Evaluation of SNAP-8 liquid NaK pump-motor (NaK PMA) following vibration and shock testing
Vibration and shock testing of SNAP 8 liquid NaK pump motor assembly
Nelson, R. B.↗
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NaK Variable Conductance Heat Pipe for Radioisotope Stirling Systems
In a Stirling radioisotope power system, heat must continually be removed from the General Purpose Heat Source (GPHS) modules to maintain the modules and surrounding insulation at acceptable temperatures. The Stirling convertor normally provides most of this cooling. If the Stirling convertor stops in the current system, the insulation is designed to spoil, preventing damage to the GPHS, but also ending use of that convertor for the mission. An alkali-metal Variable Conductance Heat Pipe (VCHP) was designed to allow multiple stops and restarts of the Stirling convertor. In the design of the VCHP for the Advanced Stirling Radioisotope Generator, the VCHP reservoir temperature can vary between 40 and 120 C. While sodium, potassium, or cesium could be used as the working fluid, their melting temperatures are above the minimum reservoir temperature, allowing working fluid to freeze in the reservoir. In contrast, the melting point of NaK is -12 C, so NaK can't freeze in the reservoir. One potential problem with NaK as a working fluid is that previous tests with NaK heat pipes have shown that NaK heat pipes can develop temperature non-uniformities in the evaporator due to NaK's binary composition. A NaK heat pipe was fabricated to measure the temperature non-uniformities in a scale model of the VCHP for the Stirling Radioisotope system. The temperature profiles in the evaporator and condenser were measured as a function of operating temperature and power. The largest delta T across the condenser was 2S C. However, the condenser delta T decreased to 16 C for the 775 C vapor temperature at the highest heat flux applied, 7.21 W/ square cm. This decrease with increasing heat flux was caused by the increased mixing of the sodium and potassium in the vapor. This temperature differential is similar to the temperature variation in this ASRG heat transfer interface without a heat pipe, so NaK can be used as the VCHP working fluid.
Tarau, Calin↗
Experimental Studies of NaK in a Simulated Space Environment
Space fission power systems are being developed at the National Aeronautics and Space Administration (NASA) and Department of Energy (DOE) with a short term goal of building a full scale, non-nuclear, Technology Demonstration Unit (TDU) test at NASA's Glenn Research Center. Due to the geometric constraints, mass restrictions, and fairly high temperatures associated with space reactors, liquid metals are typically used as the primary coolant. A eutectic mixture of sodium (22 percent) and potassium (78 percent), or NaK, has been chosen as the coolant for the TDU with a total system capacity of approximately 55 L. NaK, like all alkali metals, is very reactive, and warrants certain safety considerations. To adequately examine the risk associated with the personnel, facility, and test hardware during a potential NaK leak in the large scale TDU test, a small scale experiment was performed in which NaK was released in a thermal vacuum chamber under controlled conditions. The study focused on detecting NaK leaks in the vacuum environment as well as the molecular flow of the NaK vapor. This paper reflects the work completed during the NaK experiment and provides results and discussion relative to the findings.
Gibons, Marc↗
The NaK Population: A 2019 Status
The statistical debris measurement campaigns conducted by the Haystack Ultrawideband Satellite Imaging Radar (HUSIR) on behalf of the NASA Orbital Debris Program Office are used to characterize the long-term behavior of the small, low Earth orbit (LEO) orbital debris environment. A long-recognized, unique component of the LEO environment is composed of small Sodium-Potassium (NaK) eutectic nuclear reactor coolant droplets associated with the Soviet Radar Ocean Reconnaissance Satellite (RORSAT) program. Beginning with the flight of Cosmos 1176, RORSAT vehicles would nominally separate their reactor core at end of mission, thereby venting the NaK coolant and producing the NaK droplet population. In this paper, we describe the methodology by which NaK are segregated from the statistically sampled general debris population and their sizes inferred; the current NaK environment; how it has changed over time; and a potential new source of NaK: RORSAT vehicles that did not separate their reactor core by either design or apparent malfunction.
Matney, Mark↗
Design of a Mechanical NaK Pump for Fission Space Power
Alkali liquid metal cooled fission reactor concepts are under development for spaceflight power requirements. One such concept utilizes a sodium-potassium eutectic (NaK) as the primary loop working fluid, which has specific pumping requirements. Traditionally, electromagnetic linear induction pumps have been used to provide the required flow and pressure head conditions for NaK systems but they can be limited in performance, efficiency, and number of available vendors. The objective of the project was to develop a mechanical NaK centrifugal pump that takes advantages of technology advances not available in previous liquid metal mechanical pump designs. This paper details the design, build, and performance test of a mechanical NaK pump developed at NASA Marshall Space Flight Center. The pump was designed to meet reactor cooling requirements using commercially available components modified for high temperature NaK service.
Mireles, Omar R.↗
Stainless Steel NaK Circuit Integration and Fill Submission
The Early Flight Fission Test Facilities (EFF-TF) team has been tasked by the Marshall Space Flight Center Nuclear Systems Office to design, fabricate, and test an actively pumped alkali metal flow circuit. The system, which was originally designed to hold a eutectic mixture of sodium potassium (NaK), was redesigned to hold lithium; but due to a shift in focus, it is once again being prepared for use with NaK. Changes made to the actively pumped, high temperature loop include the replacement of the expansion reservoir, addition of remotely operated valves, and modification of the support table. Basic circuit components include: reactor segment, NaK to gas heat exchanger, electromagnetic (EM) liquid metal pump, load/drain reservoir, expansion reservoir, instrumentation, and a spill reservoir. A 37-pin partial-array core (pin and flow path dimensions are the same as those in a full design) was selected for fabrication and test. This document summarizes the integration and fill of the pumped liquid metal NaK flow circuit.
Garber, Anne E.↗
Design, Fabrication and Integration of a NaK-Cooled Circuit
The Early Flight Fission Test Facilities (EFF-TF) team has been tasked by the NASA Marshall Space Flight Center Nuclear Systems Office to design, fabricate, and test an actively pumped alkali metal flow circuit. The system, which was originally designed for use with a eutectic mixture of sodium potassium (NaK), was redesigned to for use with lithium. Due to a shi$ in focus, it is once again being prepared for use with NaK. Changes made to the actively pumped, high temperature circuit include the replacement of the expansion reservoir, addition of remotely operated valves, and modification of the support table. Basic circuit components include: reactor segment, NaK to gas heat exchanger, electromagnetic (EM) liquid metal pump, load/drain reservoir, expansion reservoir, instrumentation, and a spill reservoir. A 37-pin partial-array core (pin and flow path dimensions are the same as those in a fill design) was selected for fabrication and test. This paper summarizes the integration and preparations for the fill of the pumped liquid metal NaK flow circuit.
Garber, Anne↗
Stainless Steel NaK-Cooled Circuit (SNaKC) Fabrication and Assembly
An actively pumped Stainless Steel NaK Circuit (SNaKC) has been designed and fabricated by the Early Flight Fission Test Facility (EFF-TF) team at NASA's Marshall Space Flight Center. This circuit uses the eutectic mixture of sodium and potassium (NaK) as the working fluid building upon the experience and accomplishments of the SNAP reactor program from the late 1960's The SNaKC enables valuable experience and liquid metal test capability to be gained toward the goal of designing and building an affordable surface power reactor. The basic circuit components include a simulated reactor core a NaK to gas heat exchanger, an electromagnetic (EM) liquid metal pump, a liquid metal flow meter, an expansion reservoir and a drain/fill reservoir To maintain an oxygen free environment in the presence of NaK, an argon system is utilized. A helium and nitrogen system are utilized for core, pump, and heat exchanger operation. An additional rest section is available to enable special component testing m an elevated temperature actively pumped liquid metal environment. This paper summarizes the physical build of the SNaKC the gas and pressurization systems, vacuum systems, as well as instrumentation and control methods.
Godfroy, Thomas J.↗
Status of Kilowatt-Class Stirling Power Conversion Using a Pumped NaK Loop for Thermal Input
Free-piston Stirling power conversion has been identified as a viable option for potential Fission Surface Power (FSP) systems on the Moon and Mars. Proposed systems consist of two or more Stirling convertors, in a dual-opposed configuration, coupled to a low-temperature uranium-dioxide-fueled, liquid-metal-cooled reactor. To reduce developmental risks associated with liquid-metal loop integration, a test rig has been built to evaluate the performance of a pair of 1-kW free-piston Stirling convertors using a pumped sodium-potassium (NaK) loop for thermal energy input. Baseline performance maps have been generated at the Glenn Research Center (GRC) for these 1-kW convertors operating with an electric heat source. Each convertor was then retrofitted with a custom-made NaK heater head and integrated into a pumped NaK system at the Marshall Space Flight Center (MSFC). This paper documents baseline testing at GRC as well as the progress made in integrating the Stirling convertors into the pumped NaK loop.
Briggs, Maxwell H.↗
Initial Testing of the Stainless Steel NaK-Cooled Circuit (SNaKC)
An actively pumped alkali metal flow circuit, designed and fabricated at the NASA Marshall Space Flight Center, is currently undergoing testing in the Early Flight Fission Test Facility (EFF-TF). Sodium potassium (NaK) was selected as the primary coolant. Basic circuit components include: simulated reactor core, NaK to gas heat exchanger, electromagnetic liquid metal pump, liquid metal flowmeter, load/drain reservoir, expansion reservoir, test section, and instrumentation. Operation of the circuit is based around the 37-pin partial-array core (pin and flow path dimensions are the same as those in a full core), designed to operate at 33 kWt. This presentation addresses the construction, fill and initial testing of the Stainless Steel NaK-Cooled Circuit (SNaKC).
Garber, Anne↗
Flow Components in a NaK Test Loop Designed to Simulate Conditions in a Nuclear Surface Power Reactor
A test loop using NaK as the working fluid is presently in use to study material compatibility effects on various components that comprise a possible nuclear reactor design for use on the lunar surface. A DC electromagnetic (EM) pump has been designed and implemented as a means of actively controlling the NaK flow rate through the system and an EM flow sensor is employed to monitor the developed flow rate. These components allow for the matching of the flow rate conditions in test loops with those that would be found in a full-scale surface-power reactor. The design and operating characteristics of the EM pump and flow sensor are presented. In the EM pump, current is applied to a set of electrodes to produce a Lorentz body force in the fluid. A measurement of the induced voltage (back-EMF) in the flow sensor provides the means of monitoring flow rate. Both components are compact, employing high magnetic field strength neodymium magnets thermally coupled to a water-cooled housing. A vacuum gap limits the heat transferred from the high temperature NaK tube to the magnets and a magnetically-permeable material completes the magnetic circuit. The pump is designed to produce a pressure rise of 5 psi, and the flow sensor's predicted output is roughly 20 mV at the loop's nominal flow rate of 0.5 GPM.
Polzin, Kurt A.↗
NaK Plugging Meter Design for the Feasibility Test Loops
The design and predicted performance of a plugging meter for use in the measurement of NaK impurity levels are presented. The plugging meter is incorporated into a Feasibility Test Loop (FTL), which is a small pumped-NaK loop designed to enable the rapid, small-scale evaluation of techniques such as in situ purification methods and to permit the measurement of bulk material transport effects (not mechanisms) under flow conditions that are representative of a fission surface power reactor. The FTL operates at temperatures similar to those found in a reactor, with a maximum hot side temperature of 900 K and a corresponding cold side temperature of 860 K. In the plugging meter a low flow rate bypass loop is cooled until various impurities (primarily oxides) precipitate out of solution. The temperatures at which these impurities precipitate are indicative of the level of impurities in the NaK. The precipitates incrementally plug a small orifice in the bypass loop, which is detected by monitoring changes in the liquid metal flow rate.
Pearson, J. Boise↗
Summary of Test Results From a 1 kW(sub e)-Class Free-Piston Stirling Power Convertor Integrated With a Pumped NaK Loop
As a step towards development of Stirling power conversion for potential use in Fission Surface Power (FSP) systems, a pair of commercially available 1 kW class free-piston Stirling convertors was modified to operate with a NaK liquid metal pumped loop for thermal energy input. This was the first-ever attempt at powering a free-piston Stirling engine with a pumped liquid metal heat source and is a major FSP project milestone towards demonstrating technical feasibility. The tests included performance mapping the convertors over various hot and cold-end temperatures, piston amplitudes and NaK flow rates; and transient test conditions to simulate various start-up and fault scenarios. Performance maps of the convertors generated using the pumped NaK loop for thermal input show increases in power output over those measured during baseline testing using electric heating. Transient testing showed that the Stirling convertors can be successfully started in a variety of different scenarios and that the convertors can recover from a variety of fault scenarios.
Briggs, Maxwell H.↗
Summary of Test Results From a 1 kWe-Class Free-Piston Stirling Power Convertor Integrated With a Pumped NaK Loop
As a step towards development of Stirling power conversion for potential use in Fission Surface Power (FSP) systems, a pair of commercially available 1 kW class free-piston Stirling convertors was modified to operate with a NaK liquid metal pumped loop for thermal energy input. This was the first-ever attempt at powering a free-piston Stirling engine with a pumped liquid metal heat source and is a major FSP project milestone towards demonstrating technical feasibility. The tests included performance mapping the convertors over various hot and cold-end temperatures, piston amplitudes and NaK flow rates; and transient test conditions to simulate various start-up and fault scenarios. Performance maps of the convertors generated using the pumped NaK loop for thermal input show increases in power output over those measured during baseline testing using electric heating. Transient testing showed that the Stirling convertors can be successfully started in a variety of different scenarios and that the convertors can recover from a variety of fault scenarios.
Briggs, Maxwell H.↗
Test Results From a Pair of 1-kWe Dual-Opposed Free-Piston Stirling Power Convertors Integrated With a Pumped NaK Loop
As a step towards development of Stirling power conversion for potential use in Fission Surface Power (FSP) systems, a pair of commercially available 1-kW-class free-piston Stirling convertors were modified to operate with a NaK (sodium (Na) and potassium (K)) liquid metal pumped loop for thermal energy input. This was the first-ever attempt at powering a free-piston Stirling engine with a pumped liquid metal heat source and is a major FSP project milestone towards demonstrating technical feasibility. The convertors were successfully tested at the Marshall Space Flight Center (MSFC) from June 6 through July 14, 2009. The convertors were operated for a total test time of 66 hr and 16 min. The tests included (a) performance mapping the convertors over various hot- and cold-end temperatures, piston amplitudes, and NaK flow rates and (b) transient test conditions to simulate various startup (i.e., low-, medium-, and high-temperature startups) and fault scenarios (i.e., loss of heat source, loss of NaK pump, convertor stall, etc.). This report documents the results of this testing
Geng, Steven M.↗
Material Studies Related to the Use of NaK Heat Exchangers Coupled to Stirling Heater Heads
NASA has been supporting design studies and technology development that could provide power to an outpost on the Moon, Mars, or an asteroid. Technology development efforts have included fabrication and evaluation of components used in a Stirling engine power conversion system. Destructive material evaluation was performed on a NaK shell heat exchanger that was developed by the NASA Glenn Research Center (GRC) and integrated with a commercial 1 kWe Stirling convertor from Sunpower Incorporated. The NaK Stirling test demonstrated Stirling convertor electrical power generation using a pumped liquid metal heat source under thermal conditions that represent the heat exchanger liquid metal loop in a Fission Power Systems (FPS) reactor. The convertors were operated for a total test time of 66 hr at a maximum temperature of 823 K. After the test was completed and NaK removed, the heat exchanger assembly was sectioned to evaluate any material interactions with the flowing liquid metal. Several dissimilar-metal braze joint options, crucial for the heat exchanger transfer path, were also investigated. A comprehensive investigation was completed and lessons learned for future heat exchanger development efforts are discussed.
Locci, Ivan E.↗
Design of a Mechanical NaK Pump for Fission Space Power Systems
Alkali liquid metal cooled fission reactor concepts are under development for mid-range spaceflight power requirements. One such concept utilizes a sodium-potassium eutectic (NaK) as the primary loop working fluid. Traditionally, linear induction pumps have been used to provide the required flow and head conditions for liquid metal systems but can be limited in performance. This paper details the design, build, and check-out test of a mechanical NaK pump. The pump was designed to meet reactor cooling requirements using commercially available components modified for high temperature NaK service.
Mireles, Omar R.↗
NaK-nitrogen liquid metal MHD converter tests at 30 kW.
Description of the tests performed and test results obtained in an experiment where a NaK-nitrogen liquid metal MHD converter was operated over a range of nozzle inlet pressures of 100 to 165 N per sq cm, NaK flow rates of 46 to 72 kg/sec, and nitrogen flow rates of 3.4 to 3.8 kg/sec. The test results indicate: (1) smooth and stable operation, (2) absence of unexpected electrical or flow losses, and (3) possibility of operation with the expected full power output of 30 kW.
Cerini, D. J.↗