspect the pump. Inspection indicated contamination in the pump and fit issues may have played roles in the observed anomalies. Testing following reassembly indicated that the performance of the pump 1) matched both the predicted performance values, 2) the performance values measured prior to disassembly, and 3) was free of the anomalies noted in the pre-disassembly testing.

Schuller, Michael↗

DOE OSTI2022

Velocity Profiling of a Gas–Solid Fluidized Bed Using Electrical Capacitance Volume Tomography

In this study, a method of producing velocity profile maps from electrical capacitance volume tomography (ECVT) measurements by reconstructing displacement from measured changes in capacitance is developed and applied to fluidized bed systems. The mapping of the reconstruction leverages the gradient of the sensitivity distribution of the ECVT sensor to circumvent the need for image cross correlation techniques. Experimental data of both bubbling and slugging fluidized beds are collected in a cold flow model. Adaptation of the technique is discussed in detail, and velocity profiles are obtained for a range of gas flow rates. The produced velocity maps are compared against the established methods of cross correlation and against empirical correlations from the literature and are found to agree well in tracking slug and bubble velocity. The exception is when the tracked object is large relative to the ECVT sensor dimensions, a scenario that can be avoided through proper sensor design. The quantities of average velocity, momentum, and solid and gas volume fraction are derived from the image and velocity profiles. The results demonstrate and extend the power of ECVT as a measurement tool for the study and monitoring of gas–solid fluidized beds by providing a computationally cheaper alternative to 3-D cross correlation for deriving velocity profiles.

47 OTHER INSTRUMENTATION↗

NASA NTRS2009

Water Pump Development for the EVA PLSS

This paper describes the effort by the Texas Engineering Experiment Station (TEES) and Honeywell for NASA to design, fabricate, and test a preflight prototype pump for use in the Extravehicular activity (EVA) portable life support subsystem (PLSS). Major design decisions were driven by the need to reduce the pump s mass, power, and volume compared to the existing PLSS pump. In addition, the pump will accommodate a much wider range of abnormal conditions than the existing pump, including vapor/gas bubbles and increased pressure drop when employed to cool two suits simultaneously. A positive displacement, external gear type pump was selected because it offers the most compact and highest efficiency solution over the required range of flow rates and pressure drops. An additional benefit of selecting a gear pump design is that it is self priming and capable of ingesting noncondensable gas without becoming "air locked." The chosen pump design consists of a 28 V DC, brushless, sealless, permanent magnet motor driven, external gear pump that utilizes a Honeywell development that eliminates the need for magnetic coupling. Although the planned flight unit will use a sensorless motor with custom designed controller, the preflight prototype to be provided for this project incorporates Hall effect sensors, allowing an interface with a readily available commercial motor controller. This design approach reduced the cost of this project and gives NASA more flexibility in future PLSS laboratory testing. The pump design was based on existing Honeywell designs, but incorporated features specifically for the PLSS application, including all of the key features of the flight pump. Testing at TEES will simulate the vacuum environment in which the flight pump will operate. Testing will verify that the pump meets design requirements for range of flow rates, pressure rise, power consumption, working fluid temperature, operating time, and restart capability. Pump testing is currently scheduled for March, 2009, after which the pump will be delivered to NASA for further testing.

Schuller, Michael↗