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NASA NTRS2011

A Review of the Experimental and Modeling Development of a Water Phase Change Heat Exchanger for Future Exploration Support Vehicles

Water affords manifold benefits for human space exploration. Its properties make it useful for the storage of thermal energy as a Phase Change Material (PCM) in thermal control systems, in radiation shielding against Solar Particle Events (SPE) for the protection of crew members, and it is indisputably necessary for human life support. This paper envisions a single application for water which addresses these benefits for future exploration support vehicles and it describes recent experimental and modeling work that has been performed in order to arrive at a description of the thermal behavior of such a system. Experimental units have been developed and tested which permit the evaluation of the many parameters of design for such a system with emphasis on the latent energy content, temperature rise, mass, and interstitial material geometry. The experimental results are used to develop a robust and well correlated model which is intended to guide future design efforts toward the multi-purposed water PCM heat exchanger envisioned.

Cognata, Thomas↗

NASA NTRS2011

Performance Characterization of a Microchannel Liquid/Liquid Heat Exchanger Throughout an Extended Duration Life Test

Liquid/Liquid Heat Exchangers (L/L HX) are an integral portion of any spacecraft active thermal control system. For this study the X-38 L/L HX was used as a baseline. As detailed in a previous ICES manuscript, NASA paired with Pacific Northwest National Laboratory to develop a Microchannel L/L HX (MHX). This microchannel HX was designed to meet the same performance characteristics as the aforementioned X-38 HX. The as designed Microchannel HX has a 26% and 60% reduction in mass and volume, respectively. Due to the inherently smaller flow passages the design team was concerned about fouling affecting performance during extended missions. To address this concern, NASA has developed a test stand and is currently performing an 18 month life test on the MHX. This report will detail the up-to-date performance of the MHX during life testing.

Sheth, Rubik B.↗

NASA NTRS2010

International Space Station Common Cabin Air Assembly Condensing Heat Exchanger Hydrophilic Coating Failures and Lessons Learned

The ability to control the temperature and humidity of an environment or habitat is critical for human survival. These factors are important to maintaining human health and comfort, as well as maintaining mechanical and electrical equipment in good working order to support the human and to accomplish mission objectives. The temperature and humidity of the International Space Station (ISS) United States On-orbit Segment (USOS) cabin air is controlled by the Common Cabin Air Assembly (CCAA). The CCAA consists of a fan, a condensing heat exchanger (CHX), an air/water separator, temperature and liquid sensors, and electrical controlling hardware and software. The CHX is the primary component responsible for control of temperature and humidity. The CCAA CHX contains a chemical coating that was developed to be hydrophilic and thus attract water from the humid influent air. This attraction forms the basis for water removal and therefore cabin humidity control. However, there have been several instances of CHX coatings becoming hydrophobic and repelling water. When this behavior is observed in an operational CHX, the unit s ability to remove moisture from the air is compromised and the result is liquid water carryover into downstream ducting and systems. This water carryover can have detrimental effects on the cabin atmosphere quality and on the health of downstream hardware. If the water carryover is severe and widespread, this behavior can result in an inability to maintain humidity levels in the USOS. This paper will describe the operation of the five CCAAs within in the USOS, the potential causes of the hydrophobic condition, and the impacts of the resulting water carryover to downstream systems. It will describe the history of this behavior and the actual observed impacts to the ISS USOS. Information on mitigation steps to protect the health of future CHX hydrophilic coatings and potential remediation techniques will also be discussed.

Balistreri, Steven F.↗

NASA NTRS2010

Development of Passive Fuel Cell Thermal Management Heat Exchanger

The NASA Glenn Research Center is developing advanced passive thermal management technology to reduce the mass and improve the reliability of space fuel cell systems for the NASA Exploration program. The passive thermal management system relies on heat conduction within highly thermally conductive cooling plates to move the heat from the central portion of the cell stack out to the edges of the fuel cell stack. Using the passive approach eliminates the need for a coolant pump and other cooling loop components within the fuel cell system which reduces mass and improves overall system reliability. Previous development demonstrated the performance of suitable highly thermally conductive cooling plates that could conduct the heat, provide a sufficiently uniform temperature heat sink for each cell of the fuel cell stack, and be substantially lighter than the conventional thermal management approach. Tests were run with different materials to evaluate the design approach to a heat exchanger that could interface with the edges of the passive cooling plates. Measurements were made during fuel cell operation to determine the temperature of individual cooling plates and also to determine the temperature uniformity from one cooling plate to another.

Burke, Kenneth A.↗

NASA NTRS2010

XMM-Newton Observations of MBM 12: More Constraints on the Solar Wind Charge Exchange and Local Bubble Emissions

We present the first analysis of an XMM-Newton observation of the nearby molecular cloud MBM 12. We find that in the direction of MBM 12 the total O VII (0.57 keV) triplet emission is 1.8(+0.5/-0.6) photons/sq cm/s/sr (or Line Units - LU) while for the O VIII (0.65 keV) line emission we find a 3(sigma) upper limit of <1 LU. We also use a heliospheric model to calculate the O VII and O VIII emission generated by Solar Wind Charge-eXchange (SWCX) which we compare to the XMM-Newton observations. This comparison provides new constraints on the relative heliospheric and Local Bubble contributions to the local diffuse X-ray background. The heliospheric SWCX model predicts 0.82 LU for O VII, which accounts for approx. 46+/-15% of the observed value, and 0.33 LU for the O VIII line emission consistent with the XMM-Newton observed value. We discuss our results in combination with previous observations of the MBM 12 with CHANDRA and Suzaku.

Koutroumpa, Dimitra↗

NASA NTRS2011

Flight Simulation Model Exchange

The NASA Engineering and Safety Center Review Board sponsored an assessment of the draft Standard, Flight Dynamics Model Exchange Standard, BSR/ANSI-S-119-201x (S-119) that was conducted by simulation and guidance, navigation, and control engineers from several NASA Centers. The assessment team reviewed the conventions and formats spelled out in the draft Standard and the actual implementation of two example aerodynamic models (a subsonic F-16 and the HL-20 lifting body) encoded in the Extensible Markup Language grammar. During the implementation, the team kept records of lessons learned and provided feedback to the American Institute of Aeronautics and Astronautics Modeling and Simulation Technical Committee representative. This document contains the results of the assessment.

Murri, Daniel G.↗

NASA NTRS2011

Proton Exchange Membrane Fuel Cell Engineering Model Powerplant. Test Report: Benchmark Tests in Three Spatial Orientations

Proton exchange membrane (PEM) fuel cell technology is the leading candidate to replace the aging alkaline fuel cell technology, currently used on the Shuttle, for future space missions. This test effort marks the final phase of a 5-yr development program that began under the Second Generation Reusable Launch Vehicle (RLV) Program, transitioned into the Next Generation Launch Technologies (NGLT) Program, and continued under Constellation Systems in the Exploration Technology Development Program. Initially, the engineering model (EM) powerplant was evaluated with respect to its performance as compared to acceptance tests carried out at the manufacturer. This was to determine the sensitivity of the powerplant performance to changes in test environment. In addition, a series of tests were performed with the powerplant in the original standard orientation. This report details the continuing EM benchmark test results in three spatial orientations as well as extended duration testing in the mission profile test. The results from these tests verify the applicability of PEM fuel cells for future NASA missions. The specifics of these different tests are described in the following sections.

Loyselle, Patricia↗

NASA NTRS2000

Analysis and Test of a Proton Exchange Membrane Fuel Cell Power System for Space Power Applications

An effort is underway to develop a prototype Proton Exchange Membrane (PEM) Fuel Cell breadboard system for fuhlre space applications. This prototype will be used to develop a comprehensive design basis for a space-rated PEM fuel cell powerplant. The prototype system includes reactant pressure regulators, ejector-based reactant pumps, a 4-kW fuel cell stack and cooling system, and a passive, membranebased oxygen / water separator. A computer model is being developed concurrently to analytically predict fluid flow in the oxidant reactant system. Fuel cells have historically played an important role in human-rated spacecraft. The Gemini and Apollo spacecraft used fuel cells for vehicle electrical power. The Space Shuttle currently uses three Alkaline Fuel Cell Powerplants (AFCP) to generate all of the vehicle's 15-20kW electrical power. Engineers at the Johnson Space Center have leveraged off the development effort ongoing in the commercial arena to develop PEM fuel cel ls for terrestrial uses. The prototype design originated from efforts to develop a PEM fuel cell replacement for the current Space Shuttle AFCP' s. In order to improve on the life and an already excellent hi storical record of reliability and safety, three subsystems were focused on. These were the fuel cell stack itself, the reactant circulation devices, and reactant / product water separator. PEM fuel cell stack performance is already demonstrating the potential for greater than four times the useful life of the current Shuttle's AFCP. Reactant pumping for product water removal has historically been accomplished with mechanical pumps. Ejectors offer an effective means of reactant pumping as well as the potential for weight reduction, control simplification, and long life. Centrifugal water separation is used on the current AFCP. A passive, membrane-based water separator offers compatibility with the micro-gravity environment of space, and the potential for control simplification, elimination of moving parts in an oxygen environment, and long life. The prototype system has been assembled from components that have previously been tested and evaluated at the component level. Preliminary data obtained from tests performed with the prototype system, as well as other published data, has been used to validate the analytical component models. These components have been incorporated into an integrated oxidant fluid system model. Results obtained from both the performance tests and the analytical model are presented.

Vasquez, Arturo↗

NASA NTRS2011

Observations of Recent Arctic Sea Ice Volume Loss and Its Impact on Ocean-Atmosphere Energy Exchange and Ice Production

Using recently developed techniques we estimate snow and sea ice thickness distributions for the Arctic basin through the combination of freeboard data from the Ice, Cloud, and land Elevation Satellite (ICESat) and a snow depth model. These data are used with meteorological data and a thermodynamic sea ice model to calculate ocean-atmosphere heat exchange and ice volume production during the 2003-2008 fall and winter seasons. The calculated heat fluxes and ice growth rates are in agreement with previous observations over multiyear ice. In this study, we calculate heat fluxes and ice growth rates for the full distribution of ice thicknesses covering the Arctic basin and determine the impact of ice thickness change on the calculated values. Thinning of the sea ice is observed which greatly increases the 2005-2007 fall period ocean-atmosphere heat fluxes compared to those observed in 2003. Although there was also a decline in sea ice thickness for the winter periods, the winter time heat flux was found to be less impacted by the observed changes in ice thickness. A large increase in the net Arctic ocean-atmosphere heat output is also observed in the fall periods due to changes in the areal coverage of sea ice. The anomalously low sea ice coverage in 2007 led to a net ocean-atmosphere heat output approximately 3 times greater than was observed in previous years and suggests that sea ice losses are now playing a role in increasing surface air temperatures in the Arctic.

Kurtz, N. T.↗

NASA NTRS2011

Reactive Nitrogen, Ozone and Ozone Production in the Arctic Troposphere and the Impact of Stratosphere-Troposphere Exchange

We analyze the aircraft observations obtained during the Arctic Research of the Composition of the Troposphere from Aircraft and Satellite (ARCTAS) mission together with the GEOS-5 CO simulation to examine O3 and NOy in the Arctic and sub-Arctic region and their source attribution. Using a number of marker tracers and their probability density distributions, we distinguish various air masses from the background troposphere and examine their contribution to NOx, O3, and O3 production in the Arctic troposphere. The background Arctic troposphere has mean O3 of approximately 60 ppbv and NOx of approximately 25 pptv throughout spring and summer with CO decreases from approximately 145 ppbv in spring to approximately 100 ppbv in summer. These observed CO, NOx and O3 mixing ratios are not notably different from the values measured during the 1988 ABLE-3A and the 2002 TOPSE field campaigns despite the significant changes in the past two decades in processes that could have changed the Arctic tropospheric composition. Air masses associated with stratosphere-troposphere exchange are present throughout the mid and upper troposphere during spring and summer. These air masses with mean O3 concentration of 140-160 ppbv are the most important direct sources of O3 in the Arctic troposphere. In addition, air of stratospheric origin is the only notable driver of net O3 formation in the Arctic due to its sustainable high NOx (75 pptv in spring and 110 pptv in summer) and NOy (approximately 800 pptv in spring and approximately 1100 pptv in summer) levels. The ARCTAS measurements present observational evidence suggesting significant conversion of nitrogen from HNO3 to NOx and then to PAN (a net formation of approximately 120 pptv PAN) in summer when air of stratospheric origin is mixed with tropospheric background during stratosphere-to-troposphere transport. These findings imply that an adequate representation of stratospheric O3 and NOy input are essential in accurately simulating O3 and NOx photochemistry as well as the atmospheric budget of PAN in tropospheric chemistry transport models of the Arctic. Anthropogenic and biomass burning pollution plumes observed during ARCTAS show highly elevated hydrocarbons and NOy (mostly in the form of NOx and PAN), but do not contribute significantly to O3 in the Arctic troposphere except in some of the aged biomass burning plumes sampled during spring. Convection and/or lightning influences are negligible sources of O3 in the Arctic troposphere but can have significant impacts in the upper troposphere in the continental sub-Arctic during summer.

Liang, Q.↗

NASA NTRS2011

Assessment of the Draft AIAA S-119 Flight Dynamic Model Exchange Standard

An assessment of a draft AIAA standard for flight dynamics model exchange, ANSI/AIAA S-119-2011, was conducted on behalf of NASA by a team from the NASA Engineering and Safety Center. The assessment included adding the capability of importing standard models into real-time simulation facilities at several NASA Centers as well as into analysis simulation tools. All participants were successful at importing two example models into their respective simulation frameworks by using existing software libraries or by writing new import tools. Deficiencies in the libraries and format documentation were identified and fixed; suggestions for improvements to the standard were provided to the AIAA. An innovative tool to generate C code directly from such a model was developed. Performance of the software libraries compared favorably with compiled code. As a result of this assessment, several NASA Centers can now import standard models directly into their simulations. NASA is considering adopting the now-published S-119 standard as an internal recommended practice.

Jackson, E. Bruce↗

NASA NTRS2011

Teledyne Energy Systems, Inc., Proton Exchange Member (PEM) Fuel Cell Engineering Model Powerplant. Test Report: Initial Benchmark Tests in the Original Orientation

Proton Exchange Membrane (PEM) fuel cell technology is the leading candidate to replace the alkaline fuel cell technology, currently used on the Shuttle, for future space missions. During a 5-yr development program, a PEM fuel cell powerplant was developed. This report details the initial performance evaluation test results of the powerplant.

Loyselle, Patricia↗

NASA NTRS2011

Flight Simulation Model Exchange: Appendices - Volume 2

Murri, Daniel G.↗

NASA NTRS2011

Advances in the Lightweight Air-Liquid Composite Heat Exchanger Development for Space Exploration Applications

An advanced, lightweight composite modular Air/Liquid (A/L) Heat Exchanger (HX) Prototype for potential space exploration thermal management applications was successfully designed, manufactured, and tested. This full-scale Prototype consisting of 19 modules, based on recommendations from its predecessor Engineering Development unit (EDU) but with improved thermal characteristics and manufacturability, was 11.2 % lighter than the EDU and achieves potentially a 42.7% weight reduction from the existing state-of-the-art metallic HX demonstrator. However, its higher pressure drop (0.58 psid vs. 0.16 psid of the metal HX) has to be mitigated by foam material optimizations and design modifications including a more systematic air channel design. Scalability of the Prototype design was validated experimentally by comparing manufacturability and performance between the 2-module coupon and the 19-module Prototype. The Prototype utilized the thermally conductive open-cell carbon foam material but with lower density and adopted a novel high-efficiency cooling system with significantly increased heat transfer contact surface areas, improved fabricability and manufacturability compared to the EDU. Even though the Prototype was required to meet both the thermal and the structural specifications, accomplishing the thermal requirement was a higher priority goal for this first version. Overall, the Prototype outperformed both the EDU and the corresponding metal HX, particularly in terms of specific heat transfer, but achieved 93.4% of the target. The next generation Prototype to achieve the specification target, 3,450W would need 24 core modules based on the simple scaling factor. The scale-up Prototype will weigh about 14.7 Kg vs. 21.6 Kg for the metal counterpart. The advancement of this lightweight composite HX development from the original feasibility test coupons to EDU to Prototype is discussed in this paper.

Shin, E. Eugene↗

NASA NTRS2011

Two-Phase Cryogenic Heat Exchanger for the Thermodynamic Vent System

A two-phase cryogenic heat exchanger for a thermodynamic vent system was designed and analyzed, and the predicted performance was compared with test results. A method for determining the required size of the Joule-Thomson device was also developed. Numerous sensitivity studies were performed to show that the design was robust and possessed a comfortable capacity margin. The comparison with the test results showed very similar heat extraction performance for similar inlet conditions. It was also shown that estimates for Joule- Thomson device flow rates and exit quality can vary significantly and these need to be accommodated for with a robust system design.

Christie, Robert J.↗

NASA NTRS2011

DXL: A Sounding Rocket Mission for the Study of Solar Wind Charge Exchange and Local Hot Bubble X-Ray Emission

The Diffuse X-rays from the Local galaxy (DXL) mission is an approved sounding rocket project with a first launch scheduled around December 2012. Its goal is to identify and separate the X-ray emission generated by solar wind charge exchange from that of the local hot bubble to improve our understanding of both. With 1,000 square centimeters proportional counters and grasp of about 10 square centimeters sr both in the 1/4 and 3/4 keV bands, DXL will achieve in a 5-minute flight what cannot be achieved by current and future X-ray satellites.

Galeazzi, M.↗

NASA NTRS2012

Characterization of Turbulent Latent and Sensible Heat Flux Exchange Between the Atmosphere and Ocean in MERRA

Turbulent fluxes of heat and moisture across the atmosphere-ocean interface are fundamental components of the Earth's energy and water balance. Characterizing both the spatiotemporal variability and the fidelity of these exchanges of heat and moisture is critical to understanding the global water and energy cycle variations, quantifying atmosphere-ocean feedbacks, and improving model predictability. This study examines the veracity of the recently completed NASA Modern-Era Retrospective analysis for Research and Applications (MERRA) product with respect to its representation of the surface turbulent heat fluxes. A validation of MERRA turbulent heat fluxes and near-surface bulk variables at local, high-resolution space and time scales is achieved by making comparisons to a large suite of direct observations. Both in situ and satellite-observed gridded surface heat flux estimates are employed to investigate the spatial and temporal variability of the surface fluxes with respect to their annual mean climatologies, their seasonal covariability of near-surface bulk parameters, and their representation of extremes. The impact of data assimilation on the near-surface parameters is assessed through evaluation of incremental analysis update tendencies produced by the assimilation procedure. It is found that MERRA turbulent surface heat fluxes are relatively accurate for typical conditions but have systematically weak vertical gradients in moisture and temperature and have a weaker covariability between the near-surface gradients and wind speed than found in observations. This results in an underestimate of the surface latent and sensible heat fluxes over the western boundary current and storm track regions. The assimilation of observations mostly acts to bring MERRA closer to observational products by increasing moisture and temperature near the surface and decreasing the near-surface wind speeds. The major patterns of spatial and temporal variability of the turbulent heat fluxes produced by MERRA compare favorably to observationally based estimates. However, MERRA is distinct in terms of amplitude. These results suggest that MERRA is likely to be a valuable resource for a number of research applications though, as with all turbulent flux estimates, systematic issues should be taken into account

Robert, J. Brent↗

NASA NTRS2012

Multi-Mission Radioisotope Thermoelectric Generator Heat Exchangers for the Mars Science Laboratory Rover

The addition of the Multi-Mission Radioisotope Thermoelectric Generator (MMRTG) to the Mars Science Laboratory (MSL) Rover requires an advanced thermal control system that is able to both recover and reject the waste heat from the MMRTG as needed in order to maintain the onboard electronics at benign temperatures despite the extreme and widely varying environmental conditions experienced both on the way to Mars and on the Martian surface. Based on the previously successful Mars landed mission thermal control schemes, a mechanically pumped fluid loop (MPFL) architecture was selected as the most robust and efficient means for meeting the MSL thermal requirements. The MSL heat recovery and rejection system (HRS) is comprised of two Freon (CFC-11) MPFLs that interact closely with one another to provide comprehensive thermal management throughout all mission phases. The first loop, called the Rover HRS (RHRS), consists of a set of pumps, thermal control valves, and heat exchangers (HXs) that enables the transport of heat from the MMRTG to the rover electronics during cold conditions or from the electronics straight to the environment for immediate heat rejection during warm conditions. The second loop, called the Cruise HRS (CHRS), is thermally coupled to the RHRS during the cruise to Mars, and provides a means for dissipating the waste heat more directly from the MMRTG as well as from both the cruise stage and rover avionics by promoting circulation to the cruise stage radiators. A multifunctional structure was developed that is capable of both collecting waste heat from the MMRTG and rejecting the waste heat to the surrounding environment. It consists of a pair of honeycomb core sandwich panels with HRS tubes bonded to both sides. Two similar HX assemblies were designed to surround the MMRTG on the aft end of the rover. Heat acquisition is accomplished on the interior (MMRTG facing) surface of each HX while heat rejection is accomplished on the exterior surface of each HX. Since these two surfaces need to be at very different temperatures in order for the fluid loops to perform efficiently, they need to be thermally isolated from one another. The HXs were therefore designed for high in-plane thermal conductivity and extremely low through-thickness thermal conductivity by using aluminum facesheets and aerogel as insulation inside a composite honeycomb core. Complex assemblies of hand-welded and uniquely bent aluminum tubes are bonded onto each side of the HX panels, and are specifically designed to be easily mated and demated to the rest of the RHRS in order to ease the integration effort.

Mastropietro, A. J.↗