Thermal system engineering experiment
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.
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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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NASA Environmentally Responsible Aviation's Highly-Loaded Front Block Compressor Demonstration
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.
ERA↗
The influence of advanced processing on PWA 1480
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.
Fritzemeier, L. G.↗
Additive Manufacturing Thermal Performance Testing of Single Channel GRCop-84 SLM Components
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.
Garcia, Chance P.↗
Thermal Performance Testing of Single Channel GRCop-84 SLM Components
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.
Garcia, Chance P.↗
Development of High Fidelity, Fuel-Like Thermal Simulators for Non-Nuclear Testing
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.
Bragg-Sitton, S. M.↗
Development Status and Performance Comparisons of Environmental Barrier Coating Systems for SiCSiC Ceramic Matrix Composites
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.
Processing and Properties↗
Strength optimization of alpha-SiC by improved processing
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.
Dutta, Sunil↗
Manufacturing, Characterization and Terrestrial Passive Radiative Cooling Performance of Nanofibrous PTFR-PEO Composite Thermal Coatings
Passive heat management is desirable in many applications since it can reduce the energy expended for cooling, for example, in buildings and automobiles. Specifically, materials with wavelength-dependent reflectance and emittance can manage incident solar fluxes while enabling passive radiative cooling by thermal emission. This study demonstrates the use of polymeric nanofibers, specifically polytetrafluoroethylene (PTFE) and polyethylene oxide (PEO) composite, as thermal coatings for passive temperature control. Employing the electrospinning fabrication process, we engineer nano and micro-scale fibrous structures, studying the influence of fabrication parameters, such as precursor material concentration and rotating collector speed, on fiber geometry and optical properties. To understand the role of material and fiber geometry on optical performance, we characterize various samples' spectral reflectance, absorptance, and transmittance using spectrophotometers interfaced with integrating spheres. The results show the potential of nanofabricated PTFE-PEO coatings as promising candidates for passive thermal control. We highlight their competitive edge by comparing their solar reflectance and emittance values to existing passive radiative thermal control materials. In essence, this study contributes to advancing passive heat management technologies, offering insights into optimizing material composition and fabrication techniques for enhanced performance in various applications.
Chieloka Ibekwe↗
Robust Low Cost Liquid Rocket Combustion Chamber by Advanced Vacuum Plasma Process
Next-generation, regeneratively cooled rocket engines will require materials that can withstand high temperatures while retaining high thermal conductivity. Fabrication techniques must be cost efficient so that engine components can be manufactured within the constraints of shrinking budgets. Three technologies have been combined to produce an advanced liquid rocket engine combustion chamber at NASA-Marshall Space Flight Center (MSFC) using relatively low-cost, vacuum-plasma-spray (VPS) techniques. Copper alloy NARloy-Z was replaced with a new high performance Cu-8Cr-4Nb alloy developed by NASA-Glenn Research Center (GRC), which possesses excellent high-temperature strength, creep resistance, and low cycle fatigue behavior combined with exceptional thermal stability. Functional gradient technology, developed building composite cartridges for space furnaces was incorporated to add oxidation resistant and thermal barrier coatings as an integral part of the hot wall of the liner during the VPS process. NiCrAlY, utilized to produce durable protective coating for the space shuttle high pressure fuel turbopump (BPFTP) turbine blades, was used as the functional gradient material coating (FGM). The FGM not only serves as a protection from oxidation or blanching, the main cause of engine failure, but also serves as a thermal barrier because of its lower thermal conductivity, reducing the temperature of the combustion liner 200 F, from 1000 F to 800 F producing longer life. The objective of this program was to develop and demonstrate the technology to fabricate high-performance, robust, inexpensive combustion chambers for advanced propulsion systems (such as Lockheed-Martin's VentureStar and NASA's Reusable Launch Vehicle, RLV) using the low-cost VPS process. VPS formed combustion chamber test articles have been formed with the FGM hot wall built in and hot fire tested, demonstrating for the first time a coating that will remain intact through the hot firing test, and with no apparent wear. Material physical properties and the hot firing tests are reviewed.
Holmes, Richard↗
Microwave Debinding of Ceramics Produced by Additive Manufacturing
Microwave-assisted debinding offers an innovative approach to processing 3D-printed engineering ceramics. Ceramic parts produced with photopolymer-based additive manufacturing techniques require thermal debinding to remove polymers that bind ceramic particles during the printing process. Microwave-assisted debinding significantly reduces processing times and offers energy savings over conventional thermal treatments due to higher heating rates and more uniform heating. Finite-element modeling of the debinding process allows for the optimization and prediction of temperature distribution, stress development, and potential defects, leading to improved process control and material quality.
36 - MATERIALS SCIENCE↗
Heat Analysis Manager (HAM), a Thermal Desktop API Based Heat Map Generation Software
Thermal engineers often create custom heat maps to analyze their thermal model. However, generating a heat map is difficult because thermal simulation only readily provide attributes of simulated nodes such as temperature, capacitance, heat generation, and a network of conductances. Heat flow values are a derived quantity from the nodal attributes, and the data processing and management of heat flow between nodes quickly become difficult for large models. Deriving a network of heat flow values requires vast amount of calculations and data handling, heat map generation process generally suffers from processing speed, loss of accuracy, and/or presentation of data in a useful format. Heat Analysis Manager (HAM) is a Thermal Desktop (TD) based free multi-purpose tool developed to aid thermal engineers in analyzing their thermal model, including a heat map generation functionality. HAM’s heat map generator retains accuracy and fast processing speed by utilizing TD’s application programming interface (API) and built-in TD’s “Qflow from Results.” Furthermore, HAM’s heat map output is presented in an easily customizable format in Excel, allowing users to create various custom visual heat maps. A full description of how HAM utilizes TD’s API to create a customizable heat map is provided. A simple model demonstration is included along with step-by-step procedures on creating custom heat maps. HAM’s heat map result has been verified against TD’s and other heat map generation software, and verification methods are also included.
Thermal desktop↗
Transpiration Cooling Experiment
The transpiration cooling method was considered for a scram-jet engine to accommodate thermally the situation where a very high heat flux (200 Btu/sq. ft sec) from hydrogen fuel combustion process is imposed to the engine walls. In a scram-jet engine, a small portion of hydrogen fuel passes through the porous walls of the engine combustor to cool the engine walls and at the same time the rest passes along combustion chamber walls and is preheated. Such a regenerative system promises simultaneously cooling of engine combustor and preheating the cryogenic fuel. In the experiment, an optical heating method was used to provide a heat flux of 200 Btu/sq. ft sec to the cylindrical surface of a porous stainless steel specimen which carried helium gas. The cooling efficiencies by transpiration were studied for specimens with various porosity. The experiments of various test specimens under high heat flux have revealed a phenomenon that chokes the medium flow when passing through a porous structure. This research includes the analysis of the system and a scaling conversion study that interprets the results from helium into the case when hydrogen medium is used.
Song, Kyo D.↗
True Concurrent Thermal Engineering Integrating CAD Model Building with Finite Element and Finite Difference Methods
Thermal engineering has long been left out of the concurrent engineering environment dominated by CAD (computer aided design) and FEM (finite element method) software. Current tools attempt to force the thermal design process into an environment primarily created to support structural analysis, which results in inappropriate thermal models. As a result, many thermal engineers either build models "by hand" or use geometric user interfaces that are separate from and have little useful connection, if any, to CAD and FEM systems. This paper describes the development of a new thermal design environment called the Thermal Desktop. This system, while fully integrated into a neutral, low cost CAD system, and which utilizes both FEM and FD methods, does not compromise the needs of the thermal engineer. Rather, the features needed for concurrent thermal analysis are specifically addressed by combining traditional parametric surface based radiation and FD based conduction modeling with CAD and FEM methods. The use of flexible and familiar temperature solvers such as SINDA/FLUINT (Systems Improved Numerical Differencing Analyzer/Fluid Integrator) is retained.
Panczak, Tim↗
Truchas Overview
Truchas and Truchas-PBF are two sister codes for part-scale multi-physics modeling of manufacturing processes. Both programs are open source and made publicly available. They’re designed for efficient use of HPC resources and can be programmatically driven from Python packages. This enables automatic execution and analysis of ensembles of simulations, in some cases allowing 1000s of simulations to be evaluated in a day on HPC. Beyond just giving engineers a window into the concealed internal state of a system, the goal of Truchas is to provide a framework for developing novel manufacturing processes by understanding how the entire space of engineering inputs affects thermal state. It often is used to explore combinations of capabilities uncommon in commercial software, or to scale up analyses beyond the capabilities of commercial software.
97 MATHEMATICS AND COMPUTING↗
Process development for a dispersion strengthened cobalt base alloy Final report, 25 Jun. 1968 - 24 Mar. 1969
Flash drying selective reduction processes for oxidative and thermal resistant cobalt alloys for air breathing engines
Irani, K. K.↗
Basic failure mechanisms in advanced composites
The fundamental failure mechanisms which result from the interaction of thermal cycling and mechanical loading of carbon-epoxy composites were studied. This work was confined to epoxy resin uniderictionally reinforced with HTS carbon fibers, and consists of first identifying local fiber, matrix and interface failure mechanisms using the model composite specimen containing a small number of fibers so that optical techniques can be used for characterization. After the local fracture process has been established for both mechanical loading and thermal cycling, engineering composite properties and gross fracture modes are then examined to determine how the local events contribute to real composite performance. Flexural strength in high fiber content specimens shows an increase in strength with increased thermal cycling. Similar behavior is noted for 25 v/o material up to 200 cycles; however, there is a drastic reduction after 200 cycles indicating a major loss of integrity probably through the accumulation of local cleavage cracks in the tensile region.
Mazzio, V. F.↗
Future planetary probes for Jupiter and Saturn
The paper describes a study conducted to identify the technology developments that would allow deep atmospheric investigations of Jupiter and Saturn to proceed beyond currently planned investigation of the upper atmosphere. The study considered a deep probe mission that would provide the capability to scientifically examine planetary atmospheres to the 1000-bar level and 1400-K level. The major conclusions of the study are that (1) a probe designed for Jupiter can be used with minor changes for Saturn, (2) new science instrument technology developments are required, and (3) the only new technology developments required in the engineering subsystem are high pressure thermal insulation materials and advanced data processing techniques.
Butts, A. J.↗