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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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At least 91 records · Page 5

Navier-Stokes Simulation of Airconditioning Facility of a Large Modem Computer Room

NASA recently assembled one of the world's fastest operational supercomputers to meet the agency's new high performance computing needs. This large-scale system, named Columbia, consists of 20 interconnected SGI Altix 512-processor systems, for a total of 10,240 Intel Itanium-2 processors. High-fidelity CFD simulations were performed for the NASA Advanced Supercomputing (NAS) computer room at Ames Research Center. The purpose of the simulations was to assess the adequacy of the existing air handling and conditioning system and make recommendations for changes in the design of the system if needed. The simulations were performed with NASA's OVERFLOW-2 CFD code which utilizes overset structured grids. A new set of boundary conditions were developed and added to the flow solver for modeling the roomls air-conditioning and proper cooling of the equipment. Boundary condition parameters for the flow solver are based on cooler CFM (flow rate) ratings and some reasonable assumptions of flow and heat transfer data for the floor and central processing units (CPU) . The geometry modeling from blue prints and grid generation were handled by the NASA Ames software package Chimera Grid Tools (CGT). This geometric model was developed as a CGT-scripted template, which can be easily modified to accommodate any changes in shape and size of the room, locations and dimensions of the CPU racks, disk racks, coolers, power distribution units, and mass-storage system. The compute nodes are grouped in pairs of racks with an aisle in the middle. High-speed connection cables connect the racks with overhead cable trays. The cool air from the cooling units is pumped into the computer room from a sub-floor through perforated floor tiles. The CPU cooling fans draw cool air from the floor tiles, which run along the outside length of each rack, and eject warm air into the center isle between the racks. This warm air is eventually drawn into the cooling units located near the walls of the room. One major concern is that the hot air ejected to the middle isle might recirculate back into the cool rack side and cause thermal short-cycling. The simulations analyzed and addressed the following important elements of the computer room: 1) High-temperature build-up in certain regions of the room; 2) Areas of low air circulation in the room; 3) Potential short-cycling of the computer rack cooling system; 4) Effectiveness of the perforated cooling floor tiles; 5) Effect of changes in various aspects of the cooling units. Detailed flow visualization is performed to show temperature distribution, air-flow streamlines and velocities in the computer room.

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Solar heating, cooling, and hot water systems installed at Richland, Washington

The project described is part of the U. S. Department of Energy's solar demonstration program, and became operational in April 1978. The solar system uses 6,000 square feet of flat-plate liquid collectors in a closed loop to deliver solar energy through a liquid-liquid heat exchanger to the building heat-pump duct work or 9,000-gallon thermal energy storage tank. A 25-ton Arkla solar-driven absorption chiller provides the cooling, in conjunction with a 2,000 gallon chilled water storage tank and reflective ponds on three sides of the building surplus heat. A near-by building is essentially identical except for having conventional heat-pump heating and cooling, and can serve as an experimental control. An on-going public relations program was provided from the beginning of the program, and resulted in numerous visitors and tour groups.

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Solar heating and cooling system design and development

Application surveys and performance studies were conducted to determine a solar heating and hot water configuration that could be used in a variety of applications, and to identify subsystem modules that could be utilized in a building block fashion to adapt hardware items to single and multi-family residential and commercial systems. Topics discussed include: subsystem development for the solar collectors, controls, other components, energy management module, and the heating system configuration test. Operational tests conducted at an Illinois farmhouse, and a YWCA in Spokane, Washington are discussed.

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Development of nonmetallic solar collector and solar-powered pump

Design and building of two unique components for solar heating (1. flatplate solar collector using no metal components, and 2. solar powered pump for heating and cooling systems are outlined in report. Report also discusses hardware, deliverable end items, problems encountered during fabrication and testing, and performance certification.

Parker, J. C.↗

Additive Manufacturing of Low Cost Upper Stage Propulsion Components

NASA is currently developing Additive Manufacturing (AM) technologies and design tools aimed at reducing the costs and manufacturing time of regeneratively cooled rocket engine components. These Low Cost Upper Stage Propulsion (LCUSP) tasks are funded through NASA's Game Changing Development Program in the Space Technology Mission Directorate. The LCUSP project will develop a copper alloy additive manufacturing design process and develop and optimize the Electron Beam Freeform Fabrication (EBF3) manufacturing process to direct deposit a nickel alloy structural jacket and manifolds onto an SLM manufactured GRCop chamber and Ni-alloy nozzle. In order to develop these processes, the project will characterize both the microstructural and mechanical properties of the SLMproduced GRCop-84, and will explore and document novel design techniques specific to AM combustion devices components. These manufacturing technologies will be used to build a 25K-class regenerative chamber and nozzle (to be used with tested DMLS injectors) that will be tested individually and as a system in hot fire tests to demonstrate the applicability of the technologies. These tasks are expected to bring costs and manufacturing time down as spacecraft propulsion systems typically comprise more than 70% of the total vehicle cost and account for a significant portion of the development schedule. Additionally, high pressure/high temperature combustion chambers and nozzles must be regeneratively cooled to survive their operating environment, causing their design to be time consuming and costly to build. LCUSP presents an opportunity to develop and demonstrate a process that can infuse these technologies into industry, build competition, and drive down costs of future engines.

Protz, Christopher↗

High intensity heat-pulse source operates without cooling system

Tungsten-iodine quartz lamp with on-off control is mounted at focus of ellipsoidal reflector and shutter is mounted at conjugate focus. Flux sensor monitors lamp and actuates shutter which emits a heat pulse when the radiant flux builds up to requisite level.

Russell, L. D.↗

Additive Manufacturing Development and Hot-Fire Testing of Liquid Rocket Channel Wall Nozzles Using Blown Powder Directed Energy Deposition Inconel 625 and JBK-75 Alloys

Additive manufacturing (AM) is being investigated at NASA and across much of the rocket propulsion industry as an alternate fabrication technique to create complex geometries for liquid engine components that offers schedule and cost saving opportunities. The geometries that can be created using AM offer a significant advantage over traditional techniques. Internal complexities, such as internal coolant channels for combustion chambers and nozzles that would typically require several operations to manufacture traditionally can be fabricated in one process. Additionally, the coolant channels are closed out as a part of the AM build process, eliminating the complexities of a traditional process like brazing or plating. The primary additive manufacturing technique that has been evaluated is powder bed fusion (PBF), or selective laser melting (SLM), but there is a scale limitation for this technique. There are several alternate additive manufacturing techniques that are being investigated for large-scale nozzles and chambers including directed energy deposition (DED) processes. A significant advantage of the DED processes is the ability to adapt to a robotic or gantry CNC system with a localized purge or purge chamber, allowing unlimited build volume. This paper will discuss the development and hot-fire testing of channel-cooled nozzles fabricated utilizing one form of DED called blown powder deposition. This initial development work using blown powder DED is being explored to form the entire channel wall nozzle with integral coolant channels within a single AM build. Much of this development is focused on the design and DED-fabrication of complex and thin-walled features and on characterization of the materials properties produced with this techniques in order to evolve this process. Subscale nozzles were fabricated using this DED technique and hot-fire tested in Liquid Oxygen/Hydrogen (LOX/GH2) and LOX/Kerosene (LOX/RP-1) environments accumulating significant development time and cycles. The initial materials that were evaluated during this testing were high-strength nickel-based Inconel 625 and JBK-75. Further process development is being completed to increase the scale of this technology for large-scale nozzles. This paper will summarize the general design considerations for DED, specific channel-cooled nozzle design, manufacturing process development, property development, initial hot-fire testing and future developments to mature this technology for regeneratively-cooled nozzles. An overview of future development at NASA will also be discussed.

Gradl, Paul R.↗

Solar-heating and cooling demonstration project

Florida Solar Energy Center has retrofitted office building, approximately 5,000 square feet of area, with solar heating and air-conditioning. Information on operation, installation, controls, and hardware for system is contained in 164 page report. Document includes manufacturer's product literature and detailed drawings.

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Thermal Energy Storage: Fourth Annual Review Meeting

The development of low cost thermal energy storage technologies is discussed in terms of near term oil savings, solar energy applications, and dispersed energy systems for energy conservation policies. Program definition and assessment and research and technology development are considered along with industrial storage, solar thermal power storage, building heating and cooling, and seasonal thermal storage. A bibliography on seasonal thermal energy storage emphasizing aquifer thermal energy is included.

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Two-Phase Bidirectional Heat Exchanger

Heat exchanger transfers heat from one two-phase thermal loop to another. Condenses vapor in one loop while evaporating liquid in other. Transfers heat with very small drops in temperature and pressure, and efficiently joins heat pipes thermally without mixing of their working fluids. Several such heat exchangers used to build long, complex multiloop heat-control systems. Exchanger bidirectional: transfers heat in reverse, condensing on normally evaporating side, and vice versa. Can warm equipment it normally cools, without using auxiliary heater. In reverse transfer, wicks on evaporating side supply liquid continuously by capillary action; reverse-flow pump not needed. Design modified for other working fluids and larger heat-transfer rates.

Kroliczek, Edward↗

ATSA- A Cold, Active Telescope for Space Astronomy

The National Academies’ Decadal Survey telescope studies have produced mission design concepts that plotpathways into the future to follow on from Hubble, Spitzer, JWST and NGRST. Considering the results of theLUVOIR and HabEx studies in particular, it is clear that segmented mirrors will eventually be needed to providevery large apertures in space and that this architecture presents both a scientific opportunity and an engineeringchallenge. Furthermore, while HabEx and LUVOIR cover a great deal of spectrum, both fall short of the mid-IRregion where general astronomy and astrophysics can be undertaken that would be impossible from terrestrialobservatories and where there also exist spectral features of interest in the search for life. A telescope with similarcapabilities to Habex/LUVOIR but also capable of exoplanet work in spectral regions up to 5 µm would largelybridge the gap between those proposals and TPF-I (which would have operated from about 7 µm upwards), andis therefore worthy of study. The Active Telescope for Space Astronomy (ATSA) design study presents a possiblearchitecture and is moderately sized (6 m) to enable the use of both starshade and coronagraph technologies.While the segment gaps of a segmented primary mirror present a challenge for coronagraphy, the architecturedoes allow direct wavefront control at each segment of that mirror, enabling a great degree of control at theprimary source of contrast degradation. While active systems (for example, deformable mirrors on WFIRSTCGI) are being incorporated into telescope designs today, a fully active mirror system needs further developmentfor a future mission. With this concept in mind, and intending to build on the LUVOIR and HabEx studies, wediscuss the elements of a cooled telescope design enabling both general astrophysics and exoplanet studies fromthe near UV through to the near-IR.

Steeves, John↗

Development of the Advanced Regolith Ground Operations (ARGO) Test Bed – A Robotic Excavation and Construction Test Facility with Simulated Lunar Environments

NASA’s Artemis Program is working towards developing a sustained presence on the Moon and eventually Mars. To achieve this goal, robotic excavation, site preparation and construction technologies are under development to establish the capability to construct infrastructure such as launch/landing pads and radiation protection shelters. Technologies must be proven in simulated Lunar conditions prior to surface demonstration missions. To that end, the Relevant Additive Construction Technology (REACT) Announcement of Collaboration Opportunities (ACO) project with AI Space Factory and the NASA Kennedy Space Center’s (KSC) Granular Mechanics and Regolith Operations Laboratory (a.k.a. Swamp Works) has developed the Advanced Regolith Ground Operations (ARGO) Test Bed. ARGO includes a ~1.5m x 1.5m x 1.2m (~5x5x4ft) vacuum chamber, cryogenically cooled thermal shroud, 3-axis robotic positioning system, and regolith bin. For the REACT project, a pellet extruder, feed hopper, and heated 600mm x 600mm (23.6x23.6in) build plate have been installed on ARGO to advance the Technology Readiness Level (TRL) of regolith-polymer composite Fused Deposition Modeling (FDM) additive construction systems, processes, and materials. This paper will focus on the design and operational characteristics of the ARGO Test Bed with pellet extruder.

regolith↗

Development of the Advanced Regolith Ground Operations (ARGO) Test Bed: A Robotic Excavation and Construction Test Facility with Simulated Lunar Environments

NASA’s Artemis Program is working towards developing a sustained presence on the Moon and eventually Mars. To achieve this goal, robotic excavation, site preparation and construction technologies are under development to establish the capability to construct infrastructure such as launch/landing pads and radiation protection shelters. Technologies must be proven in simulated Lunar conditions prior to surface demonstration missions. To that end, the Relevant Additive Construction Technology (REACT) Announcement of Collaboration Opportunities (ACO) project with AI Space Factory and the NASA Kennedy Space Center’s (KSC) Granular Mechanics and Regolith Operations Laboratory (a.k.a. Swamp Works) has developed the Advanced Regolith Ground Operations (ARGO) Test Bed. ARGO includes a ~1.5m x 1.5m x 1.2m (~5x5x4ft) vacuum chamber, cryogenically cooled thermal shroud, 3-axis robotic positioning system, and regolith bin. For the REACT project, a pellet extruder, feed hopper, and heated 600mm x 600mm (23.6x23.6in) build plate have been installed on ARGO to advance the Technology Readiness Level (TRL) of regolith-polymer composite Fused Deposition Modeling (FDM) additive construction systems, processes, and materials. This paper will focus on the design and operational characteristics of the ARGO Test Bed with pellet extruder.

regolith↗

Failure detection of liquid cooled electronics in sealed packages

The theory and experimental verification of a method of detecting fluid-mass loss, expansion-chamber pressure loss, or excessive vapor build-up in NASA's Airborne Information Management System (AIMS) are presented. The primary purpose of this leak-detection method is to detect the fluid-mass loss before the volume of vapor on the liquid side causes a temperature-critical part to be out of the liquid. The method detects the initial leak after the first 2.5 pct of the liquid mass has been lost, and it can be used for detecting subsequent situations including the leaking of air into the liquid chamber and the subsequent vapor build-up.

Hoadley, A. W.↗

The Liquid Nitrogen System for Chamber A: A Change from Original Forced Flow Design to a Natural Flow (Thermo Siphon) System

NASA Johnson Space Center (JSC) in Houston is currently supplementing its 20K helium refrigeration system to meet the new requirements for testing the James Web Space Telescope in the environmental control Chamber-A (65 dia x 120 high) in Building 32. The new system is required to meet the various operating modes which include a high 20K heat load, a required temperature stability at the load, rapid (but controlled) cool down and warm up and bake out of the chamber. This paper will present the proposed modifications to the existing helium system(s) to incorporate the new requirements and the integration of the new helium refrigerator with the existing two 3.5KW 20K helium refrigerators. In addition, the floating pressure process control philosophy to achieve high efficiency over the operating range (40% to 100% of the refrigeration system capacity), and the required temperature stability of +/- 0.25 K at the load will be discussed. The refrigeration systems ability to naturally seek the operating conditions under various loads and thus minimizing operator involvement and the over all improvements to the system operability and the reliability will be explained.

Homan, Jonathan↗

Evaluation of an Active Clearance Control System Concept

Reducing blade tip clearances through active tip clearance control in the high pressure turbine can lead to significant reductions in emissions and specific fuel consumption as well as dramatic improvements in operating efficiency and increased service life. Current engines employ scheduled cooling of the outer case flanges to reduce high pressure turbine tip clearances during cruise conditions. These systems have relatively slow response and do not use clearance measurement, thereby forcing cold build clearances to set the minimum clearances at extreme operating conditions (e.g., takeoff, reburst) and not allowing cruise clearances to be minimized due to the possibility of throttle transients (e.g., step change in altitude). In an effort to improve upon current thermal methods, a first generation mechanically-actuated active clearance control (ACC) system has been designed and fabricated. The system utilizes independent actuators, a segmented shroud structure, and clearance measurement feedback to provide fast and precise active clearance control throughout engine operation. Ambient temperature performance tests of this first generation ACC system assessed individual seal component leakage rates and both static and dynamic overall system leakage rates. The ability of the nine electric stepper motors to control the position of the seal carriers in both open- and closed-loop control modes for single and multiple cycles was investigated. The ability of the system to follow simulated engine clearance transients in closed-loop mode showed the system was able to track clearances to within a tight tolerance (0.001 in. error).

Steinetz, Bruce M.↗

Evaluation of an Active Clearance Control System Concept

Reducing blade tip clearances through active tip clearance control in the high pressure turbine can lead to significant reductions in emissions and specific fuel consumption as well as dramatic improvements in operating efficiency and increased service life. Current engines employ scheduled cooling of the outer case flanges to reduce high pressure turbine tip clearances during cruise conditions. These systems have relatively slow response and do not use clearance measurement, thereby forcing cold build clearances to set the minimum clearances at extreme operating conditions (e.g., takeoff, reburst) and not allowing cruise clearances to be minimized due to the possibility of throttle transients (e.g., step change in altitude). In an effort to improve upon current thermal methods, a first generation mechanically-actuated active clearance control (ACC) system has been designed and fabricated. The system utilizes independent actuators, a segmented shroud structure, and clearance measurement feedback to provide fast and precise active clearance control throughout engine operation. Ambient temperature performance tests of this first generation ACC system assessed individual seal component leakage rates and both static and dynamic overall system leakage rates. The ability of the nine electric stepper motors to control the position of the seal carriers in both open- and closed-loop control modes for single and multiple cycles was investigated. The ability of the system to follow simulated engine clearance transients in closed-loop mode showed the system was able to track clearances to within a tight tolerance ( 0.001 in. error).

Steinetz, Bruce M.↗

Technology Utilization House Study Report

The objectives of Project TECH are: (1) to construct a single family detached dwelling for demonstrating the application of advanced technology and minimizing the requirement for energy and utility services, and (2) to help influence future development in home construction by defining the interaction of integrated energy and water management systems with building configuration and construction materials. Components and methods expected to be cost effective over a 20 year span were studied. Emphasis was placed on the utilization of natural heating and cooling characteristics. Orientation and location of windows, landscaping, natural ventilation, and characteristics of the local climate and microclimate were intended to be used to best advantage. Energy conserving homes are most efficient when design for specific sites, therefore project TECH should not be considered a prototype design suitable for all locations. However, it does provide ideas and analytical methods which can be applied to some degree in all housing.

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