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Handbook describes relationship between phase-change materials and more conventional thermal control techniques and discusses materials' space and terrestrial applications. Material properties of most promising phase-change materials and purposes and uses of metallic filler materials in phase-change material composites are provided.
Two-dimensional phase-change problem is numerically solved in cylindrical coordinates (r and z) by utilizing two Taylor series expansions for the temperature distributions in the neighborhood of the interface location. These two expansions form two polynomials in r and z directions. For the regions sufficiently away from the interface the temperature field equations are numerically solved in the usual way and the results are coupled with the polynomials. The main advantages of this efficient approach include ability to accept arbitrarily time dependent boundary conditions of all types and arbitrarily specified initial temperature distributions. A modified approach using a single Taylor series expansion in two variables is also suggested.
Thermal control of spacecraft via solid-liquid phase change materials
A research program was initiated to determine the feasibility of using cooling to increase brake life. An air cooling scheme was proposed, constructed and tested with various designs. Straight and curved slotting of the friction material was tested. A water cooling technique, similar to the air cooling procedure, was evaluated on a curved slotted rotor. Also investigated was the possibility of using a phase-change material within the rotor to absorb heat during braking. Various phase-changing materials were tabulated and a 50%, (by weight) LiF - BeF2 mixing was chosen. It was shown that corrosion was not a problem with this mixture. A preliminary design was evaluated on an actual brake. Results showed that significant improvements in lowering the surface temperature of the brake occurred when air or water cooling was used in conjunction with curved slotted rotors.
Solidification effects on performance and suitability of phase-change materials in thermal control devices
Natural convection effects in phase change thermal control devices were studied. A mathematical model was developed to evaluate natural convection effects in a phase change test cell undergoing solidification. Although natural convection effects are minimized in flight spacecraft, all phase change devices are ground tested. The mathematical approach to the problem was to first develop a transient two-dimensional conduction heat transfer model for the solidification of a normal paraffin of finite geometry. Next, a transient two-dimensional model was developed for the solidification of the same paraffin by a combined conduction-natural-convection heat transfer model. Throughout the study, n-hexadecane (n-C16H34) was used as the phase-change material in both the theoretical and the experimental work. The models were based on the transient two-dimensional finite difference solutions of the energy, continuity, and momentum equations.
The advanced Thermal Control Flight Experiment on the Applications Technology Satellite (ATS-F) will evaluate, for the first time in a space environment, the performance of a feedback-controlled variable conductance heat pipe and a heat pipe thermal diode. In addition, the temperature control aspects of a phase-change material (PCM) will be demonstrated. The methanol/stainless steel feedback-controlled heat pipe uses helium control gas that is stored in a wicked reservoir. This reservoir is electrically heated through a solid state controller that senses the temperature of the heat source directly. The ammonia/stainless steel diode heat pipe uses excess liquid to block heat transfer in the reverse direction. The PCM is octadecane. Design tradeoffs, fabrication problems, and performance during qualification and flight acceptance tests are discussed.
The Advanced Thermal Control Flight Experiment on ATS-6 was designed to demonstrate the thermal control capability of a thermal diode (one-way) heat pipe, a phase-change material for thermal storage, and a feedback-controlled heat pipe. Flight data for the different operational modes are compared to ground test data, and the performance of the components is evaluated on an individual basis and as an integrated temperature-control system.
The Solar Flux Radiometer aboard the Pioneer Venus Sounder Probe operated successfully during its descent through the atmosphere of Venus. The instrument measured atmospheric radiance over the spectral range from 400 to 1800 nm as a function of altitude. Elevation and azimuthal measurements on the radiation field were made with five optical channels. Twelve filtered Si and Ge photovoltaic detectors were maintained near 30 C with a phase-change material. The detector output currents were processed with logarithmic transimpedance converters and digitized with an 11-bit A/D converter. Atmospheric sampling in both elevation and azimuth was done according to a Gaussian integration scheme. The serial output data averaged 20 bits/sec, including housekeeping (sync, spin period, sample timing and mode). The data were used to determine the deposition of solar energy in the atmosphere of Venus between 67 km and the surface along with upward and downward fluxes and radiances with an altitude resolution of several hundred meters. The results allow for more accurate modeling of the radiation balance of the atmosphere than previously possible.
System for storing large amounts of heat per unit volume comprises encapsulated sealed pellets of phase-change materials dispersed and suspended in inert fluid-transport medium.
High temperature solar dynamic Brayton and Stirling receivers are investigated as candidate electrical power generating systems for future LEO missions. These receivers are smaller and more efficient than conventional receivers, and they offer less structural complexity and fewer thermal stress problems. Use of the advanced Direct Absorption Storage Receiver allows many of the problems associated with working with high-volumetric-change phase-change materials to be avoided. A specific mass reduction of about 1/3 with respect to the baseline receiver has been realized.
The feasibility of storing thermal energy at temperatures of 450 C to 535 C in the form of latent heat of fusion was examined for over 30 inorganic salts and salt mixtures. Alkali carbonate mixtures were chosen as phase-change storage materials in this temperature range because of their relatively high storage capacity and thermal conductivity, moderate cost, low volumetric expansion upon melting, low corrosivity, and good chemical stability. Means of improving heat conduction through the solid salt were explored.
Ramsey's (1948, 1949, 1950, 1954) arguments for the phase-change interpretation of the nature of the terrestrial core are summarized. Some of the successes of the phase-change theory in accounting for hitherto unexplained properties of earth's interior are discussed. Evidence in favor of the phase-change theory is reviewed, and calculations are examined which indicate that the liquid-core material is far more compressible at any relevant pressure than is the mantle material. Implications of the phase-change theory for Venus, Mars, Mercury, and the moon are considered.
A new technique of producing hollow spheres of many materials at a very rapid rate, at very low cost, and with high reproducibility of shell diameter and wall thickness has been developed. Shells formed of metal or of other solid materials are expected to find numerous technical and industrial applications. For example, metal shells might be used as inertial confinement fusion targets, or as the principal constituents in lightweight structural materials for NASA Space Stations or DOD large antennas and mirrors, or be employed as containers for phase-change heat-storage media, or serve as containers for hazardous materials, or be employed as catalytic surface agents.
A literature survey, materials reformulation and tailoring, fabrication problems, and materials selection and evaluation for fabricating models to be used with the phase-change technique for obtaining quantitative aerodynamic heat transfer data are presented. The study resulted in the selection of two best materials, stycast 2762 FT, and an alumina ceramic. Characteristics of these materials and detailed fabrication methods are presented.
The phase-change coating technique presents itself as a valuable tool in determining the heat transfer rate over the surface of small complex wind tunnel models. A numerical technique is described which shows that an effective thermophysical property - the square root of the product of thermal conductivity, density, and specific heat - may significantly improve the accuracy of the phase-change coating technique with allowance for model inhomogeneity and temperature dependency in a transient environment. Results of the measured steady-state variation of the effective thermophysical property with temperature and the effect of surface heating rate on the effective thermophysical property are plotted for a representative homogeneous model material and for an extreme nonhomogeneous model material. The use of an effective thermophysical property to reduce phase-change paint data is recommended. The analysis also confirms that the apparatus described by Corwin and Kramer (1975) can be used to measure directly this effective thermophysical property for use in wind tunnel model heat-transfer measurements.
A color-schlieren technique is described that combines the flow-field shock shapes and the phase-change coating to give a very descriptive account of aerodynamic heating. This technique employs, in addition to the conventional schlieren system, a temperature-sensitive material as a thin surface coating that undergoes a visible phase change from opaque solid to clear liquid at a known temperature. The resulting pictures can lead to a better understanding of shock/boundary layer interactions, as shown with the aid of a specific example.
An experimental method for direct measurement of the thermophysical properties of wind tunnel heat transfer models was developed. The technique consists of placing the model under a bank of high intensity, radiant heaters so that the fast opening water cooled shutters, which isolate the heater bank from the model, allow a step-input heat rate to be applied. Measurements of the heat transfer rate coupled with a surface-temperature time history of the same material are sufficient to determine the material thermophysical properties. An infrared thermometer is used to measure model surface temperature and a slug calorimeter provides heat transfer rate information. The output from the infrared thermometer and calorimeter is then fed into an analog-to-digital converter which provides digitized data to a computer. This computer then calculates combined thermophysical properties and a teleprinter prints out all the data. Thus, results are available within 7 minutes of test initiation as opposed to the weeks or months required using prior techniques.