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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS1986

Solid lubrication design methodology, phase 2

The high temperature performance of solid lubricated rolling elements was conducted with a specially designed traction (friction) test apparatus. Graphite lubricants containing three additives (silver, phosphate glass, and zinc orthophosphate) were evaluated from room temperature to 540 C. Two hard coats were also evaluated. The evaluation of these lubricants, using a burnishing method of application, shows a reasonable transfer of lubricant and wear protection for short duration testing except in the 200 C temperature range. The graphite lubricants containing silver and zinc orthophosphate additives were more effective than the phosphate glass material over the test conditions examined. Traction coefficients ranged from a low of 0.07 to a high of 0.6. By curve fitting the traction data, empirical equations for slope and maximum traction coefficient as a function of contact pressure (P), rolling speed (U), and temperature (T) can be developed for each lubricant. A solid lubricant traction model was incorporated into an advanced bearing analysis code (SHABERTH). For comparison purposes, preliminary heat generation calculations were made for both oil and solid lubricated bearing operation. A preliminary analysis indicated a significantly higher heat generation for a solid lubricated ball bearing in a deep groove configuration. An analysis of a cylindrical roller bearing configuration showed a potential for a low friction solid lubricated bearing.

Pallini, R. A.↗
NASA NTRS2017

Gravity Effects in Microgap Flow Boiling

Increasing integration density of electronic components has exacerbated the thermal management challenges facing electronic system developers. The high power, heat flux, and volumetric heat generation of emerging devices are driving the transition from remote cooling, which relies on conduction and spreading, to embedded cooling, which facilitates direct contact between the heat-generating device and coolant flow. Microgap coolers employ the forced flow of dielectric fluids undergoing phase change in a heated channel between devices. While two phase microcoolers are used routinely in ground-based systems, the lack of acceptable models and correlations for microgravity operation has limited their use for spacecraft thermal management. Previous research has revealed that gravitational acceleration plays a diminishing role as the channel diameter shrinks, but there is considerable variation among the proposed gravity-insensitive channel dimensions and minimal research on rectangular ducts. Reliable criteria for achieving gravity-insensitive flow boiling performance would enable spaceflight systems to exploit this powerful thermal management technique and reduce development time and costs through reliance on ground-based testing. In the present effort, the authors have studied the effect of evaporator orientation on flow boiling performance of HFE7100 in a 218 m tall by 13.0 mm wide microgap cooler. Similar heat transfer coefficients and critical heat flux were achieved across five evaporator orientations, indicating that the effect of gravity was negligible.

microscale↗
NASA NTRS2017

Gravity Effects in Microgap Flow Boiling

Increasing integration density of electronic components has exacerbated the thermal management challenges facing electronic system developers. The high power, heat flux, and volumetric heat generation of emerging devices are driving the transition from remote cooling, which relies on conduction and spreading, to embedded cooling, which facilitates direct contact between the heat-generating device and coolant flow. Microgap coolers employ the forced flow of dielectric fluids undergoing phase change in a heated channel between devices. While two phase microcoolers are used routinely in ground-based systems, the lack of acceptable models and correlations for microgravity operation has limited their use for spacecraft thermal management. Previous research has revealed that gravitational acceleration plays a diminishing role as the channel diameter shrinks, but there is considerable variation among the proposed gravity-insensitive channel dimensions and minimal research on rectangular ducts. Reliable criteria for achieving gravity-insensitive flow boiling performance would enable spaceflight systems to exploit this powerful thermal management technique and reduce development time and costs through reliance on ground-based testing. In the present effort, the authors have studied the effect of evaporator orientation on flow boiling performance of HFE7100 in a 218 m tall by 13.0 mm wide microgap cooler. Similar heat transfer coefficients and critical heat flux were achieved across five evaporator orientations, indicating that the effect of gravity was negligible.

microscale↗
DOE OSTI2023

COUPLING SMOOTHED PARTICLE HYDRODYNAMICS WITH FINITE ELEMENT METHOD TO SIMULATE RESIDUAL STRESSES FROM FRICTION STIR PROCESSING

Friction stir processing (FSP) is a solid-state material processing technique that locally modifies the microstructure but also induces undesirable residual stresses. A robust numerical model for the FSP can help in mitigating these residual stresses. Heat source models within a finite element method (FEM) framework suffer from inaccuracies. In contrast, smoothed particle hydrodynamics (SPH) model that explicitly captures the material flow near the tool and the associated heat generation are accurate. However, the computational expense of SPH simulations can be prohibitive. In this work, we propose a coupled SPH-FEM framework. SPH is used to model the heat generation accurately near the tool and which is then inserted into to the FEM model as a heat source. To verify this proposed coupling approach, a test case is set up with typical FSP conditions and it is modeled in both SPH and SPH-FEM. The temperatures profiles were compared after the simulations have reached steady-state temperatures. The similarity of the temperature profiles from SPH-FEA and SPH validated the proposed coupling approach. This proposed approach achieves the accuracy of the SPH method while potentially retaining the low computational expense of FEM.

smoothed particle hydrodynamics, Finite Element Me↗
NASA NTRS2003

Magnetic Microspheres and Tissue Model Studies for Therapeutical Applications

Hyperthermia is a well known cancer therapy and consists of heating a tumor region to the elevated temperatures in the range of 40-45 C for an extended period of time (2-8 hours). This leads to thermal inactivation of cell regulatory and growth processes with resulting widespread necrosis, carbonization and coagulation. Moreover, heat boosts the tumor response to other treatments such as radiation, chemotherapy or immunotherapy. Of particular importance is careful control of generated heat in the treated region and keeping it localized. Higher heating, to about 56 C can lead to tissue thermo-ablation. With accurate temperature control, hyperthermia has the advantage of having minimal side effects. Several heating techniques are utilized for this purpose, such as whole body hyperthermia, radio-frequency (RF) hyperthermia, ultrasound technique, inductive microwave antenna hyperthermia, inductive needles (thermoseeds), and magnetic fluid hyperthermia (MFH).MFH offers many advantages as targeting capability by applying magnets. However, this technology still suffers significant inefficiencies due to lack of thermal control. This paper will provide a review of the topic and outline the ongoing work in this area. The main emphasis is in devising ways to overcome the technical difficulty in hyperthermia breast therapy of achieving a uniform therapeutic temperature over the required region of the body and holding it steady for an extended period (2-3 hours). The basic shortcomings of the presently utilized heating methods stem from the non-uniform thermal properties of the tissue and the point heating characteristics of the techniques without any thermal control. Our approach is to develop a novel class of magnetic fluids, which have inherent thermoregulating properties. We have identified a few magnetic alloys which can serve as suitable nano to micron-size particle material. The objective is to synthesize, characterize and evaluate the efficacy of Thermo Regulating Magnetic Fluids (TRMF) for hyperthermia therapy. The development of a tissue model and testing the fluid dynamics of particle motion, settling, distribution in the tissue matrix and heat generation will be discussed.

Ramachandran, N.↗
NASA NTRS1977

Economical photovoltaic power generation with heat recovery

Three designs for conversion of solar radiation to electricity and thermal energy are analyzed. The objective of these converters is to increase the electric and thermal output for each photovoltaic array so as to lower the cell cost relative to the amount of energy delivered. An analysis of the economical aspects of conversion by photovoltaic cells with heat recovery is carried out in terms of hypothetical examples. Thus, it is shown that the original cost of say $40,000 per generated kilowat can be reduced to $572.00 per kilowatt by increasing the original electric output of 1 kW to 10 kW in electricity and 60 kW in thermal energy. The newly derived specific cost is only 1.4 percent of the original one. It is expected that a cost reduction of roughly 2% of the present specific cost per kilowatt will greatly stimulate public acceptance of photovoltaic terrestrial conversion to electricity.

Ascher, G.↗
DOE OSTI2024

System and method for performing laser powder bed fusion using controlled, supplemental in situ surface heating to control microstructure and residual stresses in formed part

The present disclosure relates to an additive manufacturing system for forming a part using a powder material. In one embodiment the system makes use of a primary heat generating subsystem to generate a fusing beam for heating and fusing at least one of select portions of a powder layer, or an entire area of a powder layer, deposited on a build plate. The system also incorporates a beam steering subsystem for steering the fusing beam over the powder layer. A supplemental heating subsystem is used to generate a wide area beam to heat a portion of the powder layer either prior to fusing, along with the fusing operation, or subsequent to fusing of the powder with the fusing beam. The wide area beam has an intensity which is insufficient to fuse the powder, and alters a microstructure of the powder layer as the powder layer is at least one of fused or as it cools, to thus relieve stress in the part.

Smith, William↗
DOE OSTI2022

Thermal Runaway of Nonflammable Localized High‐Concentration Electrolytes for Practical LiNi 0.8 Mn 0.1 Co 0.1 O 2 |Graphite‐SiO Pouch Cells

Abstract With continuous improvement of batteries in energy density, enhancing their safety is becoming increasingly urgent. Herein, practical high energy density LiNi 0.8 Mn 0.1 Co 0.1 O 2 |graphite‐SiO pouch cell with nonflammable localized high concentration electrolyte (LHCE) is proposed that presents unique self‐discharge characteristic before thermal runaway (TR), thus effectively reducing safety hazards. Compared with the reference electrolyte, pouch cell with nonflammable LHCE can increase self‐generated heat temperature by 4.4 °C, increase TR triggering temperature by 47.3 °C, decrease the TR highest temperature by 71.8 °C, and extend the time from self‐generated heat to triggering TR by ≈8 h. In addition, the cell with nonflammable LHCE presents superior high voltage cycle stability, attributed to the formation of robust inorganic‐rich electrode–electrolyte interphase. The strategy represents a pivotal step forward for practical high energy and high safety batteries.

36 MATERIALS SCIENCE↗
NASA NTRS1972

Thermal property measurements on lunar material returned by Apollo 11 and 12 missions.

Measurement of thermal diffusivity on Apollo 11 type A and type C samples in the temperature range between 150 and 440 K under atmospheric pressure. Thermal diffusivity of type C material is lower and less temperature-dependent than type A material. Both types of samples exhibit lower thermal diffusivities than nonporous terrestrial basalt. The rate of heat generation of Apollo 11 and 12 samples was calculated from the concentrations of radioactive elements: potassium, thorium, and uranium. Apollo 11 crystalline rocks show an average rate of heat generation which is not significantly different from terrestrial basalt. The Th/U ratio does not differ greatly from chondritic and terrestrial averages.

Horai, K.-I.↗
NASA NTRS2000

Thermal Aspects of Lithium-Ion Cells

Objective of this investigation is to provide the necessary inputs for a thermal model of the Li-ion battery for the Mars 2001 Lander. Two alternate configurations of this battery are under development: a) prismatic parallel plate, and b) cylindrical spiral wound. Required thermal inputs for both consist of the following: a) heat generation rates, b) thermal mass, and c) thermal conductivity. Thermal mass and conductivity were computed on the basis of known properties and configuration of the cell components. The heat generation rates were taken as the product of current and difference between open circuit voltage (OCV) and operating voltages (CCV) at a given state-of charge (SOC). Herein, it was assumed that the enthalpy voltage was equal to the OCV. OCV vs SOC data were obtained experimentally and CCV vs SOC were taken from previously obtained discharge data.

Frank, H.↗
NASA NTRS1972

The temperature distribution in an infinite medium resulting from a plane source of finite duration.

The temperature distribution in an infinite slab during and following heat generation by a plane source of finite duration is studied. An expression for the instantaneous plane source is obtained. By integration of this expression, the temperature distribution following the end of heating can be obtained. Further, the treatment is extended to time-varying heat generation functions, and an example is presented.

Montealegre, A.↗
DOE OSTI2023

A New Analytical Expression for Estimating the Adiabatic Temperature Rise in Lithium-Ion Batteries During High-Power Pulses

A coupled, thermal-electrochemical model is used to explain why the Joule heating assumption (i.e., I 2 R) does not provide a good representation of the temperature rise during high power pulses in lithium-ion batteries, even in cases where the reversible heat generation can be neglected. The poor agreement occurs because the internal resistance changes during the pulse due to the opposing effects of mass transport in the electrolyte, which raises the resistance, and heat generation (temperature rise), which lowers the resistance. These insights are used to propose a new analytical expression for predicting the temperature rise during adiabatic pulses with limited experimental and physical data. The expression accounts for thermal effects using a Taylor series expansion of an Arrhenius-type equation. It accounts for transport effects using an approximate solution to the one-dimensional diffusion equation. The new expression is shown to accurately estimate the simulated, adiabatic temperature rise across a range of loadings (1 to 4 mAh cm -2 ) and C-rates (1C to 10C) for cells containing LiNi 0.5 Mn 0.3 Co 0.2 O 2 positive electrodes and graphite negative electrodes. In conclusion, it is also shown to accurately estimate the experimental, adiabatic temperature rise measured for cells with LiFePO 4 positive electrodes and mesocarbon negative electrodes with minimal changes to the fitted parameters.

25 ENERGY STORAGE↗
NASA NTRS1980

NASA 50 amp hour nickel cadmium battery waste heat determination

A process for determining the waste heat generated in a 50-ampere-hour, nickel cadmium battery as a function of the discharge rate is described and results are discussed. The technique involved is essentially calibration of the battery as a heat transfer rate calorimeter. The tests are run at three different levels of battery activity, one at 40-watts of waste heat generated, one at 60, and one at 100. Battery inefficiency ranges from 14 to 18 percent at discharge rates of 284 to 588 watts, respectively and top-of-cell temperatures of 20 C.

Mueller, V. C.↗
DOE OSTI2022

Lithium-Ion Batteries with Safer Current Collectors

The US Department of Energy’s Oak Ridge National Laboratory and Soteria Battery Innovation Group collaborated to develop a metallized polymer film as a current collector for lithium-ion batteries and design slit patterns for electrodes to improve battery safety. The metallized polymer film serves as a fuse that will break under high temperature resulting from a short circuit. Consequently, the short circuit will be broken and the heat generated from the short circuit will be alleviated to avoid thermal runaway. The electrodes with slit patterns are expected to be broken into small segments upon mechanical impact, which can isolate the damaged electrodes from the rest. Thus, the heat generation associated with the mechanical impact will be reduced, along with the likelihood of thermal runaway. This effort aimed to improve lithium-ion battery safety by replacing traditional metal foils with metallized polymer films as current collector and introducing slit patterns to battery electrodes. The metallized polymer films were polyethylene terephthalate with a thin metal (aluminum for cathodes and copper for anodes) coating on both sides. Slit patterns with various geometries and dimensions were designed via simulation. Temperature distribution on cells with electrodes with and without slit patterns was also simulated via nemerical modeling. Electrodes on traditional metal foils and metallized polymer films were coated via a pilot-scale slot-die coater at the US Department of Energy Battery Manufacturing Facility at Oak Ridge National Laboratory. The electrodes were calendered to 35% porosity and punched out with and without slit patterns. Pouch cells were assembed with the electrodes inside a dry room for electrochemical and safety testing. Electrodes coated on metallized polymer films exhibited comparable electrochemical performance to their counterparts coated on traditional metal foils. They also showed improved safety in nail penetration and indentation tests.

25 ENERGY STORAGE↗
DOE OSTI2026

Comparative Analysis of Model Predictive Control and MPC-Informed Rule-Based Control for Thermal Storage Operation in Ultra-Low Temperature 4th Generation District Heating Networks

The integration of thermal storage and heat pumps in district heating networks (DHNs) can significantly enhance operational flexibility and energy efficiency; however, the practical deployment of advanced control strategies is often hindered by forecasting requirements and computational complexity. This study presents a comparative analysis of thermal storage control strategies in an ultra-low-temperature fourth-generation DHN, focusing on the development of a simplified rule-based control (RBC) explicitly informed by Model Predictive Control (MPC) behavior. The proposed methodology systematically analyzes the charging and discharging decisions of an MPC-controlled system under ideal forecasting conditions and extracts recurrent control patterns as a function of key system variables, including outdoor temperature, thermal demand, and electricity price. These patterns are translated into a set of structured time- and condition-based rules, resulting in an MPC-informed RBC that embeds predictive insights while preserving implementation simplicity and operational transparency. The approach is validated on a realistic mixed-use urban district in Denver, Colorado, USA, equipped with a centralized air-source heat pump, distributed water-to-water heat pumps, and a central thermal storage unit. Results show that the tuned RBC attains approximately 96% of ideal MPC economic performance (-27% of costs), preserves values of technical and environmental indicators (reduction only of 2-3%), and substantially reduces complexity. Sensitivity analyses further demonstrate the robustness of the RBC under varying operational conditions (i.e., ambient temperature, electricity price). Overall, the study demonstrates that MPC-informed rule-based control represents an effective trade-off between control performance and real-world applicability, enabling the integration of additional system components while maintaining simplicity, robustness, and ease of implementation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Numerical simulation for the design of induction heating based radio frequency reactor for ethylene production

Ethylene is a vital petrochemical compound produced in vast amounts yearly by manufacturers that have enough scale to overcome the inherent thermodynamic inefficiencies of the process. In order to address the inefficiencies that prevent smaller scale or intermittent production ethylene, investigation of new production methods are required. In this work, we investigate the use of a radio frequency (RF) based reactor system that generates heat internally as opposed to applying heat externally via steam or direct combustion of fossil fuels. In order to guide the design of an electromagnetic based reactor system, we have created a macroscale model capable of capturing heat generation at the susceptors from a produced electromagnetic field and subsequent chemical reactions. Several susceptor and induction coil designs were investigated to better understand the performance of the system.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1980

Lubrication of optimized-design tapered-roller bearings to 2.4 million DN

The performance of 120.65 mm (4.75 in.) bore high speed design, tapered roller bearings was investigated at shaft speeds to 20,000 rpm (2.4 million DN) under combined thrust and radial load. The test bearing design was computer optimized for high speed operation. Temperature distribution bearing heat generation were determined as a function of shaft speed, radial and thrust loads, lubricant flow rates, and lubricant inlet temperature. The high speed design, tapered roller bearing operated successfully at shaft speeds up to 20,000 rpm under heavy thrust and radial loads. Bearing temperatures and heat generation with the high speed design bearing were significantly less than those of a modified standard bearing tested previously. Cup cooling was effective in decreasing the high cup temperatures to levels equal to the cone temperature.

Parker, R. J.↗