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Rapid Development of Instrument Thermal Models: Perspectives and Guidelines from NASA Goddard’s Instrument Design Laboratory

The Instrument Design Laboratory (IDL), part of NASA Goddard Space Flight Center’s Integrated Design Center (IDC), is a concurrent and collaborative environment which allows for rapid development of science instrumentation concepts within the span of less than two weeks. Science goals set by a Principal Investigator from government, industry or academia are translated into engineering requirements, from which a team of engineers spanning multiple disciplines use an established study process and a suite of analysis tools to work towards an instrument point design. As part of this process, a staff thermal engineer is tasked with designing a thermal control system which meets all incoming thermal requirements, while iterating real-time with other subsystems to ensure compatibility and functionality as a completed system. Thermal engineers on spaceflight projects typically have weeks or months to develop thermal models. However, the severe time limitation in this conceptual study setting makes thermal design particularly difficult, as rapid thermal modeling solely over the span of a few days is required to develop the instrument thermal design and understand the performance over its intended mission, especially if the instrument concept contains multiple thermal challenges such as dynamic environments or high heat dissipating components. In this paper, the authors provide a condensed guide for the most efficient ways to develop thermal models and conduct thermal analysis within the span of one-to-two weeks, as informed by decades of design experience and best practices in the IDL. The authors also focus on quick methods for determining worst-case thermal environments, deciding which modeling details are essential at this early phase, and quantifying the engineering resources necessary for thermal control. This paper concludes with specific thermal design tips for different instrument types across the electromagnetic spectrum.

Kan Yang↗
DOE OSTI2016

Thermal Aging Degradation of Cast Stainless Steels in LWR Systems

Cast austenitic stainless steels (CASSs) have been extensively used for the large components of light water reactor (LWR) power plants such as primary coolant piping and pump casing. Since a large number of massive CASS components are installed in every modern nuclear power plant, any significant degradation of CASS components will raise serious concerns on the integrity of the entire power plant. Upon the presumption that the replacement cost of such massive components is prohibitive, therefore, thorough scientific understanding and systematic monitoring the thermal aging degradation of CASS components should be essential requirements for assessing the plant safety. In the past few decades many researches have concluded that the formation of Cr-rich α-phase by Spinoidal decomposition of δ-ferrite phase, which is formed in high temperature region during cooling, is the primary mechanism for the thermal embrittlement. Cracking mechanism in the thermally-embrittled duplex stainless steels consists of cleavage initiation at ferrite and crack propagation via separation of ferrite-austenite interphase. It has been known, however, that such thermal aging embrittlement is observed only in accelerated aging conditions and the cast stainless steel grades used in nuclear plants have performed well without experiencing real embrittlement. It has been speculated that long-term thermal aging for ≥ 60 years could lead to further decomposition of designed phases and increase of precipitation. This will result in significantly increased susceptibility to embrittlement or other degradation due to thermal aging-radiation synergistic effect, irradiation-induced degradation, stress-corrosion cracking, and general corrosion. Currently, therefore, the thermal embrittlement of CASS components is one of the most serious concerns for extended operation of nuclear power plants. A scientific research is underway to address the issues related to the thermal aging degradation of CASS components. The research aims to provide knowledge-based conclusive prediction for the integrity of the CASS components of LWR power plants during extended operation up to and beyond 60 years. This presentation intends to provide an introductory overview on the thermal aging phenomena in LWR relevant conditions and discussion on the measurements of mechanical property degradation after accelerated and LWR relevant thermal aging treatments. First, the thermal aging effect on toughness is discussed in terms of the causes of embrittlement and influential parameters. Second, the talk will include a comprehensive discussion on the thermal aging effects in different CASS grades (i.e., CF3, CF3M, CF8, and CF8M), which will focus on the influence of alloying elements such as molybdenum and carbon. Third, approximate analysis on thermal reaction in CASS was carried out using Arrhenius equation to decide the effective temperature range for accelerated aging experiments to simulate 60 and 80 years of services in limited time frame. The results will provide valuable insights in the degree of thermal aging. Fourth, calculation on equilibrium precipitation was performed for model CASS alloys using the CALPHAD program, and the results will be used to describe the precipitation behaviors in association with the degradation in mechanical properties. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2016

Room temperature thermal conductivity measurements of neat MOF-5 compacts with high pressure hydrogen and helium

Metal-organic frameworks (MOFs) are a highly porous crystalline material with potential in various applications including on-board vehicle hydrogen storage for fuel cell vehicles. The thermal conductivity of MOFs is an important parameter in the design and ultimate performance of an on-board hydrogen storage system. However, in-situ thermal conductivity measurements have not been previously reported. The present study reports room temperature thermal conductivity and thermal diffusivity measurements performed on neat MOF-5 cylindrical compacts (ρ = 0.4 g/mL) as a function of pressure (0.27–90 bar) and gas type (hydrogen and helium). The transient plane source technique was used to measure both the non-directional thermal properties (isotropic method) and the directional thermal properties (anisotropic method). High pressure measurements were made using our in-house built low-temperature, high pressure thermal conductivity sample cell. The intrinsic thermal properties of neat MOF-5 measured under vacuum were—Isotropic: k isotropic = 0.1319 W/m K, α isotropic = 0.4165 mm 2 /s; Anisotropic: k axial = 0.1477 W/m K, k radial = 0.1218 W/m K, α axial = 0.5096 mm 2 /s, and α radial = 0.4232 mm 2 /s. The apparent thermal properties of neat MOF-5 increased with increasing hydrogen and helium pressure, with the largest increase occurring in the narrow pressure range of 0–10 bar and then monotonically asymptoting with increasing pressures up to around 90 bar. On average, a greater than two-fold enhancement in the apparent thermal properties was observed with neat MOF-5 in the presence of helium and hydrogen compared to the intrinsic values of neat MOF-5 measured under vacuum. The apparent thermal properties of neat MOF-5 measured with hydrogen were higher than those measured with helium, which were directly related to the gas-specific thermal properties of helium and hydrogen. Neat MOF-5 exhibited a small degree of anisotropy under all conditions measured with thermal conductivities and diffusivities in the axial direction being higher than those in the radial direction. As a result, the low temperature specific heat capacities of neat MOF-5 were also measured and reported for the temperature range of 93–313 K (–180–40 °C).

36 MATERIALS SCIENCE↗
DOE OSTI2016

Electric Motor Thermal Management R&D. Annual Report

With the push to reduce component volumes, lower costs, and reduce weight without sacrificing performance or reliability, the challenges associated with thermal management increase for power electronics and electric motors. Thermal management for electric motors will become more important as the automotive industry continues the transition to more electrically dominant vehicle propulsion systems. The transition to more electrically dominant propulsion systems leads to higher-power duty cycles for electric drive systems. Thermal constraints place significant limitations on how electric motors ultimately perform, and as thermal management improves, there will be a direct trade-off between motor performance, efficiency, cost, and the sizing of electric motors to operate within the thermal constraints. The goal of this research project is to support broad industry demand for data, analysis methods, and experimental techniques to improve and better understand motor thermal management. Work in FY15 focused on two areas related to motor thermal management: passive thermal performance and active convective cooling. Passive thermal performance emphasized the thermal impact of materials and thermal interfaces among materials within an assembled motor. The research tasks supported the publication of test methods and data for thermal contact resistances and direction-dependent thermal conductivity within an electric motor. Active convective cooling focused on measuring convective heat-transfer coefficients using automatic transmission fluid (ATF). Data for average convective heat transfer coefficients for direct impingement of ATF jets was published. Also, experimental hardware for mapping local-scale and stator-scale convective heat transfer coefficients for ATF jet impingement were developed.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2015

Characterization of Contact and Bulk Thermal Resistance of Laminations for Electric Machines

Thermal management for electric motors is important as the automotive industry continues to transition to more electrically dominant vehicle propulsion systems. The transition to more electrically dominant propulsion systems leads to higher-power duty cycles for electric-drive systems. Thermal constraints place significant limitations on how electric motors ultimately perform. As thermal management improves, there will be a direct trade-off among motor performance, efficiency, cost, and the sizing of electric motors to operate within the thermal constraints. During the development of thermal finite element analysis models and computational fluid dynamics models for electric motors, it was found that there was a lack of open literature detailing the thermal properties of key materials common in electric motors that are significant in terms of heat removal. The lack of available literature, coupled with the strong interest from industry in the passive-stack thermal measurement results, led to experiments to characterize the thermal contact resistance between motor laminations. We examined four lamination materials, including the commonly used 26 gauge and 29 gauge M19 materials, the HF10 and Arnon 7 materials. These latter two materials are thinner and reduce eddy currents responsible for core losses. We measured the thermal conductivity of the lamination materials and the thermal contact resistance between laminations in a stack, as well as investigated factors affecting contact resistance between laminations such as the contact pressure and surface finish. Lamination property data will be provided and we also develop a model to estimate the through-stack thermal conductivity for materials beyond those that were directly tested in this work. For example, at a clamping pressure of 138 kPa, the 29 gauge M19 material has a through-stack thermal conductivity of 1.68 W/m-K, and the contact resistance between laminations was measured to be 193 mm^2-K/W. The measured bulk thermal conductivity for the M19 29 gauge material is 21.0 W/m-K. Density and specific heat were measured to be 7450 kg/m^3 and 463 J/kg-K, respectively. These results are helping, and will continue to help engineers and researchers in the design and development of motors.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2017

Comparison of Thermal Diffusivity Degradation of Irradiated Zirlo and SiC-SiC Composite

Zirlo (Zircaloy cladding material from Westinghouse) has been widely used as the fuel cladding material in Light Water Reactors because of its high melting point, low susceptibility to corrosion, good thermal and mechanical shock resistance, and low degradation of mechanical properties under irradiation. But as Zirlo reacts with water at high temperature, which can trigger serious accidents, efforts have been made to explore better candidates to replace Zirlo in the water-cooled reactors. SiC-SiC composite is considered as one of the most viable options due to its comparable mechanical performances and corrosion resistance. However, one of the most important properties, thermal diffusivities of both Zirlo and SiC-SiC composite, and their degradation after irradiation, are not well known yet. Ion-irradiated samples are used to study the thermal property degradation caused by irradiation instead of the neutron-irradiated ones due to the significantly lower radioactivity. The microstructural damage is estimated from the software simulation SRIM/TRIM based on the energy and fluence of the ion, and the target material, and represented by DPA (displacement by atom). Different from neutron-irradiated samples, the damaged layer of ion-irradiated samples is only a few to a few tens of micrometers thick, and the damage is depth dependent. It is impossible to directly measure the bulk property change, and a microscale measurement technique is necessary. Laser-based photothermal reflectance technique is one of the ideal methods to measure local thermal conductivity and diffusivity with high spatial resolution. The main principle of this technique is to heat the solid sample using an intensity-modulated laser, and scan the sample with a constant intensity continuous-wave (CW) laser to detect the thermal wave propagation. On bulk, isotropic material, if the heating laser intensity is modulated as a sine wave, thermal diffusivity of the sample can be derived from the phase lag of the thermal wave, scan distance and modulation frequency in a straight forward manner. By using more specific analytical models, thermal conductivity and diffusivity in complicated cases, such as layered structure materials, composite materials, and/or anisotropic materials, are measurable as well. In this work, thermal diffusivity of the light damage layer of the post-irradiation Zirlo and SiC-SiC composite are measured and compared. The Zirlo sample is irradiated by Ni{sup 9+} ion, and SiC-SiC composite material is irradiated by Si{sup 7+} ion. The peak DPA of both sample is similar as ∼10. For ion-irradiated materials, DPA is known to increase with depth before it reaches the peak, and then sharply drop to zero. In term of light damage layer in this manuscript, we mean by the layer with a DPA smaller than 5% maximum value. In this layer DPA increases slowly and smoothly with depth, and the structure and thus thermal properties are more spatially uniform. For the SiC-SiC composite, the measurements are separately conducted on fibers along radial or axial direction, and on the matrix. Our measurement results show that with similar microstructural damage, thermal diffusivity of matrix SiC reduces more significantly than that of Zirlo. For fiber SiC that has a much lower thermal diffusivity than the matrix SiC before irradiation, the post-irradiation effect on thermal diffusivity is not obvious.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Numerical Simulation and Experimental Comparison of System Analysis Module 1D Mixing Model for Cold Shock Transients in the Gallium Thermal-Hydraulic Mixing Facility

Abstract Liquid metals are being investigated as coolants in many advanced reactor designs because of their high thermal conductivity and effectiveness at high temperatures. However, they often pose challenges to reactor operation and safety because of the complex thermal mixing and stratification in the plenum of pool-type reactor designs. The advanced system analysis code System Analysis Module (SAM) currently under development at Argonne National Laboratory aims to develop and implement thermal mixing models to accurately capture these complex thermal fluid behaviors. In this study, the SAM thermal mixing model was compared against experimental data from the Gallium Thermal-Hydraulic Experiment facility, a scaled liquid metal test facility that uses gallium as a surrogate fluid to investigate the stratification and thermal mixing of low-Prandtl-number fluids in the upper plenum of a liquid metal-cooled reactor. Two cold shock transient cases were used: one with stable stratified flow (Ri = 32) and one with stronger thermal mixing (Ri = 0.5). The resultant temperatures were then compared with the experimental temperatures over the entire plenum to assess the ability of the mixing models to capture the thermal behavior and to better correspond mixing parameters to various flow scenarios. Generally, the zero-dimensional mixing model was more capable of capturing the bulk temperature of the component modeled assuming that an accurate mass flow rate was provided, but it was inherently unable to capture thermal gradients in space. The one-dimensional mixing model was capable of capturing that the thermal gradients provided accurate selection of the mixing coefficients. Further, the temperature at the outlet junction was compared over time for each of the mixing models with the recorded experimental temperature. The implemented mixing models demonstrated the ability to effectively capture the overall thermal behavior for stronger mixing scenarios but struggled with more stably stratified flows. It was found that a system analysis code's covering of the entire range of different operating conditions still remains a challenging task, and it is suggested that further model and closure improvements are necessary to accurately capture complex thermal mixing and stratification phenomena.

stratification↗
DOE OSTI2012

ON THE EXISTENCE OF 'RADIO THERMALLY ACTIVE' GALACTIC SUPERNOVA REMNANTS

In this paper, we investigate the possibility of significant production of thermal bremsstrahlung radiation at radio continuum frequencies that could be linked to some Galactic supernova remnants (SNRs). The main targets for this investigation are SNRs expanding in high-density environments. There are several indicators of radio thermal bremsstrahlung radiation from SNRs, such as a flattening at higher frequencies and thermal absorption at lower frequencies intrinsic to an SNR. In this work, we discuss the radio continuum properties of three SNRs that are the best candidates for testing our hypothesis of significant thermal emission. In the case of SNRs IC 443 and 3C 391, thermal absorption has been previously detected. For IC 443, the contribution of thermal emission at 1 GHz, from our model fit is 3%-57%. It is similar to the estimate obtained from the thermal absorption properties (10%-40% at 1 GHz). In the case of the 3C 391 the conclusions are not so clear. The results from our model fit (thermal emission contribution of 10%-25% at 1 GHz) and results obtained from the low-frequency absorption (thermal contribution of 0.15%-7% at 1 GHz) do not overlap. For the SNR 3C 396 we suggest that if previously detected thermal absorption could be intrinsic to the SNR then the thermal emission (<47% at 1 GHz from our model fit) could be significant enough to shape the radio continuum spectrum at high frequencies. Polarization observations for these SNRs can constrain the strength of a thermal component. Reliable observations at low frequencies (<100 MHz) are needed as well as more data at high radio frequencies (>1 GHz), in order to make stronger conclusions about the existence of 'radio thermally active' SNRs.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2018

COOLR: A New System for Dynamic Thermal-Aware Computing

Extreme-scale systems need to walk a fine line between the amount of cooling they receive and the thermal-induced performance and reliability degradation they can sustain. System managers are extremely motivated to battle cooling-energy cost: the largest line item in their total operating cost. On the other hand, pushing the nodes to peak performance in tightened cooling regimes places the burden on the dynamic thermal management (DTM) to protect the hardware. DTM schemes throttle performance to relieve heat accumulation within nodes when cooling cannot mitigate the problem. These interventions prevent fatal failures but introduce inevitable performance degradations and variations. Such variations can have drastic consequences on the performance of extreme-scale systems. Furthermore, distribution of heat across different system nodes depends not only on the amount of workload. Even if a strictly equal share of computational load is assigned to all nodes, there are physical attributes and topological features of each system that inherently cause uneven accumulation of heat. These can cause one subcomponent to trigger DTM prematurely and penalize the overall system. Our goal in this project is to create a holistic thermal-aware view of the system, capturing both inherent physical attributes and dynamic system state. We developed COOLR, a dynamic system with the ability to evaluate the interplay between management of computation, data, power dissipation, and thermal state. Thereby, COOLR will achieve higher overall performance at the same energy and cooling cost. First, we performed a systematic power and thermal modeling and of high performance computing architectures. Analytical and empirical techniques were blended to generate a light-weight thermal model of target systems. Second, we developed a thermal-aware OS and runtime system. Policies for managing resources and schedules for processes has been designed to co-optimize the thermal state and performance of the system. The main outcome of our proposed thermal-aware dynamic computing system are scheduling and allocation of processes and memory accesses leading to an appropriately “skewed” distribution of activity across the system. The ultimate result of this new arrangement resulted in reduced occurrences of hotspots and reduced episodes of DTM intervention, leading to improvements in performance. The overall thermal characterization and modeling methodology (thermal instrumentation techniques, model building, and systematic model reduction) resulting from this project can be applied to systems beyond our immediate scope and will be applicable to future scaling. The thermal-aware dynamic computing paradigm will impact the efficiency of extreme-scale systems. The gained “thermal slack” can be given back to further tighten the cooling budget, benefiting the management cost of next generation extreme-scale systems.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2012

Anisotropic thermal properties of the polar crystal Cs{sub 2}TeMo{sub 3}O{sub 12}

A Cs{sub 2}TeMo{sub 3}O{sub 12} single crystal with dimensions of 17 mm Multiplication-Sign 17 mm Multiplication-Sign 18 mm was grown using the top-seeded solution growth method. Thermal properties, including thermal expansion, specific heat, thermal diffusivity and thermal conductivity, were investigated as a function of temperature. The average linear thermal expansion coefficients along different crystallographic directions were measured to be {alpha}{sub a}=7.34 Multiplication-Sign 10{sup -6} K{sup -1} and {alpha}{sub c}=32.02 Multiplication-Sign 10{sup -6} K{sup -1} over the temperature range of 30-430 Degree-Sign C. The specific heat was measured to be 0.400-0.506 J g{sup -1} K{sup -1} from 22 Degree-Sign C to 440 Degree-Sign C. The thermal conductivity was calculated to be 1.86 and 0.76 W m{sup -1} K{sup -1} at 22 Degree-Sign C along the a and c axes, respectively. With increasing temperature from 22 to 430 Degree-Sign C, the thermal conductivity decreases by 33.0% along the a axis, while it decreases by 18.5% below 200 Degree-Sign C and then remains unchanged along the c axis. The relationship between structure and the thermal properties is also discussed. - Graphical Abstract: Centimeter-sized crystals of polar Cs{sub 2}TeMo{sub 3}O{sub 12} were grown using the top-seeded solution growth method. The relative large anisotropy in thermal expansion and thermal conductivity of Cs{sub 2}TeMo{sub 3}O{sub 12} is attributable to its layered structure. Highlights: Black-Right-Pointing-Pointer Cs{sub 2}TeMo{sub 3}O{sub 12} single crystals with dimensions of 17 Multiplication-Sign 17 Multiplication-Sign 18 mm{sup 3} were grown. Black-Right-Pointing-Pointer Thermal properties of Cs{sub 2}TeMo{sub 3}O{sub 12} were studied as a function of temperature. Black-Right-Pointing-Pointer The thermal expansion anisotropy of Cs{sub 2}TeMo{sub 3}O{sub 12} is explained using its structure. Black-Right-Pointing-Pointer To protect Cs{sub 2}TeMo{sub 3}O{sub 12} crystal, a small cooling rate should be used during growth. Black-Right-Pointing-Pointer A large temperature gradient should be avoided during processing and application.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Thermal Adaptation of Enzyme‐Mediated Processes Reduces Simulated Soil CO2 Fluxes Upon Soil Warming

Abstract Understanding factors influencing carbon effluxes from soils to the atmosphere is important in a world experiencing climatic change. Two important uncertainties related to soil organic carbon (SOC) stock responses to a changing climate are (a) whether soil microbial communities acclimate or adapt to changes in soil temperature and (b) how to represent this process in SOC models. To further explore these issues, we included thermal adaptation of enzyme‐mediated processes in a mechanistic SOC model (ReSOM) using the macromolecular rate theory. Thermal adaptation is defined here to encompass all potential responses of soil microbes and microbial communities following a change in temperature. To assess the effects of thermal adaptation of enzyme‐mediated processes on simulated SOC losses, ReSOM was applied to data collected from a 13‐year soil warming experiment. Results show that a model omitting thermal adaptation of enzyme‐mediated processes substantially overestimates observed CO 2 effluxes during the initial years of soil warming. The bias against observed CO 2 effluxes was lower for models including thermal adaptation of enzyme‐mediated processes. In addition, for a simulated linear 3°C soil warming over 100 years, models including thermal adaptation of enzyme‐mediated processes simulated SOC losses of a factor of three smaller than models omitting this process. As thermal adaptation of microbial community characteristics is generally not included in models simulating feedback between the soil, biosphere and atmosphere, we encourage future studies to assess the potential impact that microbial adaptation has on soil carbon – climate feedback representations in models. Plain Language Summary A major uncertainty in projecting how much soil organic carbon (SOC) will be converted to CO 2 as a consequence of climate change is related to how soil microbes may adapt to increasing soil temperatures. While this “microbial thermal adaptation” has been shown to occur in short‐term lab incubation experiments, its effect on SOC cycling on a decadal timescale is not clear. To address this knowledge gap, a mechanistic SOC model was used to simulate data collected from a 13‐year soil warming experiment, to assess how microbial thermal adaptation affects predicted SOC losses upon soil warming. The model results show that incorporating microbial thermal adaptation into the model led to reduced CO 2 effluxes from the soil to the atmosphere compared to the common approach of omitting this mechanism. Our results imply that projected SOC losses for the decades to come may be reduced when this mechanism is incorporated in land models. We therefore advocate for more research on the mechanisms controlling microbial thermal adaptation, and how to implement this mechanism in SOC models. Key Points A crucial aspect of soil organic carbon (SOC) models is the representation of soil microbes Predicted soil CO 2 fluxes upon soil warming are reduced when accounting for microbial thermal adaptation On a centennial time scale, this thermal adaptation results in up to a factor of three lower predicted SOC loss

Van de Broek, Marijn↗
DOE OSTI2016

Relationships between elastic anisotropy and thermal expansion in A 2 Mo 3 O 12 materials

Here, we report calculated elastic tensors, axial Grüneisen parameters, and thermal stress distributions in Al 2 Mo 3 O 12 , ZrMgMo 3 O 12 , Sc 2 Mo 3 O 12 , and Y 2 Mo 3 O 12 , a series of isomorphic materials for which the coefficients of thermal expansion range from low-positive to negative. Thermal stress in polycrystalline materials arises from interactions between thermal expansion and mechanical properties, and both can be highly anisotropic. Thermal expansion anisotropy was found to be correlated with elastic anisotropy: axes with negative thermal expansion were less compliant. Calculations of axial Grüneisen parameters revealed that the thermal expansion anisotropy in these materials is in part due to the Poisson effect. Models of thermal stress due to thermal expansion anisotropy in polycrystals following cooling showed thermal stresses of sufficient magnitude to cause microcracking in all cases. The thermal expansion anisotropy was found to couple to elastic anisotropy, decreasing the bulk coefficient of thermal expansion and leading to lognormal extremes of the thermal stress distributions.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Dynamic Pressure Drag on Rising Buoyant Thermals in a Neutrally Stable Environment

Abstract This study examines dynamic pressure drag on rising dry buoyant thermals. A theoretical expression for drag coefficient C d as a function of several other nondimensional parameters governing thermal dynamics is derived based on combining the thermal momentum budget with the similarity theory of Scorer. Using values for these nondimensional parameters from previous studies, the theory suggests drag on thermals is small relative to that on solid spheres in laminar or turbulent flow. Two sets of numerical simulations of thermals in an unstratified, neutrally stable environment using an LES configuration of the Cloud Model 1 (CM1) are analyzed. One set has a relatively low effective Reynolds number R e and the other has an order-of-magnitude-higher R e ; these produce laminar and turbulent resolved-scale flows, respectively. Consistent with the theoretical C d , the magnitude of drag is small in all simulations. However, whereas the laminar thermals have C d ≈ 0.01, the turbulent thermals have weakly negative drag ( C d ≈ −0.1). This difference is explained by the laminar thermals having near vertical symmetry but the turbulent thermals exhibiting considerable vertical asymmetry of their azimuthally averaged flows. In the laminar thermals, buoyancy rapidly becomes concentrated around the main centers of rotation located along the horizontal central axis, leading to expansion of thermals via baroclinic vorticity generation but doing little to break vertical symmetry of the flow. Vertical asymmetry of the azimuthally averaged flow of turbulent thermals is attributed mainly to small-scale resolved eddies that are concentrated in the upper part of the thermals.

Meteorology & Atmospheric Sciences↗
DOE OSTI2011

Report on Thermal Aging Effects on Tensile Properties of Advanced Austenitic Steels

This report provides an update on the evaluation of thermal-aging induced degradation of tensile properties of advanced HT-UPS austenitic stainless steels. The report is the second deliverable (level 3) in FY11 (M3A11AN04030103), under the Work Package A-11AN040301, “Advanced Alloy Testing” performed by Argonne National Laboratory, as part of Advanced Structural Materials Program for the Advanced Reactor Concepts. This work package supports the advanced structural materials development by providing tensile data on aged alloys and a mechanistic model, validated by experiments, with a predictive capability on long-term performance. The scope of work is to evaluate the effect of thermal aging on the tensile properties of advanced alloys such as ferritic-martensitic steels, mod.9Cr-1Mo (G91), G92, and advanced austenitic stainless steel, HT-UPS. The aging experiments have been conducted over a temperature of 550-750°C for various time periods to simulate the microstructural changes in the alloys. In addition, a mechanistic model based on thermodynamics and kinetics has been used to address the changes in microstructure of the alloys as a function of time and temperature, which is developed in the companion work package at ANL. The focus of this project is advanced alloy testing and understanding the effects of long-term thermal aging on the tensile properties. The first deliverable of FY11 reported the tensile testing results of thermally-aged G92 in the normalized and tempered condition (H1 G92), G92 in the cold-rolled condition (H2 G92), and reference alloy, G91 ferritic-martensitic steels. This report summarizes the tensile data of thermally aged HT-UPS austenitic stainless steel. Two heats of HT-UPS have been investigated, i.e., solution-annealed HT-UPS (SA HT-UPS) and hot-rolled HT-UPS (HR HT-UPS). Tensile data have been obtained for SA HT-UPS thermally-aged for up to 18031 h at 550°C and for up to 17595 h at 650°C, as well as for HR HT-UPS thermally aged for up to 6909 h at 550°C, 4293 h at 600°C, and 5407 h at 650°C. Major finding are: (1) the solution-annealed HT-UPS showed continued, moderate increase in strength and decrease in ductility with increasing aging time up to 18034 h at 550°C. Thermal aging at 650°C increased the yield stress and decreased the ultimate tensile strength and drastically reduced the ductility in the SA HT-UPS. For the HR HT-UPS, thermal aging at 550°C for up to 6909 h showed little influence on its tensile behavior. Thermal aging at 600°C for 4293 h increased the strength and decreased the ductility. The 650°C-thermally-aged HR HT-UPS specimens showed very different strengthening, strain hardening, and flow localization behavior. Thermal aging at 650°C increased the yield stress but decreased the ultimate tensile stress for the HR HT-UPS. (2) Dynamic strain aging (DSA) was observed in both the solution-annealed HT-UPS and the hot-rolled HT-UPS at temperatures between 550-650°C at a strain rate of 0.001 s -1 . Extensive precipitation in the matrix after thermal aging at 600 and 650°C significantly reduced serrated plastic flow observed in the stress-strain curves, i.e. less effect of DSA. Because the DSA phenomenon can have significant influence on tensile, creep strength, and fatigue resistance, and the DSA effects in HT-UPS steels were observed in the temperature range of interest to the SFR applications, the DSA phenomenon in the HT.

Li, Meimei↗
NASA NTRS2011

Thermally Conductive Tape Based on Carbon Nanotube Arrays

To increase contact conductance between two mating surfaces, a conductive tape has been developed by growing dense arrays of carbon nanotubes (CNTs, graphite layers folded into cylinders) on both sides of a thermally conductive metallic foil. When the two mating surfaces are brought into contact with the conductive tape in between, the CNT arrays will adhere to the mating surface. The van der Waals force between the contacting tubes and the mating surface provides adhesion between the two mating surfaces. Even though the thermal contact conductance of a single tube-to-tube contact is small, the tremendous amount of CNTs on the surface leads to a very large overall contact conductance. Interface contact thermal resistance rises from the microroughness and the macroscopic non-planar quality of mating surfaces. When two surfaces come into contact with each other, the actual contact area may be much less than the total area of the surfaces. The real area of contact depends on the load, the surface roughness, and the elastic and inelastic properties of the surface. This issue is even more important at cryogenic temperatures, where materials become hard and brittle and vacuum is used, which prevents any gas conduction through the interstitial region. A typical approach to increase thermal contact conductance is to use thermally conducting epoxies or greases, which are not always compatible with vacuum conditions. In addition, the thermal conductivities of these compounds are often relatively low. The CNTs used in this approach can be metallic or semiconducting, depending on the folding angle and diameter. The electrical resistivity of multiwalled carbon nanotubes (MWCNTs) has been reported. MWCNTs can pass a current density and remain stable at high temperatures in air. The thermal conductivity of a MWCNT at room temperature is measured to be approximately 3,000 W/m-K, which is much larger than that of diamond. At room temperature, the thermal conductance of a 0.3 sq cm array of CNTs was measured to be as high as 10 W/K. The high thermal conductivity and the nanoscale size make CNTs ideal as thermal interface materials. The CNT-based thermal tape can be used for the thermal management of microelectronic packages and electronic systems. It also can be integrated with current device technology and packaging. The material would allow for an efficient method to manage excess heat generation without requiring any additional power. Lastly, the CNT tape can be used to enhance thermal contact conductance across two mating surfaces on some NASA missions.

Kashani, Ali↗
NASA NTRS2017

Thermal cycling testing to failure of a ceramic column grid array package for space applications

Ceramic column grid array (CCGA) packages have been used increasingly in logic and microprocessor functions, telecommunications, flight avionics boards, payload electronics boards, engineering navigational and science cameras, electronic assemblies, and other applications, because of their inherent advantages such as high electrical interconnect density, very good thermal and electrical performance, and compatibility with standard surface-mount technology (SMT) packaging assembly processes. Because these advanced electronic packages tend to have less solder-joint strain-relief than do leaded flat-pack electronic packages, the reliability of CCGA packages in challenging thermal environments is a very important consideration for their short- and long-term use in JPL-NASA space missions. In this study, we assembled daisy chains of polyimide printed wiring boards from CCGA-interconnect packages, inspected the boards nondestructively, and then subjected them to thermal cycling to assess their reliability in thermal environments from +125°C to -40°C±25°C. The test hardware consists of a CCGA 1752 package (CN version). The package was divided into four daisy-chained sections that were electrically monitored for their continuity during thermal cycling. The CCGA 1752 package is roughly 45 mm × 45 mm with a 42-mm × 42-mm array of 80%/20% Pb/Sn columns on a 1.00-mm pitch. The resistance of the daisy-chained CCGA interconnects was continuously monitored during thermal cycling in a gaseous nitrogen environment. Electrical continuity resistance measurements as a function of thermal cycling are reported here; tests to date have shown significant change to an open circuit in daisy-chain resistance as a function of thermal cycling. The change in interconnect resistance becomes increasingly noticeable with increasing number of thermal cycles. This paper describes the experimental thermal-cycling test results of CCGA 1752 package reliability testing under an extremely wide temperature range. The first failure was observed at 1479th thermal cycle. We report the thermal-cycle reliability test data for ~2500 thermal cycles.

Ramesham, Rajeshuni↗
DOE OSTI2023

Study on the Thermal Stabilizing Process of Layered Double Hydroxides in PVC Resin

Poly(vinyl chloride) (PVC) is widely used in various fields and requires the use of thermal stabilizers to enhance its thermal stability during processing because of its poor thermal stability. Layered double hydroxides (LDHs) are widely considered to be one kind of highly efficient and environmentally friendly PVC thermal stabilizer. To investigate the thermal stabilizing process of layered double hydroxides (LDHs) in PVC resin, PVC and MgAl-LDHs powders with different interlayer anions (CO 3 2- , Cl - , and NO 3 - ) were physically mixed and aged at 180 °C. The structure of LDHs at different aging times was studied using XRD, SEM, and FT-IR. The results show that the thermal stabilizing process of LDHs on PVC mainly has three stages. In the first stage, the layers of LDHs undergo a reaction with HCl, which is released during the thermal decomposition of PVC. Subsequently, the ion exchange process occurs between Cl - and interlayer CO 3 2- , resulting in the formation of MgAl-Cl-LDHs. Finally, the layers of MgAl-Cl-LDHs react with HCl slowly. During the thermal stabilizing process of MgAl-Cl-LDHs, the peak intensity of XRD reduces slightly, and no new XRD peak emerges. It indicates that only the first step happens for MgAl-Cl-LDHs. The TG-DTA analysis of LDHs indicates that the interaction of LDHs with different interlayer anions has the following order: NO 3 - < CO 3 2- < Cl - , according to the early coloring in the thermal aging test of PVC composites. The results of the thermal aging tests suggest that LDHs with a weak interaction between interlayer anions and layers can enhance the early stability of PVC significantly. Furthermore, the thermal aging test demonstrates that LDHs with high HCl absorption capacities exhibit superior long-term stabilizing effects on PVC resin. This finding provides a valuable hint for designing an LDHs/PVC resin with a novel structure and excellent thermal stability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Development of Numerical Model of Metal Foam with PCM for the Estimation of Effective Thermal Conductivity

Global warming due to climate change is a threat to humankind. Nuclear energy is one of the promising solutions to reduce fossil fuel usage. Nuclear energy can handle the base load, compensating for the volatility of renewable energy. If nuclear energy could achieve load following capability, the combination with renewable energy would be more suitable. Thermal energy storage (TES) is one of the options for enabling load following of nuclear reactors. The TES makes it possible to store surplus nuclear thermal energy and release it later as needed. In Idaho National Laboratory (INL), a new concept of latent heat TES integrated with high-temperature heat pipe has been proposed and is under development, which is called Heat pipe-Integrated Thermal Battery (HITB). HITB exchanges thermal energy between the reactor system and TES via heat pipe. The heat transferred to TES medium, made of phase change material (PCM), stores energy as sensible heat and/or latent heat. As PCM typically has poor thermal conductivity, however, various heat transfer enhancement techniques are required to achieve a rapid charging cycle. There are many techniques to enhance the heat transfer ability of TES medium such as disk, fin, and metal foam. Among them, metal foam is an appropriate option to enhance the heat transfer because it maximizes the heat transfer area through metal wicks. Metal foam is a lightweight metal structure that has a high porosity of over 0.9. The typical materials for metal foam are Aluminum, Copper, Nickel, and Silicon Carbide (SiC). Metal foam not only enhances heat transfer via conduction but also increases contact surface area. In the HITB design , the metal foam is being considered as one of the options to enhance the heat transfer of TES medium (PCM) [1]. To predict the enhanced thermal performance of TES, one should properly estimate the effective thermal conductivity of metal foam combined with PCM material or calculate heat transfer in distributed model. There are many experimental works that provides effective thermal conductivity of metal foam with various PCM [2,3]. Also, many theoretical models were developed based on the unit cell model of metal foam [4,5]. With a distributed model, on the other hand, detail heat transfer characteristics between metal foam and PCM material can be analyzed considering the geometry or buoyancy effect. However, due to the complex geometry of metal foam pores, the computational cost for three-dimensional modeling highly increases. Therefore, if metal foam structure can be modeled in simple and repetitive design, the computational cost would decrease Among the various metal foam models [2], lattice model is one of the simple and extendable design. The porosity and pores per inch (PPI) can be characterized by the size and spatial distance of lattice structure. If the three-dimensional metal foam model consists of lattice structure could properly estimate the heat transfer, which is characterized by effective thermal conductivity, it would be a good option to assess the thermal performance of metal foam with PCM. In this study, a three-dimensional numerical model was developed to simulate conductive heat transfer between metal foam and PCM. The three-dimensional lattice structure of square pillars was selected as a basic structure of the metal foam. The calculation result was characterized by the effective thermal conductivity of the whole domain. A sensitivity study was conducted for mesh size, domain size, and PPI to check whether the calculation result gives a converged result or not. Lastly, the effective thermal conductivity from the lattice model was compared with existing experimental data to validate the model result

25 ENERGY STORAGE↗