Aerospace America Year in Review -Thermophysics
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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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Testing of the Multi-Fluid Evaporator Engineering Development Unit
Hamilton Sundstrand is under contract with the NASA Johnson Space Center to develop a scalable, evaporative heat rejection system called the Multi-Fluid Evaporator (MFE). It is being designed to support the Orion Crew Module and to support future Constellation missions. The MFE would be used from Earth sea level conditions to the vacuum of space. The current Shuttle configuration utilizes an ammonia boiler and flash evaporator system to achieve cooling at all altitudes. The MFE system combines both functions into a single compact package with significant weight reduction and improved freeze-up protection. The heat exchanger core is designed so that radial flow of the evaporant provides increasing surface area to keep the back pressure low. The multiple layer construction of the core allows for efficient scale up to the desired heat rejection rate. The full scale MFE prototype will be constructed with four core sections that, combined with a novel control scheme, manage the risk of freezing the heat exchanger cores. A sub-scale MFE engineering development unit (EDU) has been built, and is identical to one of the four sections of a full scale prototype. The EDU has completed testing at Hamilton Sundstrand. The overall test objective was to determine the thermal performance of the EDU. The first set of tests simulated how each of the four sections of the prototype would perform by varying the chamber pressure, evaporant flow rate, coolant flow rate and coolant temperature. A second set of tests was conducted with an outlet steam header in place to verify that the outlet steam orifices prevent freeze-up in the core while also allowing the desired thermal turn-down ratio. This paper discusses the EDU tests and results.
Quinn, Gregory↗
Staged regenerative sorption heat pump
A regenerative adsorbent heat pump process and system for cooling and heating a space. A sorbent is confined in a plurality of compressors of which at least four are first stage and at least four are second stage. The first stage operates over a first pressure region and the second stage over a second pressure region which is higher than the first. Sorbate from the first stage enters the second stage. The sorbate loop includes a condenser, expansion valve, evaporator and the compressors. A single sorbate loop can be employed for single-temperature-control such as air conditioning and heating. Two sorbate loops can be used for two-temperature-control as in a refrigerator and freezer. The evaporator temperatures control the freezer and refrigerator temperatures. Alternatively the refrigerator temperature can be cooled by the freezer with one sorbate loop. A heat transfer fluid is circulated in a closed loop which includes a radiator and the compressors. Low temperature heat is exhausted by the radiator. High temperature heat is added to the heat transfer fluid entering the compressors which are desorbing vapor. Heat is transferred from compressors which are sorbing vapor to the heat transfer fluid, and from the heat transfer fluid to the compressors which are desorbing vapor. Each compressor is subjected to the following phases, heating to its highest temperature, cooling down from its highest temperature, cooling to its lowest temperature, and warming up from its lowest temperature. The phases are repeated to complete a cycle and regenerate heat.
Jones, Jack A.↗
Intelligent Engine Systems: Thermal Management and Advanced Cooling
The objective is to provide turbine-cooling technologies to meet Propulsion 21 goals related to engine fuel burn, emissions, safety, and reliability. Specifically, the GE Aviation (GEA) Advanced Turbine Cooling and Thermal Management program seeks to develop advanced cooling and flow distribution methods for HP turbines, while achieving a substantial reduction in total cooling flow and assuring acceptable turbine component safety and reliability. Enhanced cooling techniques, such as fluidic devices, controlled-vortex cooling, and directed impingement jets, offer the opportunity to incorporate both active and passive schemes. Coolant heat transfer enhancement also can be achieved from advanced designs that incorporate multi-disciplinary optimization of external film and internal cooling passage geometry.
Bergholz, Robert↗
A High Power Frequency Doubled Fiber Laser
This slide presentation reviews the power frequencies for the doubled fiber laser. It includes information on the 780 nm laser, second harmonic generation in one crystal, cascading crystals, the tenability of laser systems, laser cooling, and directions for future work.
high power lasers↗
HyTES: Thermal Imaging Spectrometer Development
The Jet Propulsion Laboratory has developed the Hyperspectral Thermal Emission Spectrometer (HyTES). It is an airborne pushbroom imaging spectrometer based on the Dyson optical configuration. First low altitude test flights are scheduled for later this year. HyTES uses a compact 7.5-12 micrometer m hyperspectral grating spectrometer in combination with a Quantum Well Infrared Photodetector (QWIP) and grating based spectrometer. The Dyson design allows for a very compact and optically fast system (F/1.6). Cooling requirements are minimized due to the single monolithic prism-like grating design. The configuration has the potential to be the optimal science-grade imaging spectroscopy solution for high altitude, lighter-than-air (HAA, LTA) vehicles and unmanned aerial vehicles (UAV) due to its small form factor and relatively low power requirements. The QWIP sensor allows for optimum spatial and spectral uniformity and provides adequate responsivity which allows for near 100mK noise equivalent temperature difference (NEDT) operation across the LWIR passband. The QWIP's repeatability and uniformity will be helpful for data integrity since currently an onboard calibrator is not planned. A calibration will be done before and after eight hour flights to gage any inconsistencies. This has been demonstrated with lab testing. Further test results show adequate NEDT, linearity as well as applicable earth science emissivity target results (Silicates, water) measured in direct sunlight.
remote sensing↗
Long-Wave Infrared Dyson Spectrometer
Preliminary results are presented for an ultra compact long-wave infrared slit spectrometer based on the dyson concentric design. The dyson spectrometer has been integrated in a dewar environment with a quantum well infrared photodetecor (QWIP), concave electron beam fabricated diffraction grating and ultra precision slit. The entire system is cooled to cryogenic temperatures to maximize signal to noise ratio performance, hence eliminating thermal signal from transmissive elements and internal stray light. All of this is done while maintaining QWIP thermal control. A general description is given of the spectrometer, alignment technique and predicated performance. The spectrometer has been designed for optimal performance with respect to smile and keystone distortion. A spectral calibration is performed with NIST traceable targets. A 2-point non-uniformity correction is performed with a precision blackbody source to provide radiometric accuracy. Preliminary laboratory results show excellent agreement with modeled noise equivalent delta temperature and detector linearity over a broad temperature range.
imaging↗
NASA Blazes a Different Path to Energy-Efficient Supercomputing
For years, NASA had a very straightforward process for replacing high-performance computing hardware: over a three-year period, when it became more expensive to operate an older suite of hardware than it did to replace it with new products that could accomplish the same work, we simply replaced the old hardware. For NASA’s High-End Computing Capability (HECC) Project, that process changed when we reached the limits of our facility’s power, cooling, and floor-loading capacity, becoming a strategy of decommissioning the least productive hardware and replacing it with more capable counterparts. The impact was that we provided our users with less supercomputing capability than we would have without the limitations. Additionally, with 25% of our total power consumption going to cool our systems and 50,000 gallons of water per day being evaporated, we wanted a solution that would expand our compute facility while being sensitive to the impact on our environment.
Thigpen, William↗
Passive Thermal Control of the Primordial Inflation Polarization Explorer (PIPER) Flight Electronics
The scientific balloon program at NASA offers an exciting and open area of opportunity for testing new technologies and for conducting meaningful experimentation at a fraction of the cost of a space mission. This paper outlines a simple thermal model developed and employed for the Primordial Inflation Polarization ExplorER (PIPER). The sub-orbital environment that PIPER operates in hosts an interesting mix of atmospheric and space thermal challenges. The work done was to mitigate thermal loads and passively cool the payload's exterior mounted electronics at an altitude of 36.6 km. This was done by characterizing the thermal environment and then designing solutions for the heat loads through a combined radiation and conduction passive cooling radiator system thermal model. Despite the simplicity and subsequent limitations of the model, as well as some unexpected payload operational events, the model produced results between 0.31% and 11.8% difference between the predicted values and measured average temperatures. From these results, the model was able to successfully provide estimates for the electronics temperatures. Additional flights will be needed to eliminate unknowns encountered in this flight in order to further refine the model for higher accuracy.
Walts, Alexander R.↗
NASA Glenn Propulsion Systems Laboratory Customer Guide
This guide describes the Propulsion Systems Laboratory (PSL) at NASA Glenn Research Center (GRC) and was written to help customers utilizing the facility understand all the components of conducting a test program within the facility. The PSL complex supports two large engine test cells that simulate altitude flight conditions for a wide range of research and experimental tests. The test cells operate at altitudes up to 90,000 ft and speeds from subsonic to above supersonic. The way the facility sets test points at the engine or test article inlet, such as pressure, temperature, and Mach number is discussed. Support systems such as the heated and cooled combustion air system, the altitude exhaust system, the hydraulic system, the nitrogen, oxygen, and hydrogen systems, hydrogen burners, the engine exhaust gas-sampling system, and single- and multiple-axis thrust stands are addressed. Facility safety procedures, pre-test requirements, test operation standards are also stated in later sections. Past PSL tests and other capabilities are also discussed.
PSL Customer Guide↗
Ceramic thermal-barrier coatings for cooled turbines
Coating systems consisting of a plasma sprayed layer of zirconia stabilized with either yttria, magnesia or calcia over a thin alloy bond coat have been developed, their potential was analyzed and their durability and benefits evaluated in a turbojet engine. The coatings on air cooled rotating blades were in good condition after completing as many as 500 two-minute cycles of engine operation between full power at a gas temperature of 1644 K and flameout, or as much as 150 hours of steady state operation on cooled vanes and blades at gas temperatures as high as 1644 K with 35 start and stop cycles. On the basis of durability and processing cost, the yttria stabilized zirconia was considered the best of the three coatings investigated.
Liebert, C. H.↗
Operating characteristics of a liquid-cooled contained electrolyte low temperature fuel cell system over a period of 1500 hours
1500-hour performance tests of liquid-cooled contained-electrolyte low temperature fuel cell system
Easter, R. W.↗
Controllable Multi-Functional Heat Exchanger for Space Applications
Team Spacering will design SpaceRing, a cooling and waste heat recycling system that addresses NASA’s interest for a cooling and power-generating unit in its prototype deep space habitat[1]. The merits of this system are as follows: - Controllable cooling is critical in maintaining a habitable environment and in the functionality of life support systems, powering electronics and other devices in a spacecraft. - Power is expensive to produce in a space environment. Converting wasted thermal energy into electricity will save energy and money for the space station. Space habitation is a highly complex endeavor. Consequently, the SpaceRing must adhere to additional constraints, which include: - Lack of natural fluid or gas convection due to micro-gravity environment - Limited range for heat source and cold sink temperature - Subject to high fluctuations of incoming thermal energy - Minimal weight due to the high cost of transporting items into space After consulting with NASA and experts in thermal studies, several design objectives were identified and are listed below in order of importance: - High cooling capacity - Reliable safety control and alert system - Maximization of energy generation from wasted heat - Optimization of cooling capability and power generation - Long operational life and minimization of maintenance In space, conventional cooling systems utilize passive heat pipe systems for small-scale heat rejection and pumped pipes with heat exchangers for large-scale heat rejection. Thermal power generation in space is mainly achieved by using thermoelectric material that produces electric energy from temperature differentials. We propose a design that combines cooling and thermoelectric power generation. Using a hot pipe connected to a heat source, a cold pipe connected to a radiator, a heat exchanger in contact with both pipes, and a pump in each pipe to move the fluid, we make an active cooling system. The thermoelectric material is inserted in the heat exchanger between the hot and cold pipes to extract energy from the maximum temperature difference coming from the two pipes. It also provides controllable cooling capacity through the use of the thermoelectric material as cooling modules. We have tested our system under target heat source and sink conditions and measured the temperatures and flow rates. Our preliminary results are promising, demonstrating the output of 25 Watts of power on average. We are in the process of running control tests to compare the heat transfer performance without the thermoelectric generators, which is vital in determining whether or not the generators introduce an unacceptable amount of thermal resistance. While some control tests have been run already, the results have been noisy. We have modified our testing environment and data acquisition methods to allow for simple comparison between the control test results and thermoelectric performance results. Lastly, we have modified the heat exchanger design slightly to include acrylic baffles. This will allow the heat to flow through the heat exchanger more efficiently. We have presented our preliminary results to NASA and will deliver the final product by the end of May 2014.
Lee Xiong↗
Cryogenic helium 2 systems for space applications
Two cryogenic systems are described which will provide cooling for experiments to be flown on Spacelab 2 in the early 1980's. The first system cools a scanning infrared telescope by the transfer of cold helium gas from a separate superfluid helium storage dewar. The flexible design permits the helium storage dewar and transfer assembly to be designed independent of the infrared experiment. Where possible, modified commerical apparatus is used. The second cryogenic system utilizes a specially designed superfluid dewar in which a superfluid helium experiment chamber is immersed. Each dewar system employs a porous plug as a phase separator to hold the liquid helium within the dewar and provide cold gas to a vent line. To maintain the low vapor pressure of the superfluid, each system requires nearly continuous prelaunch vacuum pump service, and each will vent to space during the Spacelab 2 flight.
Urban, E.↗
Venus Mobile Explorer with RPS for Active Cooling: A Feasibility Study
We present our findings from a study to evaluate the feasibility of a radioisotope power system (RPS) combined with active cooling to enable a long-duration Venus surface mission. On-board power with active cooling technology featured prominently in both the National Research Council's Decadal Survey and in the 2006 NASA Solar System Exploration Roadmap as mission-enabling for the exploration of Venus. Power and cooling system options were reviewed and the most promising concepts modeled to develop an assessment tool for Venus mission planners considering a variety of future potential missions to Venus, including a Venus Mobile Explorer (either a balloon or rover concept), a long-lived Venus static lander, or a Venus Geophysical Network. The concepts modeled were based on the integration of General Purpose Heat Source (GPHS) modules with different types of Stirling cycle heat engines for power and cooling. Unlike prior investigations which reported on single point design concepts, this assessment tool allows the user to generate either a point design or parametric curves of approximate power and cooling system mass, power level, and number of GPHS modules needed for a "black box" payload housed in a spherical pressure vessel.
Leifer, Stephanie D.↗
The ISS 2B PVTCS Ammonia Leak: An Operational History
In 2006, the Photovoltaic Thermal Control System (PVTCS) for the International Space Station's 2B power channel began leaking ammonia at a rate of approximately 1.5lbm/year (out of a starting approximately 53lbm system ammonia mass). Initially, the operations strategy was "feed the leak," a strategy successfully put into action via Extra Vehicular Activity during the STS‐134 mission. During this mission the system was topped off with ammonia piped over from a separate thermal control system. This recharge was to have allowed for continued power channel operation into 2014 or 2015, at which point another EVA would have been required. Without these periodic EVAs to refill the 2B coolant system, the channel would eventually leak enough fluid as to risk pump cavitation and system failure, resulting in the loss of the 2B power channel - the most critical of the Space Station's 8 power channels. In mid‐2012, the leak rate increased to approximately 5lbm/year. Once discovered, an EVA was planned and executed within a 5 week timeframe to drastically alter the architecture of the PVTCS via connection to a dormant thermal control system not intended to be utilized as anything other than spare components. The purpose of this rerouting of the TCS was to increase system volume and to isolate the photovoltaic radiator, thought to be the likely leak source. This EVA was successfully executed on November 1st, 2012 and left the 2B PVTCS in a configuration where the system was now being adequately cooled via a totally different radiator than what the system was designed to utilize. Unfortunately, data monitoring over the next several months showed that the isolated radiator was not leaking, and the system itself continued to leak steadily until May 9th, 2013. It was on this day that the ISS crew noticed the visible presence of ammonia crystals escaping from the 2B channel's truss segment, signifying a rapid acceleration of the leak from 5lbm/year to 5lbm/day. Within 48 hours of the crew noticing the leak, an EVA was in progress to replace the coolant pump - the only other replaceable leak source. This paper will explore the management of the 2B PVTCS leak from the operations perspective. It will discuss the methodology of performing the STS‐134 refill, the considerations and contingency plans which went into the architectural overhaul of the system in 2012, and the unprecedented effort which went into the EVA response to the visible leak of May 2013. In particular the paper will focus on the techniques utilized by flight controllers to monitor the system health and to respond to such instances as the rapid May 2013 leak by putting the electrical system in a safe configuration for loss of cooling, and will use recorded telemetry of these events to describe system response to EVA crew and ground actions. It will discuss the innovative design for redundancy of the integrated truss structure's cooling systems which allowed for this leak to be managed with minimal impact to other ISS operations and electrical services, contrasted against the real unintended operations consequences of utilizing the flexibility of the spacecraft's design in this manner. The paper will discuss how the training of the crew and flight controller personnel has adapted to the changing architecture of the power system and the unpredictable nature of the 2B leak.
Vareha, Anthony↗
Freon 21 bearing lubrication and coolant system
Lubrication and cooling of turbopump rotor bearings by liquid Freon 21 is reported. Freon expands in rotor bearing and acts as heat sink by removing heat during warming and evaporation. Gaseous Freon is removed by vacuum pump controlling rotor chamber operation.
Bodensieck, E. J.↗
Artificial Intelligence In Computational Fluid Dynamics
Paper compares four first-generation artificial-intelligence (Al) software systems for computational fluid dynamics. Includes: Expert Cooling Fan Design System (EXFAN), PAN AIR Knowledge System (PAKS), grid-adaptation program MITOSIS, and Expert Zonal Grid Generation (EZGrid). Focuses on knowledge-based ("expert") software systems. Analyzes intended tasks, kinds of knowledge possessed, magnitude of effort required to codify knowledge, how quickly constructed, performances, and return on investment. On basis of comparison, concludes Al most successful when applied to well-formulated problems solved by classifying or selecting preenumerated solutions. In contrast, application of Al to poorly understood or poorly formulated problems generally results in long development time and large investment of effort, with no guarantee of success.
Vogel, Alison Andrews↗