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Application of ultrathin layer of molybdenum disulfied coating to copper tubing permits utilization of tubing in cast-aluminum heat exchangers. Coating prevents formation of copper/aluminum eutectic, but does not impede heat transfer.
Proposed thermal-energy-storage system based on mixture of alkali metal and one of its halide salts; metal and salt form slurry of two immiscible melts. Use of slurry expected to prevent incrustations of solidified salts on heat-transfer surfaces that occur where salts alone used. Since incrustations impede heat transfer, system performance improved. In system, charging heat-exchanger surface immersed in lower liquid, rich in halide-salt, phase-charge material. Discharging heat exchanger surface immersed in upper liquid, rich in alkali metal.
The Mars In-Situ Propellant Production (ISPP) Precursor (MIP) experiment package is planned for inclusion on the Mars 2001 Lander. This experiment package consists of five experiments whose purpose is to demonstrate the performance of various ISPP processes in-situ on Mars. The demonstrated ability to produce propellant for Mars Return Vehicles (MRV) is considered to be a necessary precursor to any future manned mission to Mars. The Mars Atmosphere Acquisition and Compression (MAAC) experiment is part of the MIP package and is intended to demonstrate that, by using a sorption compressor, CO2 can be preferentially adsorbed at about 6 torr from the Mars atmosphere during the night when the bed is cold then subsequently compressed to about 800 torr by heating the bed and desorbing CO2 during the day. The compressed CO2 produced by MAAC is to be fed to the Oxygen Generator Subsystem (OGS) where pure oxygen is to be produced. Pure oxygen is considered to be one of the primary constituents of a future manned MRV propellant system. A MAAC Development Unit (DU) has been fabricated and tested at JPL. The MAAC DU consists of 1) a sorption bed filled with a CO2 selective sorbent material, 2) a purge system to be used to periodically backflush non-CO2 gases from the sorbent bed during adsorption, 3) a JPL-developed gas-gap heat switch that allows heat transfer to a radiator for heat removal from the bed during the night time adsorption period and that impedes heat transfer during the day time desorption period, 4) a radiator to radiate heat to the night sky during the adsorption period, 5) a set of three isolation valves and connecting tubing. 6) two pressure transducers and several thermocouples for monitoring the MAAC operating conditions, and command and data handling electronics. This paper will describe the operational theory and the configuration of the MAAC DU and will discuss the current status of the MAAC experiment development including some selected results of performance testing that has been completed prior to the ISRU III meeting.
The Mars In-Situ Propellant Production (ISPP) Precursor (MIP) experiment package is planned for inclusion on the Mars 2001 Lander. This experiment package consists of five experiments whose purpose is to demonstrate the performance of various ISPP processes in-situ on Mars. The demonstrated ability to produce propellant for Mars Return Vehicles (MRV) is considered to be a necessary precursor to any future manned mission to Mars. The Mars Atmosphere Acquisition and Compression (MAAC) experiment is part of the MIP package and is intended to demonstrate that, by using a sorption compressor, CO2 can be preferentially adsorbed at about 6 torr from the Mars atmosphere during the night when the bed is cold then subsequently compressed to about 800 torr by heating the bed and desorbing C02 during the day. The compressed CO2 produced by MAAC is to be fed to the Oxygen Generator Subsystem (OGS) where pure oxygen is to be produced. Pure oxygen is considered to be one of the primary constituents of a future manned MRV propellant system. A MAAC Development Unit (DU) has been fabricated and tested at JPL. The MAAC DU consists of: (1) a sorption bed filled with a CO2 selective sorbent material; (2) a purge system to be used to periodically backflush non-CO2 gases from the sorbent bed during adsorption; (3) a JPL-developed gas-gap heat switch that allows heat transfer to a radiator for heat removal from the bed during the night time adsorption period and that impedes heat transfer during the day time desorption period; (4) a radiator to radiate heat to the night sky during the adsorption period; (5) a set of three isolation valves and connecting tubing; (6) two pressure transducers and several thermocouples for monitoring the MAAC operating conditions, and command and data handling electronics. This paper will describe the operational theory and the configuration of the MAAC DU and will discuss the current status of the MAAC experiment development including some selected results of performance testing that has been completed prior to the ISRU III meeting.
Phenolic Impregnated Carbon Ablator (PICA) gained heritage during the historic Stardust mission, where it successfully returned samples from a comet’s tail and has since been instrumental in delivering payloads to the surface of Mars [1-3]. Most recently, PICA enabled the safe return of samples collected from asteroid Bennu as part of the OSIRIS-REx mission. This rich legacy underscores PICA’s critical role in allowing NASA’s most ambitious exploration missions. However, the friable nature of its phenolic phase presents challenges during handling and pre-launch activities. To mitigate this issue, PICA is coated with a polysiloxane resin system, which serves to suppress particulate dispersion and thereby safeguard spacecraft components. A comprehensive understanding of the polysiloxane resin’s behavior is imperative, as it profoundly shapes the material response of PICA during atmospheric entry by influencing its thermal and oxidative stability. This influence extends to thermocouple plugs embedded within thermal protection systems. These plugs have demonstrated their significance in missions such as Mars Science Laboratory (MSL) and Mars 2020, where the MEDLI and MEDLI2 instrumentation suites delivered in-valuable insights into the performance of thermal protection systems during entry into the Martian atmosphere [4]. Looking ahead, missions such as Dragonfly, set to descend into Titan’s dense atmosphere, aim to leverage advanced sensor technologies to further refine our understanding of thermal protection response [5]. Moreover, thermocouple plugs play an essential role in validating cutting-edge material response models, such as those pioneered under NASA’s Entry Systems Modeling Project (ESM), designed, in-part, to predict the operational integrity of thermal protection systems under the extreme stresses of atmospheric entry. To achieve these modeling goals, ground-based experiments are crucial to provide the foundational data necessary for developing and refining these predictive tools. To this end, an extensive test campaign was conducted at the Hypersonic Materials Environmental Test System (HyMETS) to investigate the high-temperature behavior of the polysiloxane resin in an air environment [6]. These experiments revealed critical phenomena, including the formation of a silicon oxycarbide layer that enhances oxidation resistance, moderates surface temperatures, and alters in-depth thermal response. Building on these findings, subsequent tests were designed to simulate atmospheric entry conditions in reactive gases, such as CO2 and N2, to mimic the environments of Mars and Titan, respectively, as well as non-reactive gases representing the atmospheres of the Ice Giants (Neptune and Uranus). A heating rate dependent decomposition mechanism has been identified for the polysiloxane resin under oxidizing conditions (Fig. 1). In the initial stage, the resin and the underlying thermal protection system undergo pyrolysis, rapidly generating a thin amorphous silicon oxycarbide interwoven with carbonaceous char and residual fibers from PICA. During the second stage, the nascent oxide layer establishes a robust, oxidation-resistant thermal barrier coating, which significantly impedes heat transfer to the underlying carbonaceous char, resulting in a stagnation of the surface temperature. A key factor contributing to this thermal resistance is the low recombination efficiency of atomic oxygen (γ), which further diminishes the heat load on the material’s interior layers [7]. Moreover, as the surface temperature stagnates, the silicon oxycarbide phase separates into distinct regions of silica and free graphite. Ultimately, when the heat flux reaches a critical threshold, a third stage is triggered, leading to the breakdown of the coating through carbothermal reduction, exposing the underlying char layer. This exposure leads to a dramatic surface temperature spike, driven by highly exothermic reactions between atomic oxygen and the char layer, further accelerating material degradation. A detailed mass and heat transfer model of PICA coated with polysiloxane resin was implemented in the Porous material Analysis Toolbox based on OpenFOAM, PATO [8]. The initial stage was considered negligible in this model because the resin decomposition occurs rapidly within a thin surface layer. Instead, the coating was directly considered as an oxygen-resistant thermal barrier coating. For the second stage, the thin amorphous silicon oxycarbide was treated as a pure silica surface to simplify the thermochemical behavior. The model ac-counts for surface equilibrium processes using representative elements of the coating-environment system. For the third stage, specific boundary conditions were developed to estimate the onset and progression of the coating removal. Two-dimensional material response simulations were conducted to compare uncoated and coated PICA using boundary conditions calibrated with HyMETS data. Fig. 2 illustrates that the simulations closely align with experimental data, successfully reproducing measured temperature profiles. This work will include the latest advancements in the coating model, including the calibration of recombination of atomic oxygen at the surface during the second phase. These simulated results will be further validated against additional CO2 data points from HyMETS, reinforcing the models’ predictive capabilities. These mechanisms and their effects on thermal protection systems, including thermochemical behavior and thermocouple probe performance in extreme environments, provide crucial insights for optimizing spacecraft designs that safeguard scientific payload and ensure mission success in future planetary exploration endeavors.
The Superfluid Helium On-Orbit Transfer (SHOOT) Flight Demonstration is a shuttle attached payload designed to demonstrate the technology necessary to resupply liquid helium dewars in space. Many SHOOT components will also have use in other aerospace cryogenic systems. The first of two SHOOT dewar systems has been fabricated. The ground performance testing of this dewar is described. The performance tests include measurements of heat leak, impedances of the two vent lines, heat pulse mass gauging accuracy, and superfluid transfer parameters such as flow rate and efficiency. A laboratory dewar was substituted for the second flight dewar for the transfer tests. These tests enable a precise analytical model of the transfer process to be verified. SHOOT performance is thus quantified, except for components such as the liquid acquisition devices and a phase separator which cannot be verified in one gravity.
Off-the-shelf electrical equipment is frequently used in space-based applications to control costs. However, the reduced heat transfer in the spacecraft microgravity environment causes the equipment to operate at significantly higher temperatures than it would in terrestrial applications. This creates touch temperature issues where items particularly metallic ones become too hot for the crew to handle safely. A touch temperature coating layup has been developed that can be added to spacebased electrically powered hardware. The coating allows the crew to safely handle the hardware, but only slightly impedes the heat transfer from the component during normal operation. In the present work, the coating generic requirements are developed and a layup is described that meets these specifications. Analytical and experimental results are presented that demonstrate the ability of the coating layup to increase the allowable limits of touch temperature while only marginally degrading heat transfer to the environment. This allows the spacecraft crew to handle objects that, if not coated, would be hot enough to cause pain or skin damage.
The Superfluid Helium On-Orbit Transfer (SHOOT) flight experiment is designed to demonstrate the components and techniques necessary to resupply superfluid helium to satellites or Space Station based facilities. A top level description as well as the development status of the critical components to be used in SHOOT are discussed. Some of these components include the thermomechanical pump, the fluid acquisition system, the normal helium and superfluid helium phase separators, Venturi flow meter, cryogenic valves, burst disks, and astronaut-compatible EVA coupler and transfer line. The requirements for the control electronics and software are given. A preliminary description of the requirements that must be met by a satellite requiring superfluid helium servicing is given. In particular, minimum and optimum plumbing arrangements are shown, transfer line flow impedance and heat input impacts are assessed, instrumentation is described, and performance parameters are considered.
The means for making efficient use of mechanical coolers to limit the parasitic heating into the Dewar are addressed. Thermal efficiency is achieved by minimizing the parasitic heating and thermal impedance of the cooler-to-Dewar interface within the mechanical constraints. The important issues related to compatibility with the instrument system are also briefly discussed. Parasitic heating from the nonoperating (reserved or failed) cooler pair can be reduced with an active thermal switch that isolates the cooler cold tips from the cold finger. An analysis was performed to determine the optimal switch-operating characteristics for this application. Requirements associated with the use of the coolers, analyses performed, and the interface design concept are discussed.
The focal plane of the AXAF X-Ray Spectrometer requires an operating temperature of 0.1 K with a mission lifetime of 5 yrs. This demanding task is accomplished with a hybrid cryogenic subsystem consisting of mechanical coolers, a superfluid helium dewar and an adiabatic demagnetization refrigerator. By using mechanical coolers to remove heat from the dewar outer vapor-cooled shield, a 5-yr lifetime is achievable with only a 483-liter tank. This approach takes advantage of flight-proven, high-performance dewar technology and recent success in the development of split, Stirling-cycle mechanical coolers. Although the dewar design principles are similar to those used previously, parasitic heat flow is reduced to a new level by an optimized tension strap support system and careful attention to insulation system details. The benefit of the mechanical coolers is maximized by dewar interface design features that minimize parasitic heating and thermal impedance of the coupling. The dewar design and thermal performance analysis are discussed. Helium lifetime sensitivities and the effects of mechanical cooler failures are predicted.
A paper discusses an experimental regenerable sorber for removing CO2 and trace components principally, volatile organic compounds, halocarbons, and NH3 from spacecraft cabin air. This regenerable sorber is a prototype of what is intended to be a lightweight alternative to activated-carbon and zeolite-pellet sorbent beds now in use. The regenerable sorber consists mainly of an assembly of commercially available meshes that have been coated with a specially-formulated washcoat containing zeolites. The zeolites act as the sorbents while the meshes support the zeolite-containing washcoat in a configuration that affords highly effective surface area for exposing the sorbents to flowing air. The meshes also define flow paths characterized by short channel lengths to prevent excessive buildup of flow boundary layers. Flow boundary layer resistance is undesired because it can impede mass and heat transfer. The total weight and volume comparison versus the atmosphere revitalization equipment used onboard the International Space Station for CO2 and trace-component removal will depend upon the design details of the final embodiment. However, the integrated mesh-based CO2 and trace-contaminant removal system is expected to provide overall weight and volume savings by eliminating most of the trace-contaminant control equipment presently used in parallel processing schemes traditionally used for spacecraft. The mesh-based sorbent media enables integrating the two processes within a compact package. For the purpose of regeneration, the sorber can be heated by passing electric currents through the metallic meshes combined with exposure to space vacuum. The minimal thermal mass of the meshes offers the potential for reduced regeneration-power requirements and cycle time required for regeneration compared to regenerable sorption processes now in use.
Improved crucibles consisting mainly of metal-reinforced ceramic ampules have been developed for use in experiments in which material specimens are heated in the crucibles to various high temperatures, then quenched by, for example, plunging the crucibles into water at room temperature. In a traditional quench crucible, the gap between the ampule and the metal cartridge impedes the transfer of heat to such a degree that the quench rate (the rate of cooling of the specimen) can be too low to produce the desired effect in the specimen. One can increase the quench rate by eliminating the metal cartridge to enable direct quenching of the ampule, but then the thermal shock of direct quenching causes cracking of the ampule. In a quench crucible of the present improved type, there is no gap and no metal cartridge in the traditional sense. Instead, there is an overlay of metal in direct contact with the ampule, as shown on the right side of the figure. Because there is no gap between the metal overlay and the ampule, the heat-transfer rate can be much greater than it is in a traditional quench crucible. The metal overlay also reinforces the ampule against cracking.
Chromite in ordinary chondrites (OC) can be used as a shock indicator. A survey of 76 equilibrated H, L and LL chondrites shows that unshocked chromite grains occur in equant, subhedral and rounded morphologies surrounded by silicate or intergrown with metallic Fe-Ni and/or troilite. Some unmelted chromite grains are fractured or crushed during whole-rock brecciation. Others are transected by opaque veins; the veins form when impacts cause localized heating of metal-troilite intergrowths above the Fe-FeS eutectic (988 C), mobilization of metal-troilite melts, and penetration of the melt into fractures in chromite grains. Chromite-plagioclase assemblages occur in nearly every shock-stage S3-S6 OC; the assemblages range in size from 20-300 microns and consist of 0.2-20-micron-size euhedral, subhedral, anhedral and rounded chromite grains surrounded by plagioclase or glass of plagioclase composition. Plagioclase has a low impedance to shock compression. Heat from shock-melted plagioclase caused adjacent chromite grains to melt; chromite grains crystallized from this melt. Those chromite grains in the assemblages that are completely surrounded by plagioclase are generally richer in Al2O3, than unmelted, matrix chromite grains in the same meteorite. Chromite veinlets (typically 0.5-2 microns thick and 10-300 microns long) occur typically in the vicinity of chromite-plagioclase assemblages. The veinlets formed from chromite-plagioclase melts that were injected into fractures in neighboring silicate grains; chromite crystallized in the fractures and the residual plagioclase-rich melt continued to flow, eventually pooling to form plagioclase-rich melt pockets. Chromite-rich chondrules (consisting mainly of olivine, plagioclase-normative mesostasis, and 5-15 vol.% chromite) occur in many shocked OC and OC regolith breccias but they are absent from primitive type-3 OC. They may have formed by impact melting chromite, plagioclase and adjacent mafic silicates during higher-energy shock events. The melt was jetted from the impact site and formed droplets due to surface tension. Crystallization of these droplets may have commenced in flight, prior to landing on the parent-body surface. Chromite-plagioclase assemblages and chromite veinlets occur in 25 out of 25 shock-stage S1 OC of petrologic type 5 and 6 that I examined. Although these rocks contain unstrained olivine with sharp optical extinction, most possess other shock indicators such as extensive silicate darkening, numerous occurrences of metallic Cu, polycrystalline troilite, and opaque veins. It seems likely that these rocks were shocked to levels at least as high as shock-stage S3 and then annealed by heat generated during the shock event. During annealing, the olivine crystal lattices healed but other shock indicators survived. Published Ar-Ar age data for some SI OC indicate that many shock and annealing events occurred very early in the history of the parent asteroids. The common occurrence of shocked and annealed OC is consistent with collisions being a major mechanism responsible for metamorphosing OC.
The proper understanding and modeling of a microcalorimeter s response requires the accurate knowledge of a handful of parameters, such as C, G, alpha, . . . . While a few of these, such 8s the normal state resistance and the total thermal conductance to the heat bath (G) are directly determined from the DC IV characteristics, some others, notoriously the heat capacity (C) and alpha, appear in degenerate combinations in most measurable quantities. The case of a complex microcalorimeter, i.e. one in which the absorber s heat capacity is connected by a finite thermal impedance to the sensor, and subsequently by another thermal impedance to the heat bath, results in an added ambiguity in the determination of the individual C's and G's. In general, the dependence of the microcalorimeter s complex impedance on these parameters varies with frequency. This variation allows us to determine the individual parameters by fitting the prediction of the microcalorimeter model to the impedance data. We describe in this paper our efforts at characterizing the Goddard X-ray microcalorimeters. Using the parameters determined with this method we them compare the pulse shape and noise spectra predicted by the microcalorimeter model to data taken with the same devices.
An S-band antenna system and a group of off-the-shelf aircraft antenna were exposed to temperatures simulating shuttle orbital cold soak and entry heating. Radiation pattern and impedance measurements before and after exposure to the thermal environments were used to evaluate the electrical performance. The results of the electrical and thermal testing are given. Test data showed minor changes in electrical performance and established the capability of these antenna to withstand both the low temperatures of space flight and the high temperatures of entry.
Thermal waves generated by either turbine rotor blades cutting through nonuniform combustor temperature fields or unsteady burning could lead to thermal fatigue cracking in the blades. To determine the magnitude of the thermal oscillation in blades with complex shapes and material compositions, a finite element Galerkin formulation has been developed to study combustor generated thermal wave propagation in a model two-dimensional duct with a uniform plug flow profile. The reflection and transmission of the thermal waves at the entrance and exit boundaries are determined by coupling the finite element solutions at the entrance and exit to the eigenfunctions of an infinitely long adiabatic duct. Example solutions are presented. In general, thermal wave propagation from an air passage into a metallic blade wall is small and not a problem. However, if a thermal barrier coating is applied to a metallic surface under conditions of a high heat transfer, a good impedance match is obtained and a significant portion of the thermal wave can pass into the blade material.
Thermal waves generated by either turbine rotor blades cutting through nonuniform combustor temperature fields or unsteady burning could lead to thermal fatigue cracking in the blades. To determine the magnitude of the thermal oscillation in blades with complex shapes and material compositions, a finite element Galerkin formulation has been developed to study combustor generated thermal wave propagation in a model two-dimensional duct with a uniform plug flow profile. The reflection and transmission of the thermal waves at the entrance and exit boundaries are determined by coupling the finite element solutions at the entrance and exit to the eigenfunctions of an infinitely long adiabatic duct. Example solutions are presented. In general, thermal wave propagation from an air passage into a metallic blade wall is small and not a problem. However, if a thermal barrier coating is applied to a metallic surface under conditions of a high heat transfer, a good impedance match is obtained and a significant portion of the thermal wave can pass into the blade material.
Several microwave systems for use in solar cell fabrication were developed and experimentally tested. The first system used a standing wave rectangular waveguide horn applicator. Satisfactory results were achieved with this system for impedance matching and wafer surface heating uniformity. The second system utilized a resonant TM sub 011 mode cylindrical cavity but could not be employed due to its poor energy coupling efficiency. The third and fourth microwave systems utilized a circular waveguide operating in the TM sub 01 and TM sub 11 but had problems with impedance matching, efficiency, and field uniformity.