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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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Analysis of thermal test errors resulting from imperfectly collimated solar simulation beams - relative energy flux density and relative energy in penumbrae of various shadowing objects
This report details operations and maintenance (O&M) activities performed across Fiscal Years 2022 through 2024 in support of the continued capabilities of the National Solar Thermal Testing Facility (NSTTF) at Sandia National Laboratories. The NSTTF O&M project is funded by the U.S. Department of Energy Solar Energy Technologies Office (SETO) to support research activities and testing on behalf of external customers at the facility under award number CPS 38491. During the project period, the NSTTF made progress in the areas of site metrics, site maintenance and utilization tracking, and customer engagement. The O&M project also supported special initiatives including procurement of a heat exchanger for particle concentrating solar thermal processes and a scoping and cost study for refurbishment and repair of component in the NSTTF heliostat field.
In January 2004, two Mars Exploration Rovers (MER) landed on the surface of Mars to begin their mission as robotic geologists. A year prior to these historic landings, both rovers and the spacecraft that delivered them to Mars, were completing a series of environmental tests in facilities at the Jet Propulsion Laboratory. This paper describes the test program undertaken to validate the thermal design and verify the workmanship integrity of both rovers and the spacecraft. The spacecraft, which contained the rover within the aeroshell, were tested in a 7.5 m diameter thermal vacuum chamber. Thermal balance was performed for the near earth (hot case) condition and for the near Mars (cold case) condition. A solar simulator was used to provide the solar boundary condition on the solar array. IR lamps were used to simulate the solar heat load on the aeroshell for the off-sun attitudes experienced by the spacecraft during its cruise to Mars. Each rover was tested separately in a 3.0 m diameter thermal vacuum chamber over conditions simulating the warmest and coldest expected Mars diurnal temperature cycles. The environmental tests were conducted in a quiescent nitrogen atmosphere at a pressure of 8 to 10 Torr. In addition to thermal balance testing, the science instruments on board the rovers were tested successfully in the extreme environmental conditions anticipated for the mission. A solar simulator was not used in these tests.
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The characteristics of a cryogenic tank for storing liquid hydrogen, nitrogen, oxygen, methane, or helium for an extended period of time with minimum losses are discussed. A description of the tank and control module, assembly drawings and details of major subassemblies, specific requirements controlling development of the system, thermal concept considerations, thermal analysis methods, and a record of test results are provided. The oxygen thermal test article thermal protection system has proven that the insulation system for cryogenic vessels is effective.
Spacecraft testing specifications differ greatly in the criteria they specify for stability in thermal balance tests. Some specify a required temperature stabilization rate (the change in temperature per unit time, dT/dt), some specify that the final steady-state temperature be approached to within a specified difference, delta T , and some specify a combination of the two. The particular values for temperature stabilization rate and final temperature difference also vary greatly between specification documents. A one-size-fits-all temperature stabilization rate requirement does not yield consistent results for all test configurations because of differences in thermal mass and heat transfer to the environment. Applying a steady-state temperature difference requirement is problematic because the final test temperature is not accurately known a priori, especially for powered configurations. In the present work, a simplified, lumped-mass analysis has been used to explore the applicability of these criteria. A new, user-friendly, physics-based approach is developed that allows the thermal engineer to determine when an acceptable level of temperature stabilization has been achieved. The stabilization criterion can be predicted pre-test but must be refined during test to allow verification that the defined level of temperature stabilization has been achieved.
The theory shown here can provide thermal stability criteria based on physics and a goal steady state error rather than on an arbitrary "X% Q/mC(sub P)" method. The ability to accurately predict steady-state temperatures well before thermal balance is reached could be very useful during testing. This holds true for systems where components are changing temperature at different rates, although it works better for the components closest to the sink. However, the application to these test cases shows some significant limitations: This theory quickly falls apart if the thermal control system in question is tightly coupled to a large mass not accounted for in the calculations, so it is more useful in subsystem-level testing than full orbiter tests. Tight couplings to a fluctuating sink causes noise in the steady state temperature predictions.
Methods and apparatus for the testing of below-ambient temperature thermal insulation systems have been developed based on boiloff calorimetry. Boiloff calorimetry provides a direct measure of heat flow for below-ambient temperature conditions. The effective thermal conductivity (ke) and heat flux (q) of a test specimen are calculated for a fixed environmental condition (warm boundary temperature; cold boundary temperature; ambient or vacuum pressure). Through its heat of vaporization, liquid nitrogen (LN2) serves as the energy meter. Different apparatus have been built for flat-plate, cylindrical, and pipeline test specimens. Boundary temperatures can range from 353 K down to 77 K (80 C to -196 C). By interposing different insulation layers on the cold boundary, the cryogenic boiloff method is suitable for a wide range of below-ambient temperature applications. A cylindrical apparatus, Cryostat-100, as well as the pipeline test apparatus, Cryostat-P100, are thermally guarded and directly measure absolute thermal performance in watts. Pipe insulation systems can be mechanical, double-walled, or vacuum-jacketed including materials such as foams, cellular glass, aerogel blankets, clam-shell panels, and multilayer insulation. Two test pipelines, 12-meter-long, are mounted between two cold box assemblies. The test pipeline diameter is from 25-mm to 76-mm while the maximum outside diameter including insulation is up to 204-mm. The cold pipe tester design and test methods are discussed, as well as results for select thermal insulation materials. Progress toward a comparative type, bench-top cold pipe tester (Cryostat-P200) is also discussed.
Two SAFE 30 modules were tested to determinate the thermal conductivity efficiency of the tri-cusps filled between the heat pipe and the heater cores. The modules consisted of four one-inch diameter tubes with heaters joined to an empty 1 inch diam. tube. The test was conducted on a vacuum chamber with 4 configurations: tri-cusps filled with and without radiation shielding and non-filled tri-cusps with and without radiation shielding. The tri-cusps material helps the bonding of the heat pipe to the four electric heater cores, filling the gap between the pipes. The baseline configuration is a brazed joint between the pipe. The test consisted of controlling the power applied to the heaters until a set surface temperature is reach. The temperatures varied between a max. of 800 C to 500 C. Test data, input energy and chamber surface temperature from each individual test, was used as boundary conditions for the model. Nodes located on the same location as the test thermocouples were plotted again test data to determinate the accuracy of the analysis. The unknown n variables on the analysis are the radiation emissivity of the pipe and chamber and the radiation view factor between the module and the chamber. A correlation was determined using a parametric analysis varying the surface emissivity and view factor until a good match was reach.
Testing of electronic assemblies varies throughout industry, NASA, and the military. Differences include test levels, atmospheric versus vacuum testing of assemblies, dwell durations at temperature extremes (especially high temperature), and thermal cycling versus dwell testing. Of particular interest are the different philosophies of thermal cycling versus single-cycle thermal dwell. An examination of the various failure physics for electronic assemblies has been initiated at JPL. The intent is to determine which failure modes are best revealed by thermal cycling testing and which are susceptible to high-temperature dwell physics. Preliminary results of this study are presented, along with discussions of testing goals, flight environments, reliability models, and the differences between industry and JPL design/test approaches.
A spacecraft module, to be integrated with the FLTSATCOM spacecraft, was tested in a simulated orbit environment separate from the host spacecraft. Thermal vacuum testing of the module was accomplished using internal IR heating rather than conventional external heat sources. For this configuration, the technique produced boundary conditions expected for flight to enable verification of system performance and thermal design details.
The Mu2e experiment requires a production target capable of operating under extreme thermal conditions caused by an 8 GeV proton beam. This project’s objective supports the development of the Mu2e Production Target by testing the Stickman model’s thermal behavior. To test this, Angel Flores Luviano has assisted Jonathan Williams in progressing this project by contributing to the development of a Radiative Cooling Test Fixture (RCTF) that will be used to evaluate the thermal behavior of the new production target model. Engineering calculations were performed to analyze thermal performance and pressure drop within the cold well and water cooling circuit, and determine optimal sizing for key components of the water system. An engineering note was made to document the calculations. CAD models of the water circuit piping, thermocouple mount, and radiator chimney were developed, and prototype test rig components were fabricated using 3D printing. Future work will focus on conti nued RCTF development which includes control system integration, heater hardware design, and interfaces that can be scaled up to increase thermal capacity.
The Magnetospheric Multiscale (MMS) mission is a Solar Terrestrial Probes mission comprising four identically instrumented spacecraft that will use Earth's magnetosphere as a laboratory to study the microphysics of three fundamental plasma processes: magnetic reconnection, energetic particle acceleration, and turbulence. This paper presents the complete thermal balance (TB) test performed on the first of four observatories to go through thermal vacuum (TV) and the minibalance testing that was performed on the subsequent observatories to provide a comparison of all four. The TV and TB tests were conducted in a thermal vacuum chamber at the Naval Research Laboratory (NRL) in Washington, D.C. with the vacuum level higher than 1.3 x 10 (sup -4) pascals (10 (sup -6) torr) and the surrounding temperature achieving -180 degrees Centigrade. Three TB test cases were performed that included hot operational science, cold operational science and a cold survival case. In addition to the three balance cases a two hour eclipse and a four hour eclipse simulation was performed during the TV test to provide additional transient data points that represent the orbit in eclipse (or Earth's shadow) The goal was to perform testing such that the flight orbital environments could be simulated as closely as possible. A thermal model correlation between the thermal analysis and the test results was completed. Over 400 1-Wire temperature sensors, 200 thermocouples and 125 flight thermistor temperature sensors recorded data during TV and TB testing. These temperature versus time profiles and their agreements with the analytical results obtained using Thermal Desktop and SINDA/FLUINT are discussed. The model correlation for the thermal mathematical model (TMM) is conducted based on the numerical analysis results and the test data. The philosophy of model correlation was to correlate the model to within 3 degrees Centigrade of the test data using the standard deviation and mean deviation error calculation. Individual temperature error goal is to be within 5 degrees Centigrade and the heater power goal is to be within 5 percent of test data. The results of the model correlation are discussed and the effect of some material and interface parameters on the temperature profiles are presented.
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International Conference on Envronmental Systems (ICES), Seattle WA NCTS 20964-15. The Magnetospheric Multiscale (MMS) mission is a Solar Terrestrial Probes mission comprising four identically instrumented spacecraft that will use Earths magnetosphere as a laboratory tostudy the microphysics of three fundamental plasma processes: magnetic reconnection, energetic particle acceleration, and turbulence. This paper presents the complete thermal balance (TB) test performed on the first of four observatories to go through thermal vacuum (TV) and the minibalance testing that was performed on the subsequent observatories to provide a comparison of all four. The TV and TB tests were conducted in a thermal vacuum chamber at the Naval Research Laboratory (NRL) in Washington, D.C. with the vacuum level higher than 1.3 x 10-4 Pa (10-6 torr)and the surrounding temperature achieving -180 C. Three TB test cases were performed that included hot operational science, cold operational science and a cold survival case. In addition to the three balance cases a two hour eclipse and a four hour eclipse simulation was performed during the TV test to provide additional transient data points that represent the orbit in eclipse (or Earth's shadow) The goal was to perform testing such that the flight orbital environments could be simulated as closely as possible. A thermal model correlation between the thermal analysis and the test results was completed. Over 400 1-Wire temperature sensors, 200 thermocouples and 125 flight thermistor temperature sensors recorded data during TV and TB testing. These temperatureversus time profiles and their agreements with the analytical results obtained using Thermal Desktop and SINDAFLUINT are discussed. The model correlation for the thermal mathematical model (TMM) is conducted based on the numerical analysis results and the test data. The philosophy of model correlation was to correlate the model to within 3 C of the test data using the standard deviation and mean deviation error calculation. Individual temperature error goal is to be within 5 C and the heater power goal is to be within 5 of test data. The results of the model correlation are discussed and the effect of some material and interface parameters on the temperature profiles are presented.
NASAs future robotic missions to Venus and outer planets, namely, Saturn, Uranus, Neptune, result in extremely high entry conditions that exceed the capabilities of current mid density ablators (PICA or Avcoat). Therefore mission planners assume the use of a fully dense carbon phenolic heatshield similar to what was flown on Pioneer Venus and Galileo. Carbon phenolic (CP) is a robust TPS however its high density and thermal conductivity constrain mission planners to steep entries, high heat fluxes, high pressures and short entry durations, in order for CP to be feasible from a mass perspective. In 2012 the Game Changing Development Program in NASAs Space Technology Mission Directorate funded NASA ARC to investigate the feasibility of a Woven Thermal Protection System to meet the needs of NASAs most challenging entry missions. The high entry conditions pose certification challenges in existing ground based test facilities. Recent updates to NASAs IHF and AEDCs H3 high temperature arcjet test facilities enable higher heatflux (2000 Wcm2) and high pressure (5 atm) testing of TPS. Some recent thermal tests of woven TPS will be discussed in this paper. These upgrades have provided a way to test higher entry conditions of potential outer planet and Venus missions and provided a baseline against carbon phenolic material. The results of these tests have given preliminary insight to sample configuration and physical recession profile characteristics.
The aim was to simulate, in a ground test, the solar radiation environment to which the Ofeq satellite would be exposed in orbit. The solar simulator usually used is very expensive, as are its operation and maintenance, therefore an infrared (IR) simulator was used; its development involved the creation of uniform IR fluxes onto the irregular geometry of a spacecraft. The tests were carried out on a thermal model of the satellite and the model was verified in a solar simulator test at a European space center. Heat flux mapping software was developed to plan the positioning of the heating elements which generated the IR fluxes and a system was built for heat flux and temperature monitoring and control. A special heat flux sensor was developed to measure the energy absorbed by the satellite surfaces; its calibration had to be independent of wavelength, so that the measurements obtained at IR wavelengths would be equivalent to the actual solar radiation effects. The results of the verification experiment are presented; their conformity with predicted values indicates that the technique developed is a suitable tool for satellite design verification.