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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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Chemical and thermal characterization (FTIR-ATR, Soxhlet extraction, DSC) of polymeric encapsulants (EVA, POE, EPE) aged under accelerated aging conditions containing an UV source.
State of the art boundary layer stability modeling capabilities are increasingly seeing application to entry flight vehicles. With the advent of user friendly and robust implementations of two-dimensional chemical nonequilibrium stability modeling with the STABL/PSE-CHEM software, the need for flight data to calibrate such analyses capabilities becomes more critical. Recent efforts to perform entry flight testing with the Orbiter geometry related to entry aerothermodynamics and boundary layer transition is allowing for a heightened focus on the Orbiter configuration. A significant advancement in the state of the art can likely be achieved by establishing a basis of understanding for the occurrence of boundary layer transition on the Orbiter due to discrete protruding gap fillers and the nominal distributed roughness of the actual thermal protection system. Recent success in demonstrating centerline two-dimensional stability modeling on the centerline of the Orbiter at flight entry conditions provides a starting point for additional investigations. The more detailed paper will include smooth Orbiter configuration boundary layer stability results for several typical orbiter entry conditions. In addition, the numerical modeling approach for establishing the mean laminar flow will be reviewed and the method for determining boundary layer disturbance growth will be overviewed. In addition, if actual Orbiter TPS surface data obtained via digital surface scans become available, it may be possible to investigate the effects of an as-flown flight configuration on boundary layer transition compared to a smooth CAD reference.
Magnesium chloride (MgCl 2 )-based molten salt phase change materials (PCMs) are promising candidates for thermal energy storage (TES) owing to their advantageous thermophysical properties, however, their high corrosivity in the molten state limits material compatibility. In this study, the corrosion behavior of 304?L stainless steel (SS304L) exposed to MgCl2 PCM was investigated as a function of thermal cycling (up to 9000 cycles) relevant to PCM-based TES systems. Microstructural changes and elemental redistribution at the alloy-salt interface under thermal cycling conditions were characterized using synchrotron-based X-ray fluorescence (XRF) and scanning electron microscopy coupled with energy dispersive X-ray spectroscopy (SEM-EDS). Results show that corrosion is governed by selective Cr-dissolution and elemental diffusion near the interface and grain boundaries. A clear transition in the dominant corrosion mechanism is observed with increasing thermal cycles. Surface corrosion is the dominant mechanism up to 1000 cycles, whereas intergranular corrosion becomes the primary degradation mode beyond 2000 cycles. These mechanistic changes are interpreted in terms of evolving interfacial chemistry, microstructure and the diffusion-driven redistribution of alloying elements.
The development of a reusable, attitude-control propulsion system for the space transportation system is discussed. A flight weight, gaseous oxygen attitude control thruster assembly was tested to obtain data on cyclic life, thermal and hydraulic characteristics, pulse response, and performance. The basic thruster components were tested in excess of 51,000 pulses and 660 seconds, steady state, with no degradation of the 93 percent characteristic exhaust velocity efficiency level. Nominal operating conditions were a chamber pressure of 207 N sq cm (300 psia), a mixture ratio of 4.0, a pulse width of 100 ms, and a pulse frequency of 2 Hz.
A technology demonstration of a Dish Stirling solar thermal electric system can be accomplished earlier and at a much lower cost than previous planning had indicated by employing technical solutions that allow already existing hardware, with minimum modifications, to be integrated into a total system with a minimum of development. The DSSR operates with a modified United Stirling p-40 engine/alternator and the JPL Test Bed Concentrator as a completely integrated solar thermal electric system having a design output of 25 kWe. The system is augmented by fossil fuel combustion which ensures a continuous electrical output under all environmental conditions. Technical and economic studies by government and industry in the United States and abroad identify the Dish Stirling solar electric system as the most appropriate, efficient and economical method for conversion of solar energy to electricity in applications when the electrical demand is 10 MWe and less.
The Advanced Automated Directional Solidification Furnace (AADSF) is a Bridgman-Stockbarger microgravity processing facility, designed and manifested to first fly aboard the second United States Microgravity Payload (USMP-2) Space Shuttle mission. The AADSF was principally designed to produce high axial thermal gradients, and is particularly suitable for metals solidification experiments, including non-dilute alloys. To accommodate a wider range of experimental conditions, the AADSF is equipped with a reconfigurable gradient zone. The overall design of the AADSF and the relationship between gradient zone design and furnace performance are described. Parametric thermal analysis was performed and used to select gradient zone design features that fulfill the high thermal gradient requirements of the USMP-2 experiment. The thermal model and analytical procedure, and parametric results leading to the first flight gradient zone configuration, are presented. Performance for the USMP-2 flight experiment is also predicted, and analysis results are compared to test data.
This investigation completed the verification of a three-dimensional resin transfer molding/resin film infusion (RTM/RFI) process simulation model. The model incorporates resin flow through an anisotropic carbon fiber preform, cure kinetics of the resin, and heat transfer within the preform/tool assembly. The computer model can predict the flow front location, resin pressure distribution, and thermal profiles in the modeled part. The formulation for the flow model is given using the finite element/control volume (FE/CV) technique based on Darcy's Law of creeping flow through a porous media. The FE/CV technique is a numerically efficient method for finding the flow front location and the fluid pressure. The heat transfer model is based on the three-dimensional, transient heat conduction equation, including heat generation. Boundary conditions include specified temperature and convection. The code was designed with a modular approach so the flow and/or the thermal module may be turned on or off as desired. Both models are solved sequentially in a quasi-steady state fashion. A mesh refinement study was completed on a one-element thick model to determine the recommended size of elements that would result in a converged model for a typical RFI analysis. Guidelines are established for checking the convergence of a model, and the recommended element sizes are listed. Several experiments were conducted and computer simulations of the experiments were run to verify the simulation model. Isothermal, non-reacting flow in a T-stiffened section was simulated to verify the flow module. Predicted infiltration times were within 12-20% of measured times. The predicted pressures were approximately 50% of the measured pressures. A study was performed to attempt to explain the difference in pressures. Non-isothermal experiments with a reactive resin were modeled to verify the thermal module and the resin model. Two panels were manufactured using the RFI process. One was a stepped panel and the other was a panel with two 'T' stiffeners. The difference between the predicted infiltration times and the experimental times was 4% to 23%.
The Capillary Flow Experiments (CFEs) are a suite of fluid physics flight experiments designed to investigate capillary flows and phenomena in low gravity. Data obtained from the CFEs will be crucial to NASA s Space Exploration Initiative, particularly pertaining to fluids management systems such as fuels and cryogen storage systems, thermal control systems (e.g., water recycling), and materials processing in the liquid state. NASA s current plans for exploration missions assume the use of larger liquid propellant masses than have ever flown on interplanetary missions. Under low-gravity conditions, capillary forces can be exploited to control fluid orientation so that such large mission-critical systems perform predictably. The first of the CFE experiments has been conducted on the International Space Station, and the data are being analyzed. The experiment suite is described briefly.
Linear friction welding (LFW) is being considered for joining single crystal to polycrystalline nickel-base alloys for advanced high temperature gas turbine disks. Unfortunately, the transient thermal cycle during the welding generates undesirable residual stresses. Additionally, upon thermal treatment to relieve these residual stresses the weld joints often crack. To understand this issue, state-of-the-art neutron diffraction was performed near weld joints to quantify the residual stresses created by varying linear friction weld conditions. The residual stresses were measured along three orthogonal axes in both the polycrystalline LSHR and single crystal SC-180 alloys. Residual stress measurements using a contour method were used to compare the calculations obtained by neutron diffraction. The results suggest high residual stresses can be successfully reduced using both pre- and post-weld processing steps. Moreover, the effect of grain size and pre-heat temperatures on the LFW process were explored.
In a Quark-Gluon Plasma (QGP), the fundamental building blocks of matter, quarks and gluons, are under extreme conditions of temperature and density. A QGP could exist in the early stages of the Universe, and in various objects and events in the cosmos. The thermodynamic and hydrodynamic properties of the QGP are described by Quantum Chromodynamics (QCD) and can be studied in heavy-ion collisions. Despite being a key thermodynamic parameter, the QGP temperature is still poorly known. Thermal lepton pairs (e + e − and μ + μ − ) are ideal penetrating probes of the true temperature of the emitting source, since their invariant-mass spectra suffer neither from strong final-state interactions nor from blue-shift effects due to rapid expansion. Here we measure the QGP temperature using thermal e+e− production at the Relativistic Heavy Ion Collider (RHIC). The average temperature from the low-mass region (in-medium ρ 0 vector-meson dominant) is (2.01 ± 0.23) × 10 12 K, consistent with the chemical freeze-out temperature from statistical models and the phase transition temperature from Lattice QCD. The average temperature from the intermediate mass region (above the ρ0 mass, QGP dominant) is significantly higher at (3.25 ± 0.60) × 10 12 K. This work provides essential experimental thermodynamic measurements to map out the QCD phase diagram and understand the properties of matter under extreme conditions.
Due to the fast advancement of communication and information technology, intelligent buildings have garnered great interest. These buildings can forecast weather, ambient temperature, and sun irradiation and can modify heating, ventilation, and air conditioning (HVAC) operations appropriately, based on current and previous data. This change is intended to reduce HVAC system energy usage while maintaining an appropriate degree of thermal comfort and indoor air quality. Since its inception, model predictive control (MPC) has been one of the prospective solutions for HVAC management systems to reduce both costs and energy usage. Additionally, MPC is becoming increasingly practical as the processing capacity of building automation systems increases and a large quantity of monitored building data becomes available. MPC also provides the potential to improve the energy efficiency of HVAC systems via its capacity to consider limitations, to predict disruptions, and to factor in multiple competing goals such as interior thermal comfort and building energy consumption. Although substantial research has been conducted on MPC in building HVAC systems, there is a shortage of critical reviews and a lack of a comprehensive framework that formulates and defines the applications. Here, this article provides a comprehensive state-of-the-art overview of MPC in HVAC systems. Detailed discussions of modeling approaches and optimization algorithms are included. Numerous design aspects such as prediction horizon, occupancy behavior, building type, and cost function, that impact MPC performance are discussed in detail. The technical characteristics, advantages, and disadvantages of various types of modeling software are discussed. The primary objective of this work is to highlight critical design characteristics for the MPC control scheme and to give improved suggestions for future research. Moreover, numerous prospective scenarios have been suggested that might provide future research direction.
Headers are crucial components within diverse industries, especially in the energy sector, as they enable the efficient transfer of fluids. The selection of materials for headers is determined by their specific applications; for example, Grade 91 and Grade 92 steels are commonly utilized. In our research, we recommend the adoption of INCONEL alloy 740 due to its exceptional robustness and heat-resistant characteristics. One critical parameter in header systems is the heat transfer coefficient, which directly influences the efficiency of heat exchange processes and can thereby impact the structural integrity of the headers. This coefficient is closely linked with factors such as the Nusselt number, which is influenced by fluid flow characteristics and thermal properties. The flow direction within headers, whether unidirectional or multidirectional—significantly affects the overall dynamics of heat transfer. This research focuses on exploring the behavior of headers, a specific pipeline system component, using ANSYS simulation software. The study aims to predict heat transfer and mechanical behavior within headers under various conditions through steady-state and transient simulations (parts 1 and 2 of the report). Key parameters such as heat transfer coefficient, velocity, and temperature are examined with the goal of optimizing header design. Part 3 of the report addresses the critical yet underexplored relationship between pressure drop and heat transfer coefficients in the transient flow regime within headers, specifically focusing on smooth horizontal circular tubes. Limited experimental work has been conducted in this area, prompting the need for comprehensive analysis. By leveraging machine learning techniques, this research aims to establish a correlation between pressure drop and heat transfer across various flow conditions, including laminar, transient, quasi-turbulent, and turbulent regimes. The data utilized for this analysis were meticulously gathered from existing literature, capturing simultaneous measurements of pressure drops and heat transfer. Part 4: In the context of power plants, header pipes are essential components that significantly influence system performance by facilitating the collection and distribution of steam. This report highlights the critical role of header pipes in enhancing reliability, efficiency, and overall power plant performance. A key aspect of this investigation is shape optimization, which aims to maximize performance while minimizing material usage. By focusing on shape optimization, this research contributes to improved efficiency and a reduced environmental footprint for power plant installations. The methodology developed in this study emphasizes optimizing header shapes to decrease reliance on expensive alloy materials and lower maintenance costs. Furthermore, a case study was conducted using a header from an operational power plant to validate the proposed optimization techniques. Finally, part 5 addresses the challenges associated with flexible operations in boiler systems, the study outlines several strategies for enhancing the durability and reliability of steam headers. Key approaches include material selection, which involves utilizing advanced materials with superior high-temperature properties and enhanced fatigue resistance to extend the lifespan of steam headers. Design modifications are also recommended, focusing on implementing changes that mitigate thermal stress and cyclic loading to reduce the likelihood of failures under varying operating conditions. Additionally, the study emphasizes the importance of regular inspection and monitoring by establishing rigorous protocols to detect early signs of damage, allowing for timely maintenance and minimizing the risks of catastrophic failures. Furthermore, operational guidelines are developed to minimize the frequency and severity of thermal transients, ensuring stable and efficient operations. Collectively, these strategies provide a robust framework for overcoming the unique challenges posed by flexible operation in boiler systems, ultimately contributing to improved reliability and performance in power plant operations. Through this comprehensive approach, the study not only enhances the understanding of pressure drop and heat transfer relationships but also promotes advancements in design and operation that will benefit the entire power generation industry.
Hydrides that retain their hydrogen in service are critical for advanced microreactor and space nuclear systems. Hydrogen retention is affected by evolving microstructure under temperature and irradiation extremes. This study investigated microstructural features in neutron-irradiated yttrium hydride and the stability of these features under thermal cycles. Differential scanning calorimetry was used to determine hydrogen desorption and temperatures at which significant phase changes are occurring, and transmission electron microscopy was used for microstructural analysis after each thermal cycle. Cyclic heating led to crystallization and epitaxial growth of surface oxidation and dehydriding of the matrix. Other features such as the bulk matrix crystal structure, irradiation-induced cavities, and matrix precipitation remained constant after thermal cycling. Results allow us to design better hydride alloys through microstructure tailoring and potential irradiation conditioning treatments.
This brief highlight details the key takeaways from a project that utilized NLR's Fleet Research, Energy Data, and Insights (FleetREDI) data analysis pipeline related to electric school bus (ESB) operation. ESBs using battery energy as their primary heating source have a higher energy consumption rate in cold weather, which fleet managers can account for when planning ESB purchases and making dispatching and charging decisions. Researchers found that electric school buses operate 2-5 times more efficiently than conventional buses, on average. Cold weather can double electric school bus energy demands, but strategies such as thermal pre-conditioning significantly reduce this effect. Understanding these impacts can help fleets plan charging, dispatching, and purchase decisions.
With the surge in electric vehicle (EV) adoption and the need for extended driving ranges, optimizing energy efficiency, particularly through thermal management, is critical, especially in extreme weather. Managing the substantial energy needed for cabin climate control and battery temperature regulation can increase energy demands by over 50 %, severely limiting range. This study conducts a comparative analysis of thermal management systems (TMS) in three popular EV vehicles, 2020 Chevrolet Bolt, 2019 Nissan Leaf Plus, and 2020 Tesla Model 3, evaluating their distinct TMS configurations and performance under varied weather conditions. Using both numerical simulations and experimental data collected on a controlled test bench at Argonne National Laboratory, we assess how TMS architecture and operational modes influence energy consumption and range. A comprehensive TMS model was developed, integrating cabin and battery thermal sub-models in the Autonomie software platform, to simulate temperature fluctuations and range impacts. Cabin climate was modeled using a mono-zonal approach, while battery cell temperature distribution was estimated through a 2D nodal structure. Each vehicle's distinct TMS setup was evaluated: the Chevrolet Bolt and Tesla Model 3 use a dual evaporator vapor compression cycle with a PTC heater for the cabin and a coolant loop for battery thermal management; the Nissan Leaf Plus employs a heat pump with a PTC heater for the cabin and air-cooling for the battery. Tests conducted at ambient temperatures of 35°C, 22°C, -7°C, and -18°C reveal significant differences in energy use and range reduction across both configurations and conditions. At 35°C, the Tesla Model 3, Chevrolet Bolt, and Nissan Leaf Plus have a range reduction of 8%, 9%, and 13%, respectively, due to air conditioning. In winter, heating technology is paramount; at -7°C, the Nissan Leaf's heat pump configuration achieves a lower range reduction (19.3%) compared to the Tesla and Chevrolet Bolt PTC heaters, which reduce range by 28.3% and 31%, respectively. Further, this study provides valuable insights for automotive engineers, EV technology researchers, and thermal management system designers aiming to enhance electric vehicle performance by understanding how different weather conditions and TMS architectures impact energy consumption and driving range.
We consider the atomic mixing of two materials, initially separated in space, at fixed temperature– pressure conditions [T, p], and zero mass-mean velocity. Each material is composed of a specified set of atomic species whose density corresponds to the specieswise real Equation of State (EOS) $\tilde{ρ}$ i [T, p]. Because there are no spatial gradients in the mean [T, p] state, the only mechanism for mixing is a specieswise nonequilibrium thermal velocity distribution. The recipe for nonequilibrium species mass fluxes is taken directly from Hirschfelder, Curtiss, and Bird, who express the diffusion velocities in terms of gradients in the molar concentrations and pairwise coefficients of diffusion. EOS data from the SESAME library is used for all species. Data for the specieswise self diffusion coefficients is adopted from the Orbital Free Molecular Dynamics (OFMD) simulations of Ticknor et al.; the so-called Darken approximation is used to express the mutual diffusion coefficients of a mixture in the manner used by White et al. A one-dimensional spatial domain is used; with the left half occupied by one multispecies material and the right half occupied by the other, and with zero–gradient boundary conditions at the ends of the domain. Hence the total mass in the domain is a constant. At time t = 0 the materials are separated. Accordingly, spatial gradients at the separation point are infinite and the species fluxes are also infinite. As t → $\textbf{∞}$ the spatial gradients approach zero and a uniform set of species concentrations is obtained; at this point the system is said to be at “thermodynamic equilibrium.” Analytic solution of the problem is not possible in general due to the nonlinear concentration dependence of the species fluxes. Hence we utilize the numerical solution apparatus in Mathematica for obtaining accurate time-dependent solutions for the mixing of various initial species masses for conditions of interest in laser-driven Inertial Confinement Fusion. Concentration profiles and the speed of propagation of the mixing fronts are discussed in light of the nonlinearity of the problem.
Abstract Accurate knowledge of the phase transitions and thermoelastic properties of candidate iron alloys, such as Fe‐Si alloys, is essential for understanding the nature and dynamics of planetary cores. The phase diagrams of some Fe‐Si alloys between 1 atm and 16 GPa have been back‐extrapolated from higher pressures, but the resulting phase diagram of Fe 83.6 Si 16.4 (9 wt.% Si) is inconsistent with temperature‐induced changes in its electrical resistivity between 6 and 8 GPa. This study reports in situ synchrotron X‐ray diffraction (XRD) measurements on pre‐melted and powder Fe 83.6 Si 16.4 samples from ambient conditions to 60 GPa and 900 K using an externally heated diamond‐anvil cell. Upon compression at 300 K, the bcc phase persisted up to ∼38 GPa. The hcp phase appeared near 8 GPa in the pre‐melted sample, and near 17 GPa in the powder sample. The appearance of the hcp phase in the pre‐melted sample reconciles the reported changes in electrical resistivity of a similar sample, thus resolving the low‐pressure region of the phase diagram. The resulting high‐temperature Birch‐Murnaghan equation of state (EoS) and thermal EoS based on the Mie‐Gruneisen‐Debye model of the bcc and hcp structures are consistent with, and complement the literature data at higher pressures. The calculated densities based on the thermal EoS of Fe‐9wt.%Si indicate that both bcc and hcp phases agree with the reported core density estimates for the Moon and Mercury.
A dynamic building envelope integrated with thermal energy storage, such as phase change material (PCM), is an emerging technology that offers a promising solution to improve the energy efficiency of buildings. This study reports the development of insertable thermal switches, which modulate thermal resistance, thereby making building envelopes dynamic and enhancing the use of free ambient heating and cooling. The reported thermal switches are passive, meaning they work solely based on indoor and outdoor temperatures. A single switch when inserted into 10 × 10-in (0.064-m 2 ) XPS foam board insulation demonstrates effective thermal conductivity of 0.050 W/m-K in the resistive state and 0.285 W/m-K in the conductive state. Thermal switches exhibit an effective switching ratio of 5.7, with no noticeable degradation in performance over 770 cycles. Additionally, when integrated into a wall sample containing a PCM layer, switches significantly reduce the PCM solidification time by 43.2% during the cooling process.