Thermal control coating degradation data from the Pegasus experiment packages.
Thermal control coating degradation data from aluminum case containing four sensors aboard Pegasus spacecraft
Bannister, T. C.↗
SEARCH · Engineering Papers
Results for “Thermal experience”
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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Thermal Analysis on Large Format Lithium-Ion Batteries in Thermal Runaway
Lithium-ion (Li-ion) batteries can deliver electrical power across a large range of applications, and large format versions of these batteries are common in aerospace for their low mass and energy dense properties. Li-ion cells usage has increased as they are more power dense than fuel cells and have overall higher performance over lead-acid/NiCd batteries. However, Li-ion cells can experience Thermal Runaway (TR) via electro-chemical, mechanical, or thermal abuse. TR is a phenomenon where the stored energy in a cell is rapidly released along with vented gases and other effluents. A cell is generally determined to be in TR if its internal heat generation has surpassed its ability to dissipate that heat. If a Li-ion cell enters TR, propagation within the battery may occur. Propagation is the chain reaction that can occur to nearby cells due to a cell that has entered TR initially. Understanding a battery’s susceptiveness to propagation is necessary to evaluate risks associated with TR phenomenon. To determine if a battery is designed in a sufficient manner to prevent battery propagation if single cell TR occurs, testing and thermal analysis of the battery must be conducted. The presentation for TFAWS 2026 will cover considerations for battery TR thermal analysis, such as: testing methods, influences on the cells, failure mechanisms, and TR parameters. This presentation will include a walkthrough of an example battery TR thermal analysis, and the results thereof.
Lithium Ion Batteries↗
Simultaneous Heat and Electricity Storage in a Flow Battery System
This study investigates the dual-storage capability of a redox flow battery (RFB) system, enabling simultaneous storage of heat and electricity within a single platform. Through electrochemical and thermal experiments, we evaluated how heat storage affects battery performance and vice versa using a counterflow heat exchanger integrated in a conventional RFB configuration. The results show that incorporating heat storage had a minimal impact on the electrochemical charging and discharging processes. Further, the heat discharge operated independently of electrochemical storage, confirming that both functions can coexist without interference. The combined system also enhanced overall energy conversion efficiency, demonstrating its potential as an efficient solution for supplying both thermal and electrical energythe two most widely used energy forms.
Electrical energy↗
Industrial application experiment series
The deployment of parabolic dish systems into the industrial sector for the purpose of providing users, suppliers, sponsors, and developers with a realistic assessment of system feasibility in selected near-term industrial applications will be accomplished initially through the industrial module experiment and later through additional experiments involving thermal, electric, and combined thermal and electrical systems. The approach is to progress through steps, from single module to multi-module systems, from thermal-only applications to more complex combined thermal and electric applications. The experience of other solar thermal experiments, particularly those involving parabolic dish hardware, will be utilized to the fullest extent possible in experiment planning and implementation.
Bluhm, S. A.↗
Thermodynamics and dehydration/hydration behaviors of Na-sulfate, -borate, and -bicarbonate minerals
Here, detailed thermal experiments using relative humidity- (RH) and temperature-controlled X-ray diffraction (XRD) and H 2 O adsorption/desorption measurements were applied to understand the dehydration/hydration behaviors of thenardite/mirabilite (Na 2 SO 4 /Na 2 SO 4 ·10H 2 O), tincalconite/borax (Na 2 B 4 O 7 ·5H 2 O/Na 2 B 4 O 7 ·10H 2 O), nahcolite (NaHCO 3 ), and qilianshanite (NaH 4 (BO 3 ) (CO 3 )·2H 2 O or NaHCO 3 ·H 3 BO 3 ·2H 2 O). The thermal behaviors of thenardite/mirabilite and tincalconite/borax were evaluated at room temperature as a function of RH. Hydration of thenardite to mirabilite is very sluggish and does not begin until at least 85 % RH, whereas dehydration of mirabilite to thenardite occurs at ~76 % RH. The reactions are accessible in the solid state and were not completely reversible on the time scale of these measurements. Qilianshanite appears stable under room conditions, as long as the RH is >20 %, supported by 2.5 months of observation during exposure to room air of known RH. Qilianshanite persists metastably for at least two days when exposed to both wet and 0% RH atmospheres at room temperature, observed during environment-controlled XRD. Below 20 % RH, qilianshanite sluggishly reacts to form tincalconite and nahcolite. When heated, qilianshanite broke down at 70 °C based on XRD results, and thermogravimetric analysis (TGA) confirmed a dehydration temperature of ~75 °C. Tincalconite hydrated to borax at 80 % RH, and dehydration from borax to tincalconite occurred at 40–50 % RH, illustrating the effective reversibility of the reaction under room conditions. The minor phase nahcolite originally in qilianshanite remained in the residue of decomposed qilianshanite after heating to 125 °C, demonstrated by continuous XRD measurements, whereas nahcolite was largely dehydrated when heated to ~100 °C during TGA. The difference can be attributed to the slower reaction kinetics in the environmental XRD. These results shed considerable light on the behavior of these minerals in the environment, particularly in evaporite deposits in Antarctica, where all of these minerals are reacting with the atmosphere on a diurnal-to-seasonal basis.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Thermal emission spectrometer experiment - Mars Observer mission
The paper describes the thermal emission spectrometer (TES) designed for the Mars Observer mission. The TES measurements of the surface and the atmosphere of Mars will be used to determine and map the composition of the surface rocks, minerals, and the condensates. Examples of information that will be obtained from TES data include mineral abundance maps, condensate properties and their distribution in time and space, aerosol properties and their distribution in time and space, the rock abundance, the polar energy balance, and properties of gaseous species. Where appropriate, these derived parameters will be distributed in the form of gridded map, to allow direct comparison with other derived data sets.
Christensen, Philip R.↗
Predictive Inverse Model for Advective Heat Transfer in a Short–Circuited Fracture: Dimensional Analysis, Machine Learning, and Field Demonstration
Identifying fluid flow maldistribution in planar geometries is a well–established problem in subsurface science/engineering. Of particular importance to the thermal performance of enhanced (or “engineered”) geothermal systems is identifying the existence of nonuniform (i.e., heterogeneous) permeability and subsequently predicting advective heat transfer. Here, machine learning via a genetic algorithm (GA) identifies the spatial distribution of an unknown permeability field in a two–dimensional Hele–Shaw geometry (i.e., parallel plates). The inverse problem is solved by minimizing the L2 norm between simulated residence time distribution (RTD) and measurements of an inert tracer breakthrough curve (BTC) (C–Dot nanoparticle). Principal component analysis (PCA) of spatially correlated permeability fields enabled reduction of the parameter space by more than a factor of 10 and restricted the inverse search to reservoir–scale permeability variations. Thermal experiments and tracer tests conducted at the mesoscale Altona Field Laboratory (AFL) demonstrate that the method accurately predicts the effects of extreme flow channeling on heat transfer in a single bedding–plane rock fracture. However, this is only true when the permeability distributions provide adequate matches to both tracer RTD and frictional pressure loss. Without good agreement to frictional pressure loss, it is still possible to match a simulated RTD to measurements, but subsequent predictions of heat transfer are grossly inaccurate. Here, the results of this study suggest that it is possible to anticipate the thermal effects of flow maldistribution, but only if both simulated RTDs and frictional pressure loss between fluid inlets and outlets are in good agreement with measurements.
42 ENGINEERING↗
Computational Fluid Dynamics (CFD) Simulations of Jet Mixing in Tanks of Different Scales
For long-duration in-space storage of cryogenic propellants, an axial jet mixer is one concept for controlling tank pressure and reducing thermal stratification. Extensive ground-test data from the 1960s to the present exist for tank diameters of 10 ft or less. The design of axial jet mixers for tanks on the order of 30 ft diameter, such as those planned for the Ares V Earth Departure Stage (EDS) LH2 tank, will require scaling of available experimental data from much smaller tanks, as well designing for microgravity effects. This study will assess the ability for Computational Fluid Dynamics (CFD) to handle a change of scale of this magnitude by performing simulations of existing ground-based axial jet mixing experiments at two tank sizes differing by a factor of ten. Simulations of several axial jet configurations for an Ares V scale EDS LH2 tank during low Earth orbit (LEO) coast are evaluated and selected results are also presented. Data from jet mixing experiments performed in the 1960s by General Dynamics with water at two tank sizes (1 and 10 ft diameter) are used to evaluate CFD accuracy. Jet nozzle diameters ranged from 0.032 to 0.25 in. for the 1 ft diameter tank experiments and from 0.625 to 0.875 in. for the 10 ft diameter tank experiments. Thermally stratified layers were created in both tanks prior to turning on the jet mixer. Jet mixer efficiency was determined by monitoring the temperatures on thermocouple rakes in the tanks to time when the stratified layer was mixed out. Dye was frequently injected into the stratified tank and its penetration recorded. There were no velocities or turbulence quantities available in the experimental data. A commercially available, time accurate, multi-dimensional CFD code with free surface tracking (FLOW-3D from Flow Science, Inc.) is used for the simulations presented. Comparisons are made between computed temperatures at various axial locations in the tank at different times and those observed experimentally. The affect of various modeling parameters on the agreement obtained are assessed.
Breisacher, Kevin↗
Spatiotemporal Learning in Power Modules: Wavelet-Enhanced Forecasting of Thermomechanical Degradation
Detecting internal defects in power electronics packages is critical for their performance and reliability, especially under extreme operating conditions, as these defects can lead to catastrophic failure if not properly addressed. Confocal scanning acoustic microscopy (C-SAM) plays a key role in the nondestructive evaluation of bond layer degradation within a power electronics package by detecting defects such as delamination, voids, and cracks. However, accurately quantifying and predicting these defects from C-SAM images remains a significant challenge due to the low noise-to-signal ratio, which typically arises from both imaging process and bond patterns itself. In this paper, we explore machine learning strategies for processing C-SAM images and providing predictive models of defect growth. We use C-SAM images of sintered copper and sintered silver samples, which are obtained under accelerated thermal experiments, as the representative dataset for our study. We investigate the effect of Fourier transforms and wavelet transforms on these datasets to remove high-frequency noise and address noise across multiple scales with histogram equalization to enhance the contrast and improve the visibility of defects. As a result, defect boundaries can be clearly distinguished, enabling more accurate tracking of their growth over time. We then employ different time-series forecasting algorithms on the denoised images to formulate an image-based lifetime prediction model. Statistical models and deep-learning techniques are trained on images obtained in the early stages of thermal shock, and defect growth in the later stages is predicted. Our work serves as a preliminary attempt to improve the accuracy of lifetime prediction models of power electronics packages, which is critical under extreme operating environments.
24 POWER TRANSMISSION AND DISTRIBUTION↗
Scaling analysis applied to the NORVEX code development and thermal energy flight experiment
A scaling analysis is used to study the dominant flow processes that occur in molten phase change material (PCM) under 1 g and microgravity conditions. Results of the scaling analysis are applied to the development of the NORVEX (NASA Oak Ridge Void Experiment) computer program and the preparation of the Thermal Energy Storage (TES) flight experiment. The NORVEX computer program which is being developed to predict melting and freezing with void formation in a 1 g or microgravity environment of the PCM is described. NORVEX predictions are compared with the scaling and similarity results. The approach to be used to validate NORVEX with TES flight data is also discussed. Similarity and scaling show that the inertial terms must be included as part of the momentum equation in either the 1 g or microgravity environment (a creeping flow assumption is invalid). A 10(exp -4) environment was found to be a suitable microgravity environment for the proposed PCM.
Skarda, J. Raymond Lee↗
Scaling analysis applied to the NORVEX code development and thermal energy flight experiment
A scaling analysis is used to study the dominant flow processes that occur in molten phase change material (PCM) under 1 g and microgravity conditions. Results of the scaling analysis are applied to the development of the NORVEX (NASA Oak Ridge Void Experiment) computer program and the preparation of the Thermal Energy Storage (TES) flight experiment. The NORVEX computer program which is being developed to predict melting and freezing with void formation in a 1 g or microgravity environment of the PCM is described. NORVEX predictions are compared with the scaling and similarity results. The approach to be used to validate NORVEX with TES flight data is also discussed. Similarity and scaling show that the inertial terms must be included as part of the momentum equation in either the 1 g or microgravity environment (a creeping flow assumption is invalid). A 10(exp -4) environment was found to be a suitable microgravity environment for the proposed PCM.
Skarda, J. R. L.↗
Control of High-Temperature Static and Transient Thermomechanical Behavior of SiMo Ductile Iron by Al Alloying
Abstract Silicon and molybdenum ( SiMo ) ductile iron is commonly used for exhaust manifolds because these components experience thermal cycling in oxidizing environment, which requires resistance to fatigue during transient thermomechanical loads. Previous studies have demonstrated that alloying elements, such as Al , to SiMo ductile iron reduces the amount of surface degradation during static high-temperature exposure. However, deterioration of sphericity of the graphite nodules and a decrease in ductility could affect the tendency of cracking during thermal cycling. In this article, the effect of Al alloying on static and transient thermomechanical behavior of SiMo ductile iron was investigated to optimize the amount of Al alloying. A thermodynamic approach was used to confirm the effect of the Al alloying on the phase transformations in two SiMo cast irons, alloyed by 1.8% Al and 3% Al . These two alloys were cast in a laboratory along with the baseline SiMo ductile iron. Several experimental methods were used to evaluate the dimensional stability, physical properties, static oxidation, and failure resistance during constrained thermal cycling testing to compare their high-temperature capability. Experimental results verified that Al alloying increases the temperature range and decreases volume change during eutectoid transformation, which together with enhancement of oxidation protection improved the dimensional stability. Thermocycling tests showed that the number of cycles to failure depends on the amount of Al alloying and the applied high-temperature exposure during each cycle. SEM/EDX, high-resolution TEM and µCT analysis were used to verify the mechanism resulting from the Al alloying protection. It was shown that an optimal level of Al alloying for balancing oxidation and thermal cracking resistance depends on thermomechanical conditions of application.
36 MATERIALS SCIENCE↗
Characterizing and improving the performance of molten-salt-steam heat exchangers in concentrating solar power plants
Shell-and-tube heat exchangers (HXs) for steam generation from molten salts in concentrating solar power (CSP) plants experience thermal fatigue due to significant temperature gradients and inherent transient operation. Molten salt-steam HX design lifespans exceed actual lifespans, and, as a consequence, designers overpredict plant profitability and operators neglect appropriate prescriptions to optimize these lifetimes. Here, this study refines HX lifespan estimates with data benchmarked against thermal-fluid mechanical modeling of stress and accumulated fatigue. Reduced-order thermal models of the molten salt-steam, shell-and-tube evaporator and superheater predict transient temperature profiles along the two HXs salt-steam flow paths. The modeled evaporator and superheater temperature profiles enable assessment of cyclic stresses within the HX tubesheets, where molten-salt HX failures are most common. Evaporator and superheater performance data from a current 110 MW elec commercial CSP plant provide a basis for validating the reduced-order HX models. HX life predictions derived from stochastic failure distributions serve as inputs for simulating and optimizing existing plant operations. The impact of the updated lifespans on overall plant revenue depends on operating scenarios. This study suggests that typical ramping rates for a CSP plant with a high-temperature Rankine cycle result in an evaporator and superheater life of approximately 10 and 25 years, respectively, compared to the design target of 30 years. Reduced HX lifespans decrease operational plant revenue on average by 4.6-5.1%. Furthermore, there may be as many as four HX replacements over the 30-year lifetime of the plant; and, purchase agreement loss due to failure to meet contractual production requirements can have ramifications that include the risk of bankruptcy.
14 SOLAR ENERGY↗
Design and validation of a cold load for characterization of cosmic microwave background stage 4 detectors
We present the design and validation of a variable temperature cryogenic blackbody source, hereinafter called a cold load, that will be used to characterize detectors to be deployed by cosmic microwave background stage 4 (CMB-S4), the next-generation ground-based cosmic microwave background (CMB) experiment. Although cold loads have been used for detector characterization by previous CMB experiments, this cold load has three innovative design features: (1) the ability to operate from the 1-K stage of a dilution refrigerator (DR), (2) a He3 gas-gap heat switch to reduce cooling time, and (3) the ability to couple small external optical signals to measure detector optical time constants under low optical loading. The efficacy of this design was validated using a 150-GHz detector array previously deployed by the Spider experiment. Thermal tests showed that the cold load can be heated to temperatures required for characterizing CMB-S4’s detectors without significantly impacting the temperatures of other cryogenic stages when mounted to the DR’s 1-K stage. In addition, optical tests demonstrated that external signals can be coupled to a detector array through the cold load without imparting a significant optical load on the detectors, which will enable measurements of the CMB-S4 detectors’ optical time constants.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
PMT-004 Validation Testing for Thermal Scattering Laws and Some Interesting Temperature-Dependent Implications [Slides]
This presentation finds that PMT-004 has four new benchmark cases highly sensitive to PE TSL (2 cases) and PMMA TSL (2 Cases). Additionally discovered was that the PE cases were well predicted using MCNP6.2 and ENDF/B-VIII.0. PMMA cases overpredicted by approximately 0.6-0.7% in k eff likely due to the lack of integral benchmarks sensitive to PMMA. The NCSU ENDF/B-VIII.1 PMMA TSL is an improvement over VIII.0. This was Accepted at last ICSBEP meeting pending comment resolution, should be published in 2024 version of the Handbook. It was found that temperature had a large impact on reactivity of the critical configuration. This has Implications for validation work for thermal cases- need to adjust TSL data to correct temperature as it can have hundreds of pcm effects for a few °C. Future thermal experiments should try and measure reactivity at multiple temperatures to add in data testing and benchmark adjustment.
73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
IER 480: TEX-Pu Benchmark (PU-MET-THERM-004) to Test Polyethylene and Lucite Thermal Scattering Laws [Slides]
This presentation finds that PMT-004 has four new benchmark cases highly sensitive to PE TSL (2 cases) and PMMA TSL (2 Cases). PE cases were well predicted using MCNP6.2 and ENDF/B-VIII.0. PMMA cases overpredicted by approximately 0.6-0.7% in k eff at 20°C. Accepted into 2023 version of the ICSBEP Handbook. Temperature had a large impact on reactivity of the critical configuration. Implications for validation work for thermal cases- need to adjust TSL data to correct temperature as it can have hundreds of pcm effects for a few °C. Future thermal experiments should try and measure reactivity at multiple temperatures to aid in data testing and benchmark adjustment.
73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
Fracture Analysis of Cohesive Zone Models for Modeling Residual Stress Induced Delamination in Composite Structures
A fracture study of coupon-scale composite cylinders with embedded defects was conducted with an objective to assess and validate a modeling approach using two available cohesive material models. The study included experimental and simulation evaluations of initiation of crack growth and progression. Interrupted thermal experiments used acoustic emissions monitoring to identify the onset of crack progression during each cooling interval and ultrasonic scanning provided images of defect growth. Verification, validation, and uncertainty quantification (VVUQ) processes were performed in the assessment of the simulation predicted temperature at which crack propagation begins (quantity of interest). The Sobol sensitivity analysis identified the hoop direction elastic modulus in the carbon fiber reinforced polymer (CFRP) plies as the most influential parameter for simulations using both cohesive models, accounting for at least 70% of the variation in the temperature at crack propagation. The UQ temperature range for the Tvergaard-Hutchinson model was higher (more conservative) than the experimental acoustic measurement indicators of crack progression, while the temperature range for the Thouless-Parmigiani model enveloped the experimental data points for the primary defect size of 0.75 x 1 in. The simulations could not capture the stable crack growth indicated in the experiments. This is likely due to the models’ inability to represent anisotropic fracture toughness attributed to the structure of the orthotropic fiber weave in a woven composite laminate.
42 ENGINEERING↗
MSFC Skylab contamination control systems mission evaluation
Cluster external contamination control evaluation was made throughout the Skylab Mission. This evaluation indicated that contamination control measures instigated during the design, development, and operational phases of this program were adequate to reduce the general contamination environment external to the Cluster below the threshold senstivity levels for experiments and affected subsystems. Launch and orbit contamination control features included eliminating certain vents, rerouting vents for minimum contamination impact, establishing filters, incorporating materials with minimum outgassing characteristics and developing operational constraints and mission rules to minimize contamination effects. Prior to the launch of Skylab, contamination control math models were developed which were used to predict Cluster surface deposition and background brightness levels throughout the mission. The report summarizes the Skylab system and experiment contamination control evaluation. The Cluster systems and experiments evaluated include Induced Atmosphere, Corollary and ATM Experiments, Thermal Control Surfaces, Solar Array Systems, Windows and Star Tracker.
Source record↗