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DOE OSTI2025

Defects vibrations engineering for enhancing interfacial thermal transport in polymer composites

To push upper boundaries of thermal conductivity in polymer composites, understanding of thermal transport mechanisms is crucial. Despite extensive simulations, systematic experimental investigation on thermal transport in polymer composites is limited. To better understand thermal transport processes, we design polymer composites with perfect fillers (graphite) and defective fillers (graphite oxide), using polyvinyl alcohol (PVA) as a matrix model. Measured thermal conductivities of ~1.38 ± 0.22 W m -1 K -1 in PVA/defective filler composites is higher than those of ~0.86 ± 0.21 W m -1 K -1 in PVA/perfect filler composites, while measured thermal conductivities in defective fillers are lower than those of perfect fillers. We identify how thermal transport occurs across heterogeneous interfaces. Thermal transport measurements, neutron scattering, quantum mechanical modeling, and molecular dynamics simulations reveal that vibrational coupling between PVA and defective fillers at PVA/filler interfaces enhances thermal conductivity, suggesting that defects in polymer composites improve thermal transport by promoting this vibrational coupling.

42 ENGINEERING↗

DOE OSTI2011

Report on Thermal Aging Effects on Tensile Properties of Ferritic-Martensitic Steels.

This report provides an update on the evaluation of thermal-aging induced degradation of tensile properties of advanced ferritic-martensitic steels. The report is the first 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, NF616, 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 as a function of time at temperature. 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. Advanced materials examined in this project include ferritic-martensitic steels mod.9Cr-1Mo and NF616, and austenitic steel, HT-UPS. The report summarizes the tensile testing results of thermally-aged mod.9Cr-1Mo, NF616 H1 and NF616 H2 ferritic-martensitic steels. NF616 H1 and NF616 H2 experienced different thermal-mechanical treatments before thermal aging experiments. NF616 H1 was normalized and tempered, and NF616 H2 was normalized and tempered and cold-rolled. By examining these two heats, we evaluated the effects of thermal-mechanical treatments on material microstructures and associated mechanical properties during long-term aging at elevated temperatures. Thermal aging experiments at different temperatures and periods of time have been completed: 550°C for up to 5000 h, 600°C for up to 7500 h, and 650°C for more than 10,000 h. Tensile properties were measured on thermally aged specimens and aging effect on tensile behavior was assessed. Effects of thermal aging on deformation and failure mechanisms were investigated by using in-situ straining technique with simultaneous synchrotron XRD measurements.

36 MATERIALS SCIENCE↗

DOE OSTI2014

Development of an Innovative High-Thermal Conductivity UO2 Ceramic Composites Fuel Pellets with Carbon Nano-Tubes Using Spark Plasma Sintering

Uranium dioxide (UO2) is the most common fuel material in commercial nuclear power reactors. Despite its numerous advantages such as high melting point, good high-temperature stability, good chemical compatibility with cladding and coolant, and resistance to radiation, it suffers from low thermal conductivity that can result in large temperature gradients within the UO2 fuel pellet, causing it to crack and release fission gases. Thermal swelling of the pellets also limits the lifetime of UO2 fuel in the reactor. To mitigate these problems, we propose to develop novel UO2 fuel with uniformly distributed carbon nanotubes (CNTs) that can provide high-conductivity thermal pathways and can eliminate fuel cracking and fission gas release due to high temperatures. CNTs have been investigated extensively for the past decade to explore their unique physical properties and many potential applications. CNTs have high thermal conductivity (6600 W/mK for an individual single- walled CNT and >3000 W/mK for an individual multi-walled CNT) and high temperature stability up to 2800°C in vacuum and about 750°C in air. These properties make them attractive candidates in preparing nano-composites with new functional properties. The objective of the proposed research is to develop high thermal conductivity of UO2–CNT composites without affecting the neutronic property of UO2 significantly. The concept of this goal is to utilize a rapid sintering method (5–15 min) called spark plasma sintering (SPS) in which a mixture of CNTs and UO2 powder are used to make composites with different volume fractions of CNTs. Incorporation of these nanoscale materials plays a fundamentally critical role in controlling the performance and stability of UO2 fuel. We will use a novel in situ growth process to grow CNTs on UO2 particles for rapid sintering and develop UO2-CNT composites. This method is expected to provide a uniform distribution of CNTs at various volume fractions so that a high thermally conductive UO2-CNT composite is obtained with a minimal volume fraction of CNTs. The mixtures are sintered in the SPS facility at a range of temperatures, pressures, and time durations so as to identify the optimal processing conditions to obtain the desired microstructure of sintered UO2-CNT pellets. The second objective of the proposed work is to identify the optimal volume fraction of CNTs in the microstructure of the composites that provides the desired high thermal conductivity yet retaining the mechanical strength required for efficient function as a reactor fuel. We will systematically study the resulting microstructure (grain size, porosity, distribution of CNTs, etc.) obtained at various SPS processing conditions using optical microscopy, scanning electron microscopy (SEM), and transmission electron microscope (TEM). We will conduct indentation hardness measurements and uniaxial strength measurements as a function of volume fraction of CNTs to determine the mechanical strength and compare them to the properties of UO2. The fracture surfaces will be studied to determine the fracture characteristics that may relate to the observed cracking during service. Finally, we will perform thermal conductivity measurements on all the composites up to 1000° C. This study will relate the microstructure, mechanical properties, and thermal properties at various volume fractions of CNTs. The overall intent is to identify optimal processing conditions that will provide a well-consolidated compact with optimal microstructure and thermo-mechanical properties. The deliverables include: (1) fully characterized UO2-CNT composite with optimal CNT volume fraction and high thermal conductivity and (2) processing conditions for production of UO2-CNT composite pellets using SPS method.

Subhash, Ghatu↗

DOE OSTI2017

Summary report on UO 2 thermal conductivity model refinement and assessment studies

Uranium dioxide (UO 2 ) is the most commonly used fuel in light water nuclear reactors and thermal conductivity controls the removal of heat produced by fission, therefore, governing fuel temperature during normal and accident conditions. The use of fuel performance codes by the industry to predict operational behavior is widespread. A primary source of uncertainty in these codes is thermal conductivity, and optimized fuel utilization may be possible if existing empirical models were replaced with models that incorporate explicit thermal conductivity degradation mechanisms during fuel burn-up. This approach is able to represent the degradation of thermal conductivity due to each individual defect type, rather than the overall burn-up measure typically used which is not an accurate representation of the chemical or microstructure state of the fuel that actually governs thermal conductivity and other properties. To generate a mechanistic thermal conductivity model, molecular dynamics (MD) simulations of UO 2 thermal conductivity including representative uranium and oxygen defects and fission products are carried out. These calculations employ a standard Buckingham type interatomic potential and a potential that combines the many-body embedded atom method potential with Morse-Buckingham pair potentials. Potential parameters for UO 2+x and ZrO 2 are developed for the latter potential. Physical insights from the resonant phonon-spin scattering mechanism due to spins on the magnetic uranium ions have been introduced into the treatment of the MD results, with the corresponding relaxation time derived from existing experimental data. High defect scattering is predicted for Xe atoms compared to that of La and Zr ions. Uranium defects reduce the thermal conductivity more than oxygen defects. For each defect and fission product, scattering parameters are derived for application in both a Callaway model and the corresponding high-temperature model typically used in fuel performance codes. The model is validated by comparison to low-temperature experimental measurements on single crystal hyper-stoichiometric UO 2+x samples and high-temperature literature data. Ongoing works include investigation of the effect of phase separation to UO 2 +U 4 O 9 on the low temperature thermal conductivity of UO 2+x , and modeling of thermal conductivity using the Green-Kubo method. Ultimately, this work will enable more accurate fuel performance simulations as well as extension to new fuel types and operating conditions, all of which improve the fuel economics of nuclear energy and maintain high fuel reliability and safety.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2017

Thermal safety characterization on PETN, PBX-9407, LX-10-2, LX-17-1 and detonator in the LLNL's P-ODTX system

Incidents caused by fire and other thermal events can heat energetic materials that may lead to thermal explosion and result in structural damage and casualty. Thus, it is important to understand the response of energetic materials to thermal insults. The One-Dimensional-Time to Explosion (ODTX) system at the Lawrence Livermore National Laboratory (LLNL) has been used for decades to characterize thermal safety of energetic materials. In this study, an integration of a pressure monitoring element has been added into the ODTX system (P-ODTX) to perform thermal explosion (cook-off) experiments (thermal runaway) on PETN powder, PBX-9407, LX-10-2, LX-17-1, and detonator samples (cup tests). The P-ODTX testing generates useful data (thermal explosion temperature, thermal explosion time, and gas pressures) to assist with the thermal safety assessment of relevant energetic materials and components. This report summarizes the results of P-ODTX experiments that were performed from May 2015 to July 2017. Recent upgrades to the data acquisition system allows for rapid pressure monitoring in microsecond intervals during thermal explosion. These pressure data are also included in the report.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2017

Parametric study for use of stainless steel as a material for thermal shield in PIP2IT transferline at Fermilab [Slides]

Proton Improvement Plant – II (PIP-II) has been planned at Fermilab for providing high-intensity proton beams to the laboratory’s experiments. Fermilab has undertaken the PIP-II Injector Test (PIP2IT) for integrated systems testing of critical components comprising the PIP-II front end. PIP2IT includes two cryomodules, to be tested using a pre-existing Supercritical helium refrigerator and distribution box. The PIP2IT transferline connects the Distribution box to the cryomodules of PI2IT. It contains 5 process lines as follows - supercritical 5K He supply and return lines, thermal shield supply(40K) and return(80K) lines and a sub-atmospheric 2K return line. Such cryogenic transferlines are generally provided with cylindrical thermal shields at 80K, enclosing multiple process lines. The thermal shields are cooled by dedicated cooling lines welded/brazed to the shield at a single point along the circumference. Higher thermal diffusivity provides faster cooling and uniformity o f temperature along the shield surface. Hence, Copper/Aluminium is widely used to fabricate thermal shields. However, raw material price, the cost of fabrication depending on standard sizes of pipes/tubes, often drives up the final price of thermal shields. To reduce the cost by making use of easily available stock of standard pipe/tube, it is decided to use stainless steel as a material in thermal shields for the PIP2IT transferline. To this effect, a parametric study has been undertaken to evaluate the suitability of replacing Copper/Aluminium with stainless steel in thermal shields. The low thermal conductivity of steel results in bowing of the shield due to differential temperature distribution along the circumferential direction. The resulting suitable design has limiting parameters in terms of maximum allowable length of a shield section and the maximum allowable heat transfer coefficient for cooling flow. Starting with the design specific to PIP2IT transferline, an at tempt is made to have non-dimensionalised parameters for sim! ilar thermal shields.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Bio-Based Phase Change Materials (PCMs) for Thermal Energy Storage (Final Scientific/Technical Report)

The goal of this project is to develop a novel bio-based phase change material (PCM) derived from squid ring teeth (SRT) proteins, and design a prototype heat exchanger based on these bio-based PCMs for energy storage and dynamic heat exchange for building thermal energy storage systems. The PCMs, derived from SRT proteins, will demonstrate room temperature energy storage capacities and switchable thermal conductivities that redefine the current state-of-the-art (SOA) for building thermal energy storage. Further, in a single material and with a single manufacturing processes, our proposed thermal battery will be developed with “on demand” thermal conductivity for rapid charging/discharging but superior insulation during energy storage periods. More specifically, our bio-based PCMs have demonstrated: 1) the potential for increased energy storage capacity (i.e., greater than paraffines at room temperature); 2) tunability in thermal conductivity with the largest thermal conductivity switching ratios for an intrinsic material reported to date, and 3) a 100% recyclable and biodegradable PCM with low volatility and toxicity and scalability in its manufacture for both residential and commercial applications. The already established ability for roll-to-roll processing of these non-toxic, non-flammable SRT composites along with their carbon-neutral manufacturing processes that has been pioneered by our team make this solution a disruptive and impactful technology to redefine the current SOA of energy storage technologies. The outcomes of this effort have been: 1) the identification of new bio-based PCM that establishes a new SOA for thermal conductivity and energy storage density at room temperature and 2) the development of a new experimental technique to measure the energy storage density via latent heat measurements during melting of thin films. This new technique can be applied to thin films (as thin as < 1 micrometer), and represents a novel approach for thin film energy storage density measurements. Dynamic thermal energy storage is the missing technology that will enable a grid- interactive efficient building (GEB). For a “smart” building capable of connecting with the power grid, the media must be inexpensive and possess thermal switching capabilities to control the time-dependent heat flow into (and out of) the PCM on demand. Unique to the material system in this program, programmable SRT-based PCM show improvements as compared to traditionally used PCMs, and thus its technical performance will represent a leap forward for the future GEB concept.

25 ENERGY STORAGE↗

DOE OSTI2023

Development, Monitoring, and Control of Fracture Thermal Energy Storage in Crystalline Rock Formations (DEMO-FTES) [Abstract]

Approximately half of global energy consumption is used for heating and cooling. Because fossil fuels are used to meet most of this demand, heating and cooling of buildings produces a large portion of global greenhouse gas (GHG) emissions. The proposed project seeks to demonstrate the feasibility of a seasonal thermal energy storage concept called fracture thermal energy storage (FTES), which has the potential to dramatically lower energy requirements for heating and cooling and improve the resilience of building energy systems. FTES is a technique for building a highly efficient heat exchanger by creating a carefully designed set of fractures in the ground below a building. This heat exchanger allows thermal energy to be stored over seasonal timeframes—for example, hot thermal energy that is easily captured in the summer or energy from waste heat sources—to meet heating needs during colder months. FTES offers a solution with a relatively small footprint and lower cost compared to currently operating aquifer thermal energy storage (ATES) systems and could be used in the many areas without aquifers suitable for ATES. If commercialized, FTES systems could exceed the 2.5 TWh of energy storage per year from the more than 2,800 ATES systems in operation worldwide, which range from 0.1 MW to 30 MW. The savings in CO2 emissions per year are also expected to match or exceed individual ATES projects, with the largest, a 30 MW system used to provide heating and cooling to the University of Technology in Eindhoven in the Netherlands, estimated to save 13,000 tons of CO2 emissions per year. FTES utilizes mature drilling and fracturing technology and therefore has the potential to be rapidly commercialized once demonstrated. The ability to construct and establish flow through an FTES heat exchanger has been demonstrated by a previous project and the potential for efficient, large-capacity energy storage has been shown using numerical models. However, no experimental validation of these numerical estimates of thermal energy storage has been made. The first crucial need to advance FTES technology is to identify the sensitivity of key metrics such as thermal energy storage and production rates, capacities, and efficiencies to design parameters such as the number of fractures, depth/temperature of fractures, size of fractures, and circulation rates. The second crucial need is experimental testing of achievable thermal performance with optimized system design parameters. The proposed scope of work seeks to systematically address these two critical needs through a highly complementary international collaboration spanning theory, laboratory, and mesoscale field evaluation. The proposed work plan calls for using dimensional analysis and existing state-of-the-art numerical simulators to design carefully scaled laboratory and 10-meter-scale field tests of the thermal efficiency of FTES. The existing advanced laboratory and intermediate-scale field testbeds that will be used for this project will allow for detailed monitoring of the system performance during the test and of how the performance changes across time and length scales. These results will determine the feasibility of full- scale FTES systems. If the thermal performance is consistent with model predictions, the results will provide a strong economic justification for rapid commercialization of FTES technology in a wide range of geographical areas.

25 ENERGY STORAGE↗

DOE OSTI2024

A thermal-driven graupel generation process to explain dry-season convective vigor over the Amazon

Large-eddy simulations (LESs) are conducted for each day of the intensive observation periods (IOPs) of the Green Ocean Amazon (GoAmazon) field campaign to characterize the updrafts and microphysics within deep convective cores while contrasting those properties between Amazon wet and dry seasons. Mean Doppler velocity (V dop ) values simulated using LESs are compared with 2-year measurements from a radar wind profiler (RWP) as viewed by statistical composites separated according to wet- and dry-season conditions. In the observed RWP and simulated LES V dop composites, we find more intense low-level updraft velocity, vigorous graupel generation, and intense surface rain during the dry periods compared with the wet periods. To investigate coupled updraft–microphysical processes further, single-day golden cases are selected from the wet and dry periods to conduct detailed cumulus thermal tracking analysis. Tracking analysis reveals that simulated dry-season environments generate more droplet-loaded low-level thermals than wet-season environments. This tendency correlates with seasonal contrasts in buoyancy and vertical moisture advection profiles in large-scale forcing. Employing a normalized time series of mean thermal microphysics, the simulated cumulus thermals appear to be the primary generator of cloud droplets. When subsequent thermals penetrate the ice crystal layer, droplets within the thermals interact with entrained ice crystals, which enhances riming in the thermals. This appears to be a production pathway of graupel/hail particles within simulated deep convective cores. In addition, less-diluted dry-case thermals tend to be elevated higher, and graupel grows further during sedimentation after spilling out from thermals. Therefore, greater concentrations of low-level moist thermals likely result in more graupel/hail production and associated dry-season convective vigor.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Aerosol-deep convection interaction based on joint cell-thermal tracking in Large Eddy Simulations during the TRACER campaign

In cumulus clouds, aerosol concentrations control cloud droplet concentrations, modifying cloud radiative properties, precipitation processes, and cloud electrification. However, mechanisms of aerosol-deep convection interactions are not well understood due to complex cloud dynamics and microphysics. We investigate the interaction of aerosols with isolated deep convection using Large Eddy Simulations of two cases during the TRacking Aerosol Convection interactions ExpeRiment (TRACER) near Houston, Texas, using a joint cell-thermal tracking algorithm. Cumulus thermals are droplet generators, since supersaturation and droplet nucleation coincide with thermal centers, where the strongest updrafts occur. Primary ice crystal formation does not take place inside thermals, but at layers where previous thermals detrained moisture. As subsequent thermals containing supercooled droplets penetrate these layers, hail and graupel form at or near these thermals. Higher aerosol concentrations result in higher droplet concentrations that suppress drizzle, delay warm rain processes, and transport more moisture aloft. This increases snow and ice amount, as well as graupel and hail, leading to more lightning. Polluted thermals initiate at slightly higher altitudes, and are slightly larger and faster, suggesting a weak invigoration. We also find more thermals per cell, but fewer isolated cells, since convection is more aggregated and intense, especially near the end of the 24 h simulation. Non-linear mesoscale feedback likely triggered by temperature and moisture responses to aerosol-thermal interactions causes the aggregation. Time-lagged aerosol-reinitialization experiments show that the mesoscale response is the predominant forcing for the invigoration. These changes happen within one day, on a smaller scale than previously suggested.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2016

Modeling the spatiotemporal variability in subsurface thermal regimes across a low-relief polygonal tundra landscape

Vast carbon stocks stored in permafrost soils of Arctic tundra are under risk of release to the atmosphere under warming climate scenarios. Ice-wedge polygons in the low-gradient polygonal tundra create a complex mosaic of microtopographic features. This microtopography plays a critical role in regulating the fine-scale variability in thermal and hydrological regimes in the polygonal tundra landscape underlain by continuous permafrost. Modeling of thermal regimes of this sensitive ecosystem is essential for understanding the landscape behavior under the current as well as changing climate. Here, we present an end-to-end effort for high-resolution numerical modeling of thermal hydrology at real-world field sites, utilizing the best available data to characterize and parameterize the models. We also develop approaches to model the thermal hydrology of polygonal tundra and apply them at four study sites near Barrow, Alaska, spanning across low to transitional to high-centered polygons, representing a broad polygonal tundra landscape. A multiphase subsurface thermal hydrology model (PFLOTRAN) was developed and applied to study the thermal regimes at four sites. Using a high-resolution lidar digital elevation model (DEM), microtopographic features of the landscape were characterized and represented in the high-resolution model mesh. The best available soil data from field observations and literature were utilized to represent the complex heterogeneous subsurface in the numerical model. Simulation results demonstrate the ability of the developed modeling approach to capture – without recourse to model calibration – several aspects of the complex thermal regimes across the sites, and provide insights into the critical role of polygonal tundra microtopography in regulating the thermal dynamics of the carbon-rich permafrost soils. Moreover, areas of significant disagreement between model results and observations highlight the importance of field-based observations of soil thermal and hydraulic properties for modeling-based studies of permafrost thermal dynamics, and provide motivation and guidance for future observations that will help address model and data gaps affecting our current understanding of the system.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1985

Derivation and test of elevated temperature thermal-stress-free fastener concept

Future aerospace vehicles must withstand high temperatures and be able to function over a wide temperature range. New composite materials are being developed for use in designing high-temperature lightweight structures. Due to the difference between coefficients of thermal expansion for the new composite materials and conventional high-temperature metallic fasteners, innovative joining techniques are needed to produce tight joints at all temperatures without excessive thermal stresses. A thermal-stress-free fastening technique is presented that can be used to provide structurally tight joints at all temperatures even when the fastener and joined materials have different coefficients of thermal expansion. The derivation of thermal-stress-free fasteners and joint shapes is presented for a wide variety of fastener materials and materials being joined together. Approximations to the thermal-stress-free shapes that result in joints with low-thermal-stresses and that simplify the fastener/joint shape are discussed. The low-thermal-stress fastener concept is verified by thermal and shear tests in joints using oxide-dispersion-strengthened alloy fasteners in carbon-carbon material. The test results show no evidence of thermal stress damage for temperatures up to 2000 F and the resulting joints carried shear loads at room temperature typical of those for conventional joints.

Sawyer, J. W.↗

NASA NTRS1990

In situ SEM thermal fatigue of Al/graphite metal matrix composites

Several thermal fatigue-induced failure mechanisms are deduced for unidirectional graphite-reinforced 6061 Al-alloy MMCs subjected to in situ thermal cycling. These thermal cycling conditions are representative of MMC service cycles in aerospace environments, where thermal fatigue is primarily associated with changes in the stress states near the interfaces due to coefficient of thermal expansion mismatch between fiber and matrix. This in situ SEM thermal-cycling study clarified such factors affecting MMCs' thermal fatigue as local fiber content and distribution, void volume, fiber stiffness, thermal excursion magnitude, and number of thermal cycles. MMC microfailure modes in thermal fatigue have been deduced.

Zong, G. S.↗

NASA NTRS1993

Thermal shock resistance of ceramic matrix composites

The experimental and analytical investigation of the thermal shock phenomena in ceramic matrix composites is detailed. The composite systems examined were oxide-based, consisting of an aluminosilicate matrix with either polycrystalline aluminosilicate or single crystal alumina fiber reinforcement. The program was divided into three technical tasks; baseline mechanical properties, thermal shock modeling, and thermal shock testing. The analytical investigation focused on the development of simple expressions for transient thermal stresses induced during thermal shock. The effect of various material parameters, including thermal conductivity, elastic modulus, and thermal expansion, were examined analytically for their effect on thermal shock performance. Using a simple maximum stress criteria for each constituent, it was observed that fiber fracture would occur only at the most extreme thermal shock conditions and that matrix fracture, splitting parallel to the reinforcing fiber, was to be expected for most practical cases. Thermal shock resistance for the two material systems was determined experimentally by subjecting plates to sudden changes in temperature on one surface while maintaining the opposite surface at a constant temperature. This temperature change was varied in severity (magnitude) and in number of shocks applied to a given sample. The results showed that for the most severe conditions examined that only surface matrix fracture was present with no observable fiber fracture. The impact of this damage on material performance was limited to the matrix dominated properties only. Specifically, compression strength was observed to decrease by as much as 50 percent from the measured baseline.

Carper, D. M.↗

NASA NTRS1995

Asteroid orbit evolution due to thermal drag

Thermal drag, a variant of the Yarkovsky effect, may act on small asteroids with sizes from a few meters to a few tens of meters. Yarkovsky thermal drag comes from an asteroid's absorbing sunlight in the visible and reradiating it in the infrared. Since the infrared photons have momentum, by action-reaction, they kick the asteroid when they leave its surface. The reradiation, which is asymmetric in latitude over the asteroid, gives a net force along the asteroid's pole. Due to the asteroid's thermal inertia, averaging this force over one orbital period produces a net drag if the spin axis has a component in the orbital plane. Thermal drag tends to circularize orbits. It can increase or decrease orbital inclinations. An object whose spin axis points in random directions over its lifetime displays little change in orbital inclination. Thermal drag appears to have little to do with the delivery of chondrites from the asteroid belt; the thermal drag timescale (10(exp 8) years for meter-sizzed objects) is long compared with their cosmic ray exposure ages, and aphelia in the asteroid belt are not expected for mature thermal drag orbits. However, Yarkovsky thermal drag may act on the recently discovered near-Earth asteroids, which have radii of 10-30 m. Asteroid 1992 DA, for instance, might have its orbit shrunk by 0.1 AU in 3 x 10(exp 7) years, removing it from an Earth-crossing orbit. The near-Earth asteroids also tend to have small to moderate orbital eccentricities, as expected for highly evolved thermal drag objects. However, the time needed to bring them in from the asteroid belt (about 10(exp 9) years) is long compared with the collisonal and dynamical lifetimes (both about 10(exp 8) years) for Earth-crossing objects, arguing against their emplacement by thermal drag.

Rubincam, David Parry↗

NASA NTRS1998

An Integrated Tool for the Coupled Thermal and Mechanical Analysis of Pyrolyzing Heatshield Materials

Materials that pyrolyze at elevated temperature have been commonly used as thermal protection materials in hypersonic flight, and advanced pyrolyzing materials for this purpose continue to be developed. Because of the large temperature gradients that can arise in thermal protection materials, significant thermal stresses can develop. Advanced applications of pyrolytic materials are calling for more complex heatshield configurations, making accurate thermal stress analysis more important, and more challenging. For non-pyrolyzing materials, many finite element codes are available and capable of performing coupled thermal-mechanical analyses. These codes do not, however, have a built-in capability to perform analyses that include pyrolysis effects. When a pyrolyzing material is heated, one or more components of the original virgin material pyrolyze and create a gas. This gas flows away from the pyrolysis zone to the surface, resulting in a reduction in surface heating. A porous residue, referred to as char, remains in place of the virgin material. While the processes involved can be complex, it has been found that a simple physical model in which virgin material reacts to form char and pyrolysis gas, will yield satisfactory analytical results. Specifically, the effects that must be modeled include: (1) Variation of thermal properties (density, specific heat, thermal conductivity) as the material composition changes; (2) Energy released or absorbed by the pyrolysis reactions; (3) Energy convected by the flow of pyrolysis gas from the interior to the surface; (4) The reduction in surface heating due to surface blowing; and (5) Chemical and mass diffusion effects at the surface between the pyrolysis gas and edge gas Computational tools for the one-dimensional thermal analysis these materials exist and have proven to be reliable design tools. The objective of the present work is to extend the analysis capabilities of pyrolyzing materials to axisymmetric configurations, and to couple thermal and mechanical analyses so that thermal stresses may be efficiently and accurately calculated.

Pronchick, Stephen W.↗

NASA NTRS2002

Vacuum Ultraviolet Radiation and Atomic Oxygen Durability Evaluation of HST Bi-Stem Thermal Shield Materials

Bellows-type thermal shields were used on the bi-stems of replacement solar arrays installed on the Hubble Space Telescope (HST) during the first HST servicing mission (SMI) in December 1993. These thermal shields helped reduce the problem of thermal gradient- induced jitter observed with the original HST solar arrays during orbital thermal cycling and have been in use on HST for eight years. This paper describes ground testing of the candidate solar array bi-stem thermal shield materials including backside aluminized Teflon(R)FEP (fluorinated ethylene propylene) with and without atomic oxygen (AO) and ultraviolet radiation protective surface coatings for durability to AO and combined AO and vacuum ultraviolet (VOV) radiation. NASA Glenn Research Center (GRC) conducted VUV and AO exposures of samples of candidate thermal shield materials at HST operational temperatures and pre- and post-exposure analyses as part of an overall program coordinated by NASA Goddard Space Flight Center (GSFC) to determine the on-orbit durability of these materials. Coating adhesion problems were observed for samples having the AO- and combined AO/UV-protective coatings. Coating lamination occurred with rapid thermal cycling testing which simulated orbital thermal cycling. This lack of adhesion caused production of coating flakes from the material that would have posed a serious risk to HST optics if the coated materials were used for the bi-stem thermal shields. No serious degradation was observed for the uncoated aluminized Teflon(R) as evaluated by optical microscopy, although atomic force microscopy (AFM) microhardness testing revealed that an embrittled surface layer formed on the uncoated Teflon(R) surface due to vacuum ultraviolet radiation exposure. This embrittled layer was not completely removed by AO erosion, No cracks or particle flakes were produced for the embrittled uncoated material upon exposure to VUV and AO at operational temperatures to an equivalent exposure of approximately five years in the HST environment. Uncoated aluminized FEP Teflon(R) was determined to be the most appropriate thermal shield material and was used on the bi-stems of replacement solar arrays installed on HST during SMI in December 1993. The SMI -installed solar arrays air scheduled to be replaced during MST's fourth servicing mission (SM3B) in early 2002.

Dever, Joyce↗

NASA NTRS2002

A Modified Wall Matching Treatment to Account for Local Solid to Fluid Thermal Coupling

The wall-matching methodology of Wilcox is modified to include a solid-wall, thermal-conduction model. This coupled fluid-thermal-structure model is derived assuming that the wall thermal-structure behavior is locally one-dimensional and that structural deformations, due to thermally induced stresses, are not significant. The one-dimensional coupled fluid-thermal-structure model is derived such that the wall temperature is removed as an independent boundary condition variable. The one-dimensional coupled fluid-thermal-structure model is also derived for the general case of an arbitrary mixture of thermally prefect gases and a wall of arbitrary thickness and conductivity by using a compressible, streamwise-pressure-gradient-corrected, wall-matching function and Fourier's law of heat conduction. The resulting model was implemented in the VULCAN CFD code as a new boundary condition type. VULCAN was then used to simulate a two-dimensional Mach 6 wind tunnel facility nozzle flow to demonstrate/validate the one-dimensional coupled fluid-thermal-structure model. The nozzle internal-wall surface temperature and heat transfer distributions computed using the one-dimensional coupled fluid-thermal-structure model are compared to wall temperature and heat transfer distributions from an iterative multi-dimensional analysis obtained by coupling the VULCAN CFD code and the MSC/NASTRAN-thermal code. The one-dimensional coupled fluid-thermal-structure model analysis is shown to be very robust and in excellent agreement with the multi-dimensional iteratively coupled analysis. It is also shown that the one-dimensional analysis can be used as an initial guess for the multi-dimensional iteratively coupled analysis.

White, Jeffery A.↗