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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Rapid Development of Instrument Thermal Models: Perspectives and Guidelines from NASA Goddard’s Instrument Design Laboratory

The Instrument Design Laboratory (IDL), part of NASA Goddard Space Flight Center’s Integrated Design Center (IDC), is a concurrent and collaborative environment which allows for rapid development of science instrumentation concepts within the span of less than two weeks. Science goals set by a Principal Investigator from government, industry or academia are translated into engineering requirements, from which a team of engineers spanning multiple disciplines use an established study process and a suite of analysis tools to work towards an instrument point design. As part of this process, a staff thermal engineer is tasked with designing a thermal control system which meets all incoming thermal requirements, while iterating real-time with other subsystems to ensure compatibility and functionality as a completed system. Thermal engineers on spaceflight projects typically have weeks or months to develop thermal models. However, the severe time limitation in this conceptual study setting makes thermal design particularly difficult, as rapid thermal modeling solely over the span of a few days is required to develop the instrument thermal design and understand the performance over its intended mission, especially if the instrument concept contains multiple thermal challenges such as dynamic environments or high heat dissipating components. In this paper, the authors provide a condensed guide for the most efficient ways to develop thermal models and conduct thermal analysis within the span of one-to-two weeks, as informed by decades of design experience and best practices in the IDL. The authors also focus on quick methods for determining worst-case thermal environments, deciding which modeling details are essential at this early phase, and quantifying the engineering resources necessary for thermal control. This paper concludes with specific thermal design tips for different instrument types across the electromagnetic spectrum.

Kan Yang↗
NASA NTRSDate not supplied

MEDLI2 Material Response Model Development and Validation

During the entry of Mars Science Laboratory (MSL) the heatshield was equipped with the instrumentation suite Mars Entry, Descent, and Landing Instruments (MEDLI). In-depth thermocouple (TC) data was used to reconstruct the surface heating and temperatures. Discrepancies between MEDLI’s recorded in-depth heating data and the predicted thermal response and recession led to a campaign to characterize and test Mars Entry, Descent, and Landing Instrument 2 (MEDLI2) flight lot thermal protection materials (TPS) at relevant temperatures and pressures for Martian entry conditions. This paper covers the development and validation of MEDLI2 flight lot material response models for the heatshield material Phenolic Impregnated Carbon Ablator (PICA) and the backshell material Super-Lightweight Ablator (SLA-561V). Virgin and char thermal conductivities were updated as a function of temperature and pressure in the MEDLI2 specific material response models. Other material properties such as virgin and char density, emissivity, absorptivity, and specific heat capacitance was also characterized and compared to the “Heritage” models used during the TPS design phase of Mars 2020. Fully Implicit Ablation and Thermal response (FIAT) simulations were completed using the Heritage and MEDLI2 material response models to provide evidence of the increased accuracy of the MEDLI2 model. FIAT predicted in-depth temperatures were compared to flight lot certification ground-test arc jet test data and MEDLI2 flight thermocouple data.

Material response↗
NASA NTRSDate not supplied

Isolating the Surface Type Influence on Arctic Cloud Properties

In response to anthropogenic climate change, substantial declines in sea ice have been observed. An urgent question is whether and how clouds respond to the changing Arctic surface. Due to the important radiative influence of clouds, the response of clouds to sea ice cover change constitutes a potentially important climate feedback within the Arctic. The sign of this feedback is strongly influenced by the seasonality of the cloud response to sea ice loss. Given the importance of this phenomenon, previous research focused on using observations of inter-annual variability to quantify the cloud-sea ice relationship. However, the reliance on inter-annual variability to assess the covariance between clouds and sea ice make it challenging to control for the influence of large-scale meteorology on the clouds. We have devised an approach that applies an in situ, airborne observational strategy to quantify the influence of surface type on Arctic clouds to satellite data. Our event-based method composites cloud property differences for ocean, marginal ice zone, and sea ice surface types for >5000 MIZ crossing events. We find that cloud properties in non-summer months below ~1.5 km are influenced by surface type such that greater cloud fraction and water content are found over ocean relative to sea ice regions. Results are statistically significantly at the 95% confidence level. During summer, the surface type does not influence the cloud properties. The primary cause of the surface type dependent cloud property differences is the thermodynamic profiles differences that occur between the two surface types: namely, ocean footprints are warmer, moister, have more positive surface turbulent fluxes and are less stable than their sea ice counterparts. We find that the differences in thermodynamic profiles by surface type that correspond to the cloud property differences also explains a significant portion of the variability across events. Our analysis provides evidence that the influence of surface type on cloud properties fundamentally occurs due to the inherent surface temperature differences between the surface types. Significant surface type influences on cloud properties are only found in the presence of surface temperature differences between the surface types and only non-summer months meet this criterion. A conceptual model of this process is as follows, fundamental properties of the ocean and sea ice surface types (e.g., surface albedo, heat capacity/thermal inertia, surface roughness, and thermal conductance) lead to systematic differences in the surface temperature by surface type. In response to this surface temperature difference, atmosphere boundary layer processes (including turbulent mixing and radiation) communicate the surface temperature differences to the lower atmosphere driving the greater stability over sea ice than ocean. These differences in the background thermodynamic state profiles between the surface types yield atmospheric conditions that are more conducive to cloud development over ocean than sea ice. The details of these boundary layer processes are sensitive to the surface type but may not be fundamental to the resulting thermodynamic structure and cloud differences. Thus, our results indicate that to accurately model that cloud response to sea ice loss in climate models the surface type properties that yield the systematic differences in ocean and sea ice temperature (e.g., surface albedo, surface turbulent fluxes parameters, and thermal conductance) must be accurately represented.

Arctic radiation budget↗
NASA NTRSDate not supplied

Extinction of the Stagnation Point Diffusion Flame: Effect of Conductive Heat Loss into Solid Interior

The planned microgravity experiment Growth and Extinction Limit (GEL) is designed to study the material flammability and extinction of thermally thick solid with an emphasis to quantify the effect of conductive heat loss into the solid interior by measuring the in-depth temperature profile. To obtain a more detailed understanding of the extinction phenomena, a previously developed one-dimensional axisymmetric stagnation-point diffusion flame model is expanded to account for the excessive heat loss into the solid beyond the steady burning state. This is important because for thick solids, this is important because the burning period can have a long and slow solid transient with a quasi-steady gas -phase. A non-dimensional excessive conductive heat loss parameter Ψ is defined in the paper and extensive numerical computations have been performed to determine the extinction boundary and the characteristics of near-limit flames. The classical U-shaped flammability boundary in the oxygen vs. stretch rate plot now becomes a series of U-shaped boundaries as a function of Ψ. For a given oxygen ambient, extinction boundary is a function of Ψ. The boundary consists of a blowoff branch and a radiative quenching branch. This is similar to the steady burning flammability boundary (Ψ =0) in the oxygen vs stretch rate plot. Extensive computed data including flame and pyrolysis temperatures, burning rate, flame standoff distance, and reaction rate are presented along the extinction boundaries. In particular, we note that the non-dimensional gas reaction rate is the ratio of diffusion reaction time to the reaction diffusion time, so it has the classical Damhkoler number character. By examining the maximum non-dimensional reaction rates, we observe that along the extinction boundaries, they are approximate constant across the entire range of stretch rates (from quenching to blow-off). These critical values are of the order unity but may vary in different oxygen ambient. The implication will be discussed in the presentation together with the near-limit flame structures.

Chengyao Li↗
NASA NTRS1975

Hypersonic aeroheating test of space shuttle vehicle configuration 3 (model 22-OTS) in the NASA-Ames 3.5-foot hypersonic wind tunnel (IH20), volume 1

The results of hypersonic wind tunnel testing of an 0.0175 scale version of the vehicle 3 space shuttle configuration are presented. Temperature measurements were made on the launch configuration, orbiter plus tank, orbiter alone, tank alone, and solid rocket booster alone to provide heat transfer data. The test was conducted at free-stream Mach numbers of 5.3 and 7.3 and at free-stream Reynolds numbers of 1.5 million, 3.7 million, 5.0 million, and 7.0 million per foot. The model was tested at angles of attack from -5 deg to 20 deg and side slip angles of -5 deg and 0 deg.

Kingsland, R. B.↗
NASA NTRS1989

High capacity demonstration of honeycomb panel heat pipes

The feasibility of performance enhancing the sandwich panel heat pipe was investigated for moderate temperature range heat rejection radiators on future-high-power spacecraft. The hardware development program consisted of performance prediction modeling, fabrication, ground test, and data correlation. Using available sandwich panel materials, a series of subscale test panels were augumented with high-capacity sideflow and temperature control variable conductance features, and test evaluated for correlation with performance prediction codes. Using the correlated prediction model, a 50-kW full size radiator was defined using methanol working fluid and closely spaced sideflows. A new concept called the hybrid radiator individually optimizes heat pipe components. A 2.44-m long hybrid test vehicle demonstrated proof-of-principle performance.

Tanzer, H. J.↗
NASA NTRS1983

Saturn's icy satellites - Thermal and structural models

Thermal history models which assume formation as homogeneous ice-silicate mixtures are constructed for the small, icy Saturnian satellites Mimas, Tethys, Dione, Rhea, and Iapetus, including the effects of radiogenic and accretional heating, conductive and subsolidus convective heat transfer, and lithosphgeric growth. Accretional heating is not likely to have melted the water ice in the interiors of these bodies, and solid state creep of the ice-dominated material precludes melting by radiogenic heating. The four largest satellites are sufficiently large and rich in heat-producing silicates to possess a solid state convection system beneath a rigid lithosphere, irrespective of initial conditions. The model thermal histories are qualitatively consistent with the present appearances of these satellites.

Ellsworth, K.↗
NASA NTRS1988

Thermodynamic behavior near a metal-insulator transition

Measurements of the low-temperature specific heat of phosphorus-doped silicon for densities near the metal-insulator transition show an enhancement over the conduction-band itinerant-electron value. The enhancement increases toward lower temperatures but is less than that found for the spin susceptibility. The data are compared with various theoretical models; the large ratio of the spin susceptibility to specific heat indicates the presence of localized spin excitations in the metallic phase as the metal-insulator transition is approached.

Paalanen, M. A.↗
NASA NTRSDate not supplied

Enabling Mission Flexibility to Battery Driven Deep Space Endeavors With Generalized Battery-Health-Monitoring Using Physics-Based and Data-Driven Reduced-Order Models

The needs and requirements for an electrochemical energy storage for deep space exploration is well explored. It is often understood that different mission sites and environmental conditions require different battery chemistries or technologies. Additionally, various engineering solutions are deployed to overcome specific chemical challenges. One often overlooked need is the “health” monitoring of an electrochemical storage system. The term generalized health monitoring, as envisioned in this work, refers to the monitoring of various aspects such as electrode health, electrolyte health, reaction pathway health, cooling system health, sensor health, and BMS health [1]. Generalized health monitoring allows mission leads, engineers, and scientists to incorporate flexibility in mission designs, make on-the-fly mission changes, and extend the duration of science missions. Moreover, it enables automation and data-driven decision-making without compromising safety and performance. Recently, our group developed a hierarchy of thermal reduced-order models (TROM) by combining a physics-based modeling approach and data-driven model reduction techniques applied to flight data [2]. The resulting TROMs were found to be not only accurate but also identifiable from the flight data. Consequently, the coefficient of variance of the model parameters is small over the course of hundreds of flights, allowing for monitoring the parameter evolution trajectories as the battery ages and degrades. These parameters constitute the metrics of the generalized health of a battery. Monitoring their evolution allows such models to be used for anomaly detection and prognostics, improving early detection of abnormal behavior and thus enabling timely maintenance, longer battery life, and enhanced battery safety. For this presentation, the practicality of the thermal model will be validated on a pack of 14cells under various topology configurations such as 1S14P, 2P7S, 7S2P, and 1P14S. It is well known that manufacturing and non-uniform aging lead to variability in the performance of a cell, which is exacerbated by cell balancing during active load. Additionally, in extreme scenarios, the paramount objective is to complete the mission, regardless of the stresses on the battery. Topology-induced balancing issues further stress the battery. The goal of this study is to determine if the noise (identifiability) in the reduced-order thermal model parameters is sensitive to topology, cell spacing, cooling strategy, and manufacturing or age variability. The variability in cells is considered by assuming a multimodal distribution for microscopic parameters of a cell (such as porosity, tortuosity, reaction kinetics, volumetric thermal conductivity, and volumetric heat capacity). The compounded effect of manufacturing variability, topological selection, cooling strategies, and cell balancing ages each cell in a battery differently. The study aims to clarify whether the challenge in extracting maximum information depends on the minimum number of sensors or models used for data extraction.

Automation↗
NASA NTRS1990

Space Station solar water heater

The feasibility of directly converting solar energy for crew water heating on the Space Station Freedom (SSF) and other human-tended missions such as a geosynchronous space station, lunar base, or Mars spacecraft was investigated. Computer codes were developed to model the systems, and a proof-of-concept thermal vacuum test was conducted to evaluate system performance in an environment simulating the SSF. The results indicate that a solar water heater is feasible. It could provide up to 100 percent of the design heating load without a significant configuration change to the SSF or other missions. The solar heater system requires only 15 percent of the electricity that an all-electric system on the SSF would require. This allows a reduction in the solar array or a surplus of electricity for onboard experiments.

Horan, D. C.↗
NASA NTRS2010

Ablative Rocket Deflector Testing and Computational Modeling

A deflector risk mitigation program was recently conducted at the NASA Stennis Space Center. The primary objective was to develop a database that characterizes the behavior of industry-grade refractory materials subjected to rocket plume impingement conditions commonly experienced on static test stands. The program consisted of short and long duration engine tests where the supersonic exhaust flow from the engine impinged on an ablative panel. Quasi time-dependent erosion depths and patterns generated by the plume impingement were recorded for a variety of different ablative materials. The erosion behavior was found to be highly dependent on the material s composition and corresponding thermal properties. For example, in the case of the HP CAST 93Z ablative material, the erosion rate actually decreased under continued thermal heating conditions due to the formation of a low thermal conductivity "crystallization" layer. The "crystallization" layer produced near the surface of the material provided an effective insulation from the hot rocket exhaust plume. To gain further insight into the complex interaction of the plume with the ablative deflector, computational fluid dynamic modeling was performed in parallel to the ablative panel testing. The results from the current study demonstrated that locally high heating occurred due to shock reflections. These localized regions of shock-induced heat flux resulted in non-uniform erosion of the ablative panels. In turn, it was observed that the non-uniform erosion exacerbated the localized shock heating causing eventual plume separation and reversed flow for long duration tests under certain conditions. Overall, the flow simulations compared very well with the available experimental data obtained during this project.

Allgood, Daniel C.↗
NASA NTRS1992

Aerospace applications of SINDA/FLUINT at the Johnson Space Center

SINDA/FLUINT has been found to be a versatile code for modeling aerospace systems involving single or two-phase fluid flow and all modes of heat transfer. Several applications of SINDA/FLUINT are described in this paper. SINDA/FLUINT is being used extensively to model the single phase water loops and the two-phase ammonia loops of the Space Station Freedom active thermal control system (ATCS). These models range from large integrated system models with multiple submodels to very detailed subsystem models. An integrated Space Station ATCS model has been created with ten submodels representing five water loops, three ammonia loops, a Freon loop and a thermal submodel representing the air loop. The model, which has approximately 800 FLUINT lumps and 300 thermal nodes, is used to determine the interaction between the multiple fluid loops which comprise the Space Station ATCS. Several detailed models of the flow-through radiator subsystem of the Space Station ATCS have been developed. One model, which has approximately 70 FLUINT lumps and 340 thermal nodes, provides a representation of the ATCS low temperature radiator array with two fluid loops connected only by conduction through the radiator face sheet. The detailed models are used to determine parameters such as radiator fluid return temperature, fin efficiency, flow distribution and total heat rejection for the baseline design as well as proposed alternate designs. SINDA/FLUINT has also been used as a design tool for several systems using pressurized gasses. One model examined the pressurization and depressurization of the Space Station airlock under a variety of operating conditions including convection with the side walls and internal cooling. Another model predicted the performance of a new generation of manned maneuvering units. This model included high pressure gas depressurization, internal heat transfer and supersonic thruster equations. The results of both models were used to size components, such as the heaters and gas bottles and also to point to areas where hardware testing was needed.

Ewert, Michael K.↗
NASA NTRS1990

Hot gas ingestion characteristics and flow visualization of a vectored thrust STOVL concept

A 9.2 percent scale short takeoff and vertical landing (STOVL) hot gas ingestion model was designed and built by McDonnell Douglas Corporation (MCAIR) and tested in the NASA Lewis Research Center 9- by 15-Foot Low Speed Wind Tunnel (LSWT). Hot gas ingestion, the entrainment of heated engine exhaust into the inlet flow field, is a key development issue for advanced short takeoff and vertical landing aircraft. The Phase 1 test program, conducted by NASA Lewis and McDonnell Douglas Corporation, evaluated the hot ingestion phenomena and control techniques and Phase 2 test program which was conducted by NASA Lewis are both reported. The Phase 2 program was conducted at exhaust nozzles temperatures up to 1460 R and utilized a sheet laser system for flow visualization of the model flow field in and out of ground effects. Hot gas ingestion levels were measured for the several forward nozzle splay configurations and with flow control/lift improvement devices which reduced the hot gas ingestion. The model support system had four degrees of freedom, heated high pressure air for nozzle flow, and a suction system exhaust for inlet flow. The headwind (freestream) velocity for Phase 1 was varied from 8 to 90 kn, with primary data taken in the 8 to 23 kn headwind velocity range. Phase 2 headwind velocity varied from 10 to 23 kn. Results of both Phase 1 and 2 are presented. A description of the model, facility, a new model support system, and a sheet laser illumination system are also provided. Results are presented over a range of main landing gear height (model height) above the ground plane at a 10 kn headwind velocity. The results contain the compressor face pressure and temperature distortions, total pressure recovery, compressor face temperature rise, and the environmental effects of the hot gas. The environmental effects include the ground plane temperature and pressure distributions, model airframe heating, and the location of the ground flow separation. Results from the sheet laser flow visualization test are also shown.

Johns, Albert L.↗
NASA NTRS1995

A dynamic model of the three-fluid solar wind: Equilibrium structures and fluxes

We report results from a dynamic approach to equilibrium for a three fluid solar-wind model in spherical 1D. We advance the mass, momentum and energy transport equations for protons, alpha particles and electrons, with full interspecies coulomb coupling and the simplifications recommended by Burgi (1992). They include no ion heat conduction and an ambipolar electric field in place of the negligible electron momentum coupling. At the inner boundary (the solar surface) we specify the inflow velocity, mass flux, and temperature for each species, and at the outer boundary at large radius we allow the fluids to flow freely from the computational domain. Starting from an initial wind model (e.g.. single fluid) we evolve to a three-fluid steady state. We will describe comparisons with Burgi's static equilibrium results. and examine the stability of the discontinuities which appear in his derived parameter variations.

Ruden, S. P.↗
NASA NTRS1993

Computational analysis of hypersonic shock wave/wall jet interaction

The purpose of this study is to investigate the CFD code General Aerodynamic Simulation Program (GASP) for application to a specific scramjet combustor phenomenon, that of an adverse pressure gradient caused by an oblique shock wave impinging upon a wall cooling film. The basis of this investigation is data available from an existing experimental study, which includes wall pressure, wall heat transfer, and schlieren photographs. This experimental study was conducted at a nominal Mach number of 6.0 in the Calspan 48-inch shock tunnel. The particular case of interest generates flow separation at the shock impingement point. Two algebraic turbulence models, the Baldwin-Lomax model and the Goldberg model, are considered for this computational study. Resultant computational wall pressure and heat transfer for both turbulence models are compared with experimental data. The Goldberg turbulence model provides a more accurate prediction of the recirculation region, and as a result, a better comparison with the experimental data.

Mekkes, Gregory L.↗
NASA NTRS2020

An Improved Plastically Dilatant Unified Viscoplastic Constitutive Formulation for Multiscale Analysis of Polymer Matrix Composites Under High Strain Rate Loading

Polymer matrix composites are commonly used to fabricate energy-absorbing structures expected to experience impact loading. As such, a detailed understanding of the dynamic response of the constituent materials is necessary. Since the rate, temperature, and pressure dependence of carbon fiber reinforced polymer matrix composites are primarily manifestations of the rate, temperature, and pressure dependence of the polymer matrix, it is crucial that the constitutive behavior of the matrix be accurately characterized. In this work, an existing unified viscoplastic constitutive formulation is extended to ensure thermodynamic consistency and to more accurately account for the tension-compression asymmetry observed in the response of polymeric materials. A new plastic potential function is proposed, and elementary loading conditions are utilized to determine relations between model constants to ensure nonnegative plastic dissipation, a necessary thermodynamic requirement. Expressions for plastic Poisson’s ratios are derived and are bounded by enforcing nonnegative plastic dissipation. The model is calibrated against available experimental data from tests conducted over a range of strain rates, temperatures, and loading cases on a representative thermoset epoxy; good correlation between simulations and experimental data is obtained. Temperature rises due to the conversion of plastic work to heat are computed via the adiabatic heat energy equation. The viscoplastic polymer model is then used as a constitutive model in the generalized method of cells micromechanics theory to investigate the effects of matrix adiabatic heating on the high strain rate response of a unidirectional composite. The thermodynamic consistency of the model ensures plastic dissipation can only cause an increase in temperature. Simulation results indicate that significant thermal softening due to the conversion of plastic work to heat is observed in the composite for matrix dominated deformation modes.

Impact loading↗
NASA NTRS1974

NASTRAN variance analysis and plotting of HBDY elements

The NASTRAN Thermal Analyzer has been intended to do variance analysis and plot the thermal boundary elements. The objective of the variance analysis addition is to assess the sensitivity of temperature variances resulting from uncertainties inherent in input parameters for heat conduction analysis. The plotting capability provides the ability to check the geometry (location, size and orientation) of the boundary elements of a model in relation to the conduction elements. Variance analysis is the study of uncertainties of the computed results as a function of uncertainties of the input data. To study this problem using NASTRAN, a solution is made for both the expected values of all inputs, plus another solution for each uncertain variable. A variance analysis module subtracts the results to form derivatives, and then can determine the expected deviations of output quantities.

Harder, R. L.↗
NASA NTRS1975

Design of experiments for measuring heat-transfer coefficients with a lumped-parameter calorimeter

A theoretical investigation was conducted to determine optimum experimental conditions for using a lumped-parameter calorimeter to measure heat-transfer coefficients and heating rates. A mathematical model of the transient temperature response of the calorimeter was used with the measured temperature response to predict the heat-transfer coefficient and the rate of heating. A sensitivity analysis was used to determine the optimum transient experiment for simultaneously measuring the heat addition during heating and the convective heat-transfer coefficient during heating and cooling of a lumped-parameter calorimeter. Optimum experiments were also designed for measuring the convective heat-transfer coefficient during both heating and cooling and cooling only.

Vanfossen, G. J., Jr.↗