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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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NASA NTRS2003

Conducting the Heat

Heat conduction plays an important role in the efficiency and life span of electronic components. To keep electronic components running efficiently and at a proper temperature, thermal management systems transfer heat generated from the components to thermal surfaces such as heat sinks, heat pipes, radiators, or heat spreaders. Thermal surfaces absorb the heat from the electrical components and dissipate it into the environment, preventing overheating. To ensure the best contact between electrical components and thermal surfaces, thermal interface materials are applied. In addition to having high conductivity, ideal thermal interface materials should be compliant to conform to the components, increasing the surface contact. While many different types of interface materials exist for varying purposes, Energy Science Laboratories, Inc. (ESLI), of San Diego, California, proposed using carbon velvets as thermal interface materials for general aerospace and electronics applications. NASA s Johnson Space Center granted ESLI a Small Business Innovation Research (SBIR) contract to develop thermal interface materials that are lightweight and compliant, and demonstrate high thermal conductance even for nonflat surfaces. Through Phase II SBIR work, ESLI created Vel-Therm for the commercial market. Vel-Therm is a soft, carbon fiber velvet consisting of numerous high thermal conductivity carbon fibers anchored in a thin layer of adhesive. The velvets are fabricated by precision cutting continuous carbon fiber tows and electrostatically flocking the fibers into uncured adhesive, using proprietary techniques.

Source record↗

NASA NTRS1991

Expert System For Heat Exchanger

Diagnosis simplified for non-engineers. Developmental expert-system computer program assists operator in controlling, monitoring operation, diagnosing malfunctions, and ordering repairs of heat-exchanger system dissipating heat generated by 20-kW radio transmitter. System includes not only heat exchanger but also pumps, fans, sensors, valves, reservoir, and associated plumbing. Program conceived to assist operator while avoiding cost of keeping engineer in full-time attendance. Similar programs developed for heating, ventilating, and air-conditioning systems.

Bagby, D. Gordon↗

NASA NTRS1992

Thermal issues at the SSC

A variety of heat transfer problems arise in the design of the Superconducting Super Collider (SSC). One class of problems is to minimize heat leak from the ambient to the SSC rings, since the rings contain superconducting magnets maintained at a temperature of 4 K. Another arises from the need to dump the beam of protrons (traveling around the SSC rings) on to absorbers during an abort of the collider. Yet another category of problems is the cooling of equipment to dissipate the heat generated during operation. An overview of these problems and sample heat transfer results are given in this paper.

Ranganathan, Raj P.↗

NASA NTRS2000

A Shocking New Pump

Hydro Dynamics, Inc. received a technical helping hand from NASA that made their Hydrosonic Pump (HPump) a reality. Marshall engineers resolved a bearing problem in the rotor of the pump and recommended new bearings, housings and mounting hardware as a solution. The resulting HPump is able to heat liquids with greater energy efficiency using shock waves to generate heat.

Source record↗

NASA NTRS1987

Mechanisms of rolling contact spalling

The results of a study aimed at analyzing the mechanical material interactions responsible for rolling contact spalling of the 440 C steel, high pressure oxygen turbopump bearings are presented. A coupled temperature displacement finite element analysis of the effects of friction heating under the contact is presented. The contact is modelled as a stationary, heat generating, 2 dimensional indent in an elastic perfectly plastic half-space with heat fluxes up to 8.6 x 10000 KW/m sq comparable to those generated in the bearing. Local temperatures in excess of 1000 C are treated. The calculations reveal high levels of residual tension after the contact is unloaded and cools. Efforts to promote Mode 2/Mode 3 fatigue crack growth under cyclic torsion in hardened 440 C steel are described. Spalls produced on 440 C steel by a 3 ball/rod rolling contact testing machine were studied with scanning microscopy. The shapes of the cyclic, stress strain hysteresis loops displayed by hardened 440 C steel in cyclic torsion at room temperature are defined for the plastic strain amplitudes encountered in rolling/sliding contact. Results of these analyses are discussed in detail.

Kumar, A. M.↗

NASA NTRS2021

Thermal Systems Modeling of Chemical Integrated Power Source (CHIPS) to Survive Lunar Night Environments

This paper presents the results of the systems level thermal modeling for a conceptual Chemical Heat Integrated Power Source (CHIPS). This proposed system offers a combined thermal and electrical power source to support survival of spacecraft operating in extreme low temperature lunar environments, without the use of radioisotope-based sources. A conceptual design study has been completed for this system, that uses heat generated by an exothermic chemical reaction in place of radioisotope or electrical heat sources. The goal of the study was to evaluate the feasibility of such as system through thermodynamic and chemical analysis and thermal modeling, and to identify technology gaps to inform a technology development and maturation plan. The specific technical objectives focused on delivery of 90-100 Wth thermal power and 30-40 We electrical power for 336 hours to a representative Commercial Lunar Payload Services (CLPS) lander, to support lunar surface survival and limited operations through a lunar night. The total system mass was targeted at ≤50 kg. A highly exothermic chemical reaction system is used to generate on-board electrical power for spacecraft systems, and thermal power to maintain critical spacecraft/lander systems within their allowable flight temperature (AFTs). Based on the very high energy content of the chemical reaction system, a much higher amount of heat per unit mass can be delivered to the spacecraft, relative to a rechargeable lithium-ion battery and electrical heater(s). Since radioisotope heaters or generators are not used, the system will be orders of magnitude lower in cost than a radioisotope heating/power unit, without the attendant regulatory complexities. As part of the CHIPS concept, a fraction of the thermal power generated is converted to electrical power via an appropriate thermal-to-electric converter technology (such as a free piston Stirling converter or a thermoelectric generator module), to provide power to critical loads. This approach is ideally suited to support operation of commercial landers (e.g., via the CLPS program). In most cases, these landers are only designed to operate during a portion of the lunar day, with no provision for survival through the lunar night. By supporting lunar night survival, a mission can be extended through the lunar night and at least into another lunar day, thus turning a nominal eight-day mission into a 36-day mission. Therefore, the current system demonstration will focus on scalability to support at least 336 hours (one lunar night) of continuous thermal and electrical power generation. Although initially targeted to support lunar equatorial landings, the technology is extensible to missions at the lunar poles, other extreme environments in the Solar System or even air-independent applications on Earth (e.g., ocean exploration).

West, William↗

NASA NTRS2021

Thermal Systems Modeling of Chemical Heat Integrated Power Source (CHIPS) to Survive Lunar Night Environments

This paper presents the results of the systems level thermal modeling for a conceptual Chemical Heat Integrated Power Source (CHIPS). This proposed system offers a combined thermal and electrical power source to support survival of spacecraft operating in extreme low temperature lunar environments, without the use of radioisotope-based sources. A conceptual design study has been completed for this system, that uses heat generated by an exothermic chemical reaction in place of radioisotope or electrical heat sources. The goal of the study was to evaluate the feasibility of such a system through thermodynamic and chemical analysis and thermal modeling, and to identify technology gaps to inform a technology development and maturation plan. The specific technical objectives focused on delivery of 90 to 100 Wth thermal power and 30 to 40 We electrical power for 336 hours to a representative Commercial Lunar Payload Services (CLPS) lander, to support lunar surface survival and limited operations through a lunar night. The total system mass was targeted at ≤50 kg. A highly exothermic chemical reaction system is used to generate on-board electrical power for spacecraft systems, and thermal power to maintain critical spacecraft/lander systems within their allowable flight temperature (AFTs). Based on the very high energy content of the chemical reaction system, a much higher amount of heat per unit mass can be delivered to the spacecraft, relative to a rechargeable lithium-ion battery and electrical heater(s). Since radioisotope heaters or generators are not used, the system will be orders of magnitude lower in cost than a radioisotope heating/power unit, without the attendant regulatory complexities. As part of the CHIPS concept, a fraction of the thermal power generated is converted to electrical power via an appropriate thermal-to-electric converter technology (such as a free piston Stirling converter or a thermoelectric generator module), to provide power to critical loads. This approach is ideally suited to support operation of commercial landers (e.g., via the CLPS program). In most cases, these landers are only designed to operate during a portion of the lunar day, with no provision for survival through the lunar night. By supporting lunar night survival, a mission can be extended through the lunar night and at least into another lunar day, thus turning a nominal eight-day mission into a 36-day mission. Therefore, the current system demonstration will focus on scalability to support at least 336 hours (one lunar night) of continuous thermal and electrical power generation. Although initially targeted to support lunar equatorial landings, the technology is extensible to missions at the lunar poles, other extreme environments in the Solar System or even air-independent applications on Earth (e.g., ocean exploration).

West, William↗

NASA NTRS1967

The Surveyor Thermal Switch

The extemal temperatme extremes of the lunar swjace dictated that a means be found to control the two electronic compartments on the Surveyot soft lunar landing vehicle within a narrower temperatme band to assure satisfactory component pmjonnance. Accordingly, thermal switches were developed to conduct heat away from temperature-sensitive components while heat-generating components were operating during the lunar day, and to retain heat at night when the equipment was off. Future equipment required to vary thermal conductivities, should this principle be employed, can benefit greatly from the results of the many problems encountered and studies made.

LUNAR SURFACE↗

NASA NTRS1982

U.S. welding technology - Constraints to space implementation

U.S. and European efforts to develop welding techniques for satellite solar arrays are described. Soldering practices in the U.S. have benefitted from Mo solders, which are well fitted to Si solar cell material thermal characteristics. Analyses have indicated that welds are the preferred method for interconnections and bonds. Extensive work has been done with the parallel gap resistance method (RW), which involves process heat generated by passing a current through resistive layers. Confining the primary heat input to the interconnector/cell contact interface results in welds being formed beneath both electrodes. Pulse welding has become the dominant RW technique in Europe, while ultrasonic welding is used in the U.S.; silver is employed as the interconnect material on both continents. The bonding techniques have been developed empirically instead of theoretically. An IR inspection technique has been produced for monitoring the weld temperature.

Stella, P. M.↗

NASA NTRS1989

Influence of heating mode on three-dimensional mantle convection

Numerical models of three-dimensional thermal convection in highly viscous spherical shells with different combinations of internal and basal heating consistently have upwelling concentrations in the form of cylindrical plumes and downwelling in planar sheets. As the proportion of internal heating increases, the number of upwelling plumes increases, and downwelling sheets become more vigorous and time-dependent. With any amount of basal heating, the entire convective pattern, during its evolution, is anchored to the upwelling plumes. As the proportion of internal heating increases, the heat flow carried by the upwelling plumes remains a large fraction of the basal heat flow. Downwelling sheets carry only a minor fraction (approximately 30 percent) of the basal heat flow (even when the shell is entirely heated from below), but they advect almost all of the internally generated heat. The relatively large number of plumes in the earth's mantle (inferred from hotspots), the possibility that downwelling slabs are vigorous enough to penetrate the lower mantle, and the small fraction of terrestrial surface heat flow carried by plumes all suggest that the mantle is predominantly heated from within.

Bercovici, D.↗

NASA NTRS1999

A View of the Lunar Interior Through Lunar Laser Range Analysis

Laser ranges between observatories on the Earth and retroreflectors on the Moon started in 1969 and continue to the present. Recent range accuracies are 2 cm while earliest ranges are an C, order of magnitude less certain. Four retroreflectors are ranged: three located at the Apollo 11, 14, and 15 sites and one on the Lunakhod 2 rover. Accurate analysis of the range data determines a number of lunar science parameters. The lunar interior variables include a fluid core parameter. The Lunar Laser Ranging effort is reviewed elsewhere. Many parameters are detected through their influence on rotation. Also detected are solid-body tides and accurate selenocentric reflector locations. Determined through the rotation are moment-of-inertia differences, gravitational harmonics, potential Love number, and dissipation effects due to tides and molten core. The rotation of the Moon is not at its minimum energy state; some recently active process has caused free librations. The moment differences contributed to the recent improvement of the Moon's moment of inertia from the Lunar Prospector gravity field. The Love numbers provide bulk elastic properties. Future possibilities for measurement include oblateness of the core-mantle boundary and core moment. A study of dissipation signatures in the rotation determines tidal Q vs. frequency and concludes that the Moon has a molten core. At 1 month the tidal Q is 37 and at 1 yr it is 60. The core radius is < or = 352 km for Fe and < or = 374 km for the Fe-FeS eutectic. The core detection exceeds 3x its uncertainty. The spin of the core is not aligned with the spin of the mantle and torque arises from the velocity difference at the boundary. Yoder's turbulent boundary layer theory is used to compute the radii. The present heat generation from tides and core interaction is minor compared to radiogenic heating. The heating for ancient times is more interesting. Peale and Cassen investigated lunar tidal heating while the lunar orbit expanded due to tides on Earth. Their calculations predate the measurement of Q and should be multiplied by 3.45 to match the lunar-laser-determined Love number and monthly Q. Tidal-heating computations depend on how fast the lunar orbit evolved and whether the tidal dissipation is localized. Neither is known, but plausible assumptions lead to early central region temperature increases of several hundred degrees. Most of the energy is deposited early in the Moon's history. The turbulent boundary layer theory allows a prediction of energy dissipated at the core-mantle boundary during orbit evolution. Under the assumption that the properties of the early core are the same as at present, the energy dissipated by core-mantle interaction is about the same as for tidal dissipation, but it is deposited in a smaller volume. This source of energy is capable of promoting convection in an early fluid core and driving a dynamo. This is a transient phase with a duration depending on the rate of orbit evolution. Plausible assumptions lead to a duration of a few hundred million years. Thus, the remnant magnetization of many lunar rocks is compatible with a brief global magnetic field powered by dynamical energy dissipation. Analysis of the lunar laser ranges is providing information on lunar geophysics. Future data will improve accuracies of present solution parameters, and several more interior effects should be detectable.

Williams, J. G.↗

NASA NTRS1999

Friction Stir Welding of Curved Plates

Friction stir welding (FSW) is a remarkable technology for making butt and lap joints in aluminum alloys. The process operates by passing a rotating tool between two closely butted plates. This process generates heat and the heated material is stirred from both sides of the plates to generate a high quality weld. Application of this technique has a very broad field for NASA. In particular, NASA is interested in using this welding process to manufacture tanks and curved elements. Therefore, this research has been oriented to the study the FSW of curved plates. The study has covered a number of topics that are important in the model development and to uncover the physical process involve in the welding itself. The materials used for the experimental welds were as close to each other as we could possibly find, aluminum 5454-0 and 5456-0 with properties listed at http://matweb.com. The application of FSW to curved plates needs to consider the behavior that we observed in this study. There is going to be larger force in the normal direction (Fz) as the curvature of the plate increases. A particular model needs to be derived for each material and thickness. A more complete study should also include parameters such as spin rate, tool velocity, and power used. The force in the direction of motion (Fx) needs to be reconsidered to make sure of its variability with respect to other parameters such as velocity, thickness, etc. It seems like the curvature does not play a role in this case. Variations in temperature were found with respect to the curvature. However, these changes seem to be smaller than the effect on Fz. The temperatures were all below the melting point. We understand now that the process of FSW produces a three dimensional flow of material that takes place during the weld. This flow needs to be study in a more detailed way to see in which directions the flow of material is stronger. It could be possible to model the flow using a 2-dimensional model in the particular directions where the flow moves faster. More experimental information is required to enrich the knowledge about FSW, and from this point, derive useful mathematical formulas to optimize the process and the design of the machines that will perform it. More experiments and experimental equipment are required to uncover the mathematics of the process.

Sanchez, Nestor↗

NASA NTRS2016

Turbo-Electric Compressor/Generator Using Halbach Arrays

The present invention is a turbojet design that integrates power generation into the turbojet itself, rather than use separate generators attached to the turbojet for power generation. By integrating the power generation within the jet engine, the weight of the overall system is significantly reduced, increasing system efficiency. Also, by integrating the power generating elements of the system within the air flow of the jet engine, the present invention can use the heat generated by the power generating elements (which is simply expelled waste heat in current designs) to increase the engine performance.

Kloesel, Kurt J.↗

NASA NTRS1980

Thermal buffering of receivers for parabolic dish solar thermal power plants

A parabolic dish solar thermal power plant comprises a field of parabolic dish power modules where each module is composed of a two-axis tracking parabolic dish concentrator which reflects sunlight (insolation) into the aperture of a cavity receiver at the focal point of the dish. The heat generated by the solar flux entering the receiver is removed by a heat transfer fluid. In the dish power module, this heat is used to drive a small heat engine/generator assembly which is directly connected to the cavity receiver at the focal point. A computer analysis is performed to assess the thermal buffering characteristics of receivers containing sensible and latent heat thermal energy storage. Parametric variations of the thermal inertia of the integrated receiver-buffer storage systems coupled with different fluid flow rate control strategies are carried out to delineate the effect of buffer storage, the transient response of the receiver-storage systems and corresponding fluid outlet temperature. It is concluded that addition of phase change buffer storage will substantially improve system operational characteristics during periods of rapidly fluctuating insolation due to cloud passage.

Manvi, R.↗

NASA NTRS1969

Technique for predicting temperature distribution in gases

Simple algebraic equations enable calculation of the temperature distribution throughout a heat generating, radiation gas. They apply over the entire range of opacities, for any heat flux, for a temperature dependent absorption coefficient, and for a non-uniform distribution of volumetric heat sources.

Kascak, A.↗

NASA NTRS1983

Thermal control - Heat buses will operate like a public utility

Active thermal control for the NASA space station concept requires long life heat rejection, highly versatile thermal transport, and efficient system integration. By a significant margin, the heat radiator will be the largest and most exposed portion of the space station thermal system. Transport requirements encompass the collection and movement of thermal energy from the space station's heat sources to the radiator heat sink at required temperature levels. In a decentralized thermal system, each space station module would collect and reject all of the waste heat generated, thereby requiring no module interconnections. This scheme does not, however, allow waste heat from one module to be used by another. In a centralized system, heat must be transported across module boundaries. A high capacity monogroove heat pipe has been developed to simplify space radiators design and operation.

Ellis, W. E.↗

NASA NTRS2004

Pseudo-Random Modulation of a Laser Diode for Generating Ultrasonic Longitudinal Waves

Laser generated ultrasound systems have historically been more complicated and expensive than conventional piezoelectric based systems, and this fact has relegated the acceptance of laser based systems to niche applications for which piezoelectric based systems are less suitable. Lowering system costs, while improving throughput, increasing ultrasound signal levels, and improving signal-to-noise are goals which will help increase the general acceptance of laser based ultrasound. One current limitation with conventional laser generated ultrasound is a material s damage threshold limit. Increasing the optical power to generate more signal eventually damages the material being tested due to rapid, high heating. Generation limitations for laser based ultrasound suggests the use of pulse modulation techniques as an alternate generation method. Pulse modulation techniques can spread the laser energy over time or space, thus reducing laser power densities and minimizing damage. Previous experiments by various organizations using spatial or temporal pulse modulation have been shown to generate detectable surface, plate, and bulk ultrasonic waves with narrow frequency bandwidths . Using narrow frequency bandwidths improved signal detectability, but required the use of expensive and powerful lasers and opto-electronic systems. The use of a laser diode to generate ultrasound is attractive because of its low cost, small size, light weight, simple optics and modulation capability. The use of pulse compression techniques should allow certain types of laser diodes to produce usable ultrasonic signals. The method also does not need to be limited to narrow frequency bandwidths. The method demonstrated here uses a low power laser diode (approximately 150 mW) that is modulated by controlling the diode s drive current and the resulting signal is recovered by cross correlation. A potential application for this system which is briefly demonstrated is in detecting signals in thick composite materials where attenuation is high and signal amplitude and bandwidth are at a premium.

Madaras, Eric I.↗

NASA NTRS2015

Cost Scaling of a Real-World Exhaust Waste Heat Recovery Thermoelectric Generator: A Deeper Dive

Cost is equally important to power density or efficiency for the adoption of waste heat recovery thermoelectric generators (TEG) in many transportation and industrial energy recovery applications. In many cases the system design that minimizes cost (e.g., the $/W value) can be very different than the design that maximizes the system's efficiency or power density, and it is important to understand the relationship between those designs to optimize TEG performance-cost compromises. Expanding on recent cost analysis work and using more detailed system modeling, an enhanced cost scaling analysis of a waste heat recovery thermoelectric generator with more detailed, coupled treatment of the heat exchangers has been performed. In this analysis, the effect of the heat lost to the environment and updated relationships between the hot-side and cold-side conductances that maximize power output are considered. This coupled thermal and thermoelectric treatment of the exhaust waste heat recovery thermoelectric generator yields modified cost scaling and design optimization equations, which are now strongly dependent on the heat leakage fraction, exhaust mass flow rate, and heat exchanger effectiveness. This work shows that heat exchanger costs most often dominate the overall TE system costs, that it is extremely difficult to escape this regime, and in order to achieve TE system costs of $1/W it is necessary to achieve heat exchanger costs of $1/(W/K). Minimum TE system costs per watt generally coincide with maximum power points, but Preferred TE Design Regimes are identified where there is little cost penalty for moving into regions of higher efficiency and slightly lower power outputs. These regimes are closely tied to previously-identified low cost design regimes. This work shows that the optimum fill factor Fopt minimizing system costs decreases as heat losses increase, and increases as exhaust mass flow rate and heat exchanger effectiveness increase. These findings have profound implications on the design and operation of various thermoelectric (TE) waste heat 3 recovery systems. This work highlights the importance of heat exchanger costs on the overall TEG system costs, quantifies the possible TEG performance-cost domain space based on heat exchanger effects, and provides a focus for future system research and development efforts.

cost analysis↗