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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
NASA NTRS1987

Thermal modeling of high rate Li-SOCl2 primary cylindrical cells

Four different heat transfer paths were separately investigated in a spirally-wound D-size cell. Thermal resistances of the relating components along each heat transfer path were calculated, and the total network of thermal resistances was constructed, resulting in the total thermal resistance of approximately 16.4 C/W at Tw = 40 C, and 12.2 C/W at Tw = 100 C. The amount of heat transferred along the radial direction, which is normal to the electrodes, was found to be about 91 percent of the total heat dissipation. Based on the present results obtained at the component level, the present D-size lithium cell may be operated at a C/2 discharge rate under normal discharge conditions below the cut-off voltage of 2.5 V.

Cho, Young I.↗
NASA NTRS2005

Development of Detectability Limits for On-Orbit Inspection of Space Shuttle Wing Leading Edge

At the conclusion of the Columbia Accident Investigation, one of the recommendations of the Columbia Accident Investigation Board (CAIB) was that NASA develop and implement an inspection plan for the Reinforced Carbon-Carbon (RCC) system components of the Space Shuttle. To address these issues, a group of scientists and engineers at NASA Langley Research Center proposed the use of an IR camera to inspect the RCC. Any crack in an RCC panel changes the thermal resistance of the material in the direction perpendicular to the crack. The change in thermal resistance can be made visible by introducing a heat flow across the crack and using an IR camera to image the resulting surface temperature distribution. The temperature difference across the crack depends on the change in the thermal resistance, the length of the crack, the local thermal gradient, and the rate of radiation exchange with the environment. This paper describes how the authors derived the minimum thermal gradient detectability limits for a through crack in an RCC panel. This paper will also show, through the use of a transient, 3-dimensional, finite element model, that these minimum gradients naturally exist on-orbit. The results from the finite element model confirm that there are sufficient thermal gradient to detect a crack on 96% of the RCC leading edge.

Stephan, Ryan A.↗
NASA NTRS1988

Self-Protecting Heat Exchanger

Double-wall heat-exchanger tube protects from overloads by changing thermal resistance automatically. When temperature at any location on tube increases above prescribed limit, thermal resistance through walls of tube increases at location. Prevents local excess heat load from overheating tube or boosting internal pressure and weakening tube, shortening life expectancy, or destroying it. When heat load falls to normal level, tube automatically lowers thermal resistance and resumes heat exhange at rated capacity.

Wagner, William R.↗
NASA NTRS1968

Reinforced thermal-shock resistant ceramics

Composite material, made by dispersing short tungsten-rhenium fibers randomly throughout zirconium oxide, is highly resistant to oxidizing environments at temperatures above 2000 degrees F. This reinforced ceramic is also thermal stress resistant.

Crump, D. N.↗
DOE OSTI2023

Differential multi-probe thermal transport measurements of multi-walled carbon nanotubes grown by chemical vapor deposition

Carbon nanotubes (CNTs) are quasi-one dimensional nanostructures that display both high thermal conductivity for potential thermal management applications and intriguing low-dimensional phonon transport phenomena. In comparison to the advances made in the theoretical calculation of the lattice thermal conductivity of CNTs, thermal transport measurements of CNTs have been limited by either the poor temperature sensitivity of Raman thermometry technique or the presence of contact thermal resistance errors in sensitive two-probe resistance thermometry measurements. Here we report advances in a multi-probe measurement of the intrinsic thermal conductivity of individual multi-walled CNT samples that are transferred from the growth substrate onto the measurement device. The sample-thermometer thermal interface resistance is directly measured by this multi-probe method and used to model the temperature distribution along the contacted sample segment. The detailed temperature profile helps to eliminate the contact thermal resistance error in the obtained thermal conductivity of the suspended sample segment. A differential electro-thermal bridge measurement method is established to enhance the signal-to-noise ratio and reduce the measurement uncertainty by over 40%. The obtained thermal resistances of multiple suspended segments of the same MWCNT samples increase nearly linearly with increasing length, revealing diffusive phonon transport as a result of phonon-defect scattering in these MWCNT samples. The measured thermal conductivity increases with temperature and reaches up to 390 ± 20 W m –1 K –1 at room temperature for a 9-walled MWCNT. In conclusion, theoretical analysis of the measurement results suggests submicron phonon mean free paths due to extrinsic phonon scattering by extended defects such as grain boundaries. The obtained thermal conductivity is decreased by a factor of 3 upon electron beam damage and surface contamination of the CNT sample.

42 ENGINEERING↗
DOE OSTI2025

Strength and thermal shock resistance of porous reaction-bonded silicon nitride by direct nitriding of binder jet additively manufactured silicon

The direct nitridation of binder jet additively manufactured silicon to produce porous silicon nitride was explored. The Taguchi Design of Experiments method was used to systematically study the effect of time, temperature, and nitrogen flow rate on the direct nitriding of binder jet additively manufactured silicon to produce porous reaction-bonded silicon nitride (RBSN). Highly porous (61%) samples with high conversion (99%) to silicon nitride were achieved using a thermal profile that utilized two isothermal holds. Further, it was shown that these samples exhibited thermal shock resistance and a low coefficient of thermal expansion. These results indicate that RBSN is readily achievable through additive manufacturing.

Ceramics↗
DOE OSTI2021

Climate benefits and building energy efficiency gains from improved roofing insulation in cold climates

The high thermal resistivity of polyisocyanurate insulation is attributed to its closed cell structure that is filled with low-thermal-conductivity blowing agent vapor. However, existing polyisocyanurate products exhibit a decrease in their thermal-resistance values at lower temperatures due to the condensation of the blowing agent vapor. Because use of insulation with higher thermal resistivity can lead to improved energy efficiency of commercial buildings, which results in lower operational greenhouse gas emissions, there is a clear need to address this reduced performance at lower temperatures through product innovation.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1986

Heat dissipation of high rate Li-SOCl sub 2 primary cells

The heat dissipation problem occurring in the lithium thionyl chloride cells discharged at relatively high rates under normal discharge conditions is examined. Four heat flow paths were identified, and the thermal resistances of the relating cell components along each flow path were accordingly calculated. From the thermal resistance network analysis, it was demonstrated that about 90 percent of the total heat produced within the cell should be dissipated along the radial direction in a spirally wound cell. In addition, the threshold value of the heat generation rate at which cell internal temperature could be maintained below 100 C, was calculated from total thermal resistance and found to be 2.9 W. However, these calculations were made only at the cell components' level, and the transient nature of the heat accumulation and dissipation was not considered. A simple transient model based on the lumped-heat-capacity concept was developed to predict the time-dependent cell temperature at different discharge rates. The overall objective was to examine the influence of cell design variable from the heat removal point of view under normal discharge conditions and to make recommendations to build more efficient lithium cells.

Cho, Y. I.↗
NASA NTRS1991

An investigation of the thermal shock resistance of lunar regolith and the recovery of hydrogen from lunar soil heated using microwave radiation

The objective is to develop a better understanding of the thermal shock properties of lunar regolith sintered using 2.45 GHz electromagnetic radiation and to do a preliminary study into the recovery of bound hydrogen in lunar soil heated using 2.45 GHz radiation. During the first phase of this work, lunar simulant material was used to test whether or not microhardness data could be used to infer thermal shock resistance and later actual lunar regolith was used. Results are included on the lunar regolith since this is of primary concern and not the simulant results. They were similar, however. The second phase investigated the recovery of hydrogen from lunar regolith and results indicate that microwave heating of lunar regolith may be a good method for recovery of bound gases in the regolith.

Meek, T. T.↗
DOE OSTI2020

Thermal shock resistance of multilayer silicon carbide receiver tubes for 800°C molten salt concentrating solar power application

CSP power tower receiver systems during rapid transient weather periods can be vulnerable to thermal shock conditions from rain that which can facilitate the onset of leaks and failures that can have catastrophic consequences. Silicon carbide (SiC) materials have attractive receiver application characteristics for being light weight, having high-strength and excellent thermal shock resistance performance which make them a particularly good fit for receiver absorber materials in CSP. In this investigation, the performance characteristics of Ceramic Tubular Products (CTP) SiC ceramic matrix composite (CMC), multilayered tubes were explored with respect to thermal shock performance for solar receiver applications in next generation CSP plants. Here, thermal shock testing was performed at the Sandia National Laboratories (SNL) Solar Furnace facility using a dynamic stage and thermal shock tube test setup. The tubes tested under incident solar heat flux of 100 W/cm2 were heated with inner tube temperatures reaching approximately 800 °C, with outer temperatures exceeding or just reaching 1000 El for the multilayer and monolithic SiC tubes respectively. The tubes were then quenched with simulated rain. The tubes were then cooled and subjected to hoop stress analysis using an Instron device to assess their subsequent mechanical strength. Furthermore, the on-sun study experimental results indicate an average of 24.2% and 97% higher hoop strength for the CMC tubes than those composed of monolithic SiC and aluminum oxide (A1203) respectively.

14 SOLAR ENERGY↗
DOE OSTI2025

Thermal shock resistance of lightweight cements developed for geothermal conditions

Cements are a critical component in well construction, as they act to prevent well fluid and gas escape, prevent corrosion of the casing, and strengthen the wellbore to prevent deformation. Under the high temperature/pressure conditions common in geothermal systems, the injection of cold water for energy production is expected to induce cyclic damage to the borehole cement through the rapid temperature fluctuations. These “thermal shocks” are expected to cause casing shrinkage, annulus formation, and cement tensile stresses. To understand the effect of cold water injection on the wellbore environment, a set of rock-cement-steel samples were created to simulate the structure of a geothermal well. Lightweight thermally-insulating cement blends were tested under thermal shock conditions in this study. In each test, the samples were pressurized to an effective pressure of ~3.5 MPa and placed at high temperatures. Thermal shocks were performed by injecting cold water (~10-15 °C) through the samples at a constant rate while keeping the samples at high temperatures until the sample temperature stopped decreasing and deformation ceased. Eight thermal shock tests were conducted with each sample – two at 100 °C and six at 200 °C. Post-tests analysis was then conducted by cutting open each sample to examine the damage in each component of the simulated wellbore. Experimental results suggest that all samples experienced similar degrees of axial and lateral contraction during cold water injection, but for the most part this contraction is recoverable when injection halts. Post-test analysis revealed that fly ash cenosphere pre-treatment had the best effect on improving thermal shock resistance in the cement blends. Thermomechanical modeling of likely stress paths experienced by the cements during heating/cooling cycles shows that elasto-plastic cement constitutive behavior results in most plastic strain occurring during the initial heating steps, with mostly elastic strain occurring during the thermal shock cycles. In conclusion, this agrees with experimental evidence, suggesting that cement damage from shocking occurs via other mechanisms such as chemical alteration, corrosion, and fatigue.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Thermal Optimization and Experimental Demonstration of a Silicon Carbide, Half-Bridge Power Module

This paper describes modeling and experimental work to design and demonstrate a silicon carbide (SiC), single-side-cooled power module. Two SiC metal-oxide-semiconductor field-effect transistors (MOSFET) were used for each switch position and packaged on a metalized ceramic substrate. Thermal modeling was first conducted to optimize the module packaging to minimize junction-to-fluid thermal resistance and device temperature variations. This procedure identified the optimal device placement and baseplate thickness to maximize thermal performance. A heat exchanger - incorporating impinging jets of water-ethylene glycol - was designed to cool the module's baseplate to minimize thermal resistance and pumping power. The heat exchanger used relatively low fluid velocities (<1.5 m/s) to minimize erosion-corrosion effects and relatively large fluid channel sizes (>=1 mm) to prevent clogging. The power module concept was fabricated, and experiments were conducted to measure its thermal performance. Direct current was used to power the module devices, and junction temperatures were measured via device temperature-sensitive parameters. The experimental results were found to be in good agreement with model predictions (within 2%) and yielded junction-to-fluid thermal resistance values as low as about 15 mm2 K/W at relatively low pumping power values. The results demonstrate the improved performance associated with jet impingement cooling and represent an improvement over existing channel-flow-type cold plates, which can enable improvements to power density and reliability.

36 MATERIALS SCIENCE↗
NASA NTRS1983

Silicon nitride: A ceramic material with outstanding resistance to thermal shock and corrosion

The known physical, mechanical and chemical properties of reaction-sintered silicon nitride are summarized. This material deserves interest especially because of its unusually good resistance to thermal shock and corrosion at high temperatures. Two types are distinguished: reaction-sintered (porous) and hot-pressed (dense) Si3N4. Only the reaction-sintered material which is being produced today in large scale as crucibles, pipes, nozzles and tiles is considered.

Huebner, K. H.↗
DOE OSTI2020

Intrinsic thermal interfacial resistance measurement in bonded metal–polymer foils

Heat conduction through bonded metal–polymer interfaces often limits the overall heat transfer in electronic packaging, batteries, and heat recovery systems. To design the thermal circuit in such systems, it is essential to measure the thermal interfacial resistance (TIR) across ~1 µm to 100 µm junctions. Previously reported TIR of metal–polymer junctions utilize ASTM E1530-based two-block systems that measure the TIR by applying pressure across the interface through external heating and cooling blocks. Here, we report a novel modification of the ASTM-E1530 technique that employs integrated heaters and sensors to provide an intrinsic TIR measurement of an adhesively bonded metal–polymer junction. We design the measurement technique using finite element simulations to either passively suppress or actively compensate the lateral heat diffusion through the polymer, which can minimize the systematic error to ≲5%. Through proof-of-concept experiments, we report the TIR of metal–polymer interfaces made from DuPont’s Pyralux double-side copper-clad laminates, commonly used in flexible printed circuit boards. Our TIR measurement errors are <10%. We highlight additional sources of errors due to non-idealities in the experiment and discuss possible ways to overcome them. Our measurement technique is also applicable to interfaces that are electrically insulating such as adhesively joined metal–metal junctions and sputter-coated or welded metal–polymer junctions. Altogether, the technique is capable of measuring TIR ≳10 –5 m 2 KW –1 in bonded metal–polymer foils and can be tailored for in situ measurements in flexible electronics, circuit packaging, and other hybrid metal–polymer systems.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Variable gap thermal conductivity apparatus and method

An apparatus and a method for determining the thermal conductivity of a fluid specimen are provided. The apparatus and the method include determining thermal conductivity using a quasi-steady state variable gap axial flow technique. The fluid specimen is heated on one side by a heat source with a known power output and cooled on the other side. After reaching steady state, a resulting temperature drop through the fluid specimen exists. This temperature drop, the known fluid specimen thickness (or gap distance), and the known power output are used to calculate the thermal resistance of the fluid specimen. The thermal conductivity of the fluid specimen is then determined using a curve fit of thermal resistance with respect to gap distance.

Gallagher, Ryan C.↗