NASA Contributions to Development of Special-Purpose Thermocouples. A Survey

The thermocouple has been used for measuring temperatures for more than a century, but new materials, probe designs, and techniques are continually being developed. Numerous contributions have been made by the National Aeronautics and Space Administration and its contractors in the aerospace program. These contributions have been collected by Midwest Research Institute and reported in this publication to enable American industrial engineers to study them and adapt them to their own problem areas. Potential applications are suggested to stimulate ideas on how these contributions can be used

A high temperature apparatus for measurement of the Seebeck coefficient

A high temperature Seebeck coefficient measurement apparatus with various features to minimize typical sources of error is designed and built. Common sources of temperature and voltage measurement error are described and principles to overcome these are proposed. With these guiding principles, a high temperature Seebeck measurement apparatus with a uniaxial 4-point contact geometry is designed to operate from room temperature to over 1200 K. This instrument design is simple to operate, and suitable for bulk samples with a broad range of physical types and shapes

Trick or Heat? Manipulating Critical Temperature-Based Control Systems Using Rectification Attacks

Temperature sensing and control systems are widely used in the closed-loop control of critical processes such as maintaining the thermal stability of patients, or in alarm systems for detecting temperature-related hazards. However, the security of these systems has yet to be completely explored, leaving potential attack surfaces that can be exploited to take control over critical systems. In this paper we investigate the reliability of temperature-based control systems from a security and safety perspective. We show how unexpected consequences and safety risks can be induced by physical-level attacks on analog temperature sensing components. For instance, we demonstrate that an adversary could remotely manipulate the temperature sensor measurements of an infant incubator to cause potential safety issues, without tampering with the victim system or triggering automatic temperature alarms. This attack exploits the unintended rectification effect that can be induced in operational and instrumentation amplifiers to control the sensor output, tricking the internal control loop of the victim system to heat up or cool down. Furthermore, we show how the exploit of this hardware-level vulnerability could affect different classes of analog sensors that share similar signal conditioning processes. Our experimental results indicate that conventional defenses commonly deployed in these systems are not sufficient to mitigate the threat, so we propose a prototype design of a low-cost anomaly detector for critical applications to ensure the integrity of temperature sensor signals.Comment: Accepted at the ACM Conference on Computer and Communications Security (CCS), 201

Study of a micro-structured PHE for the thermal management of a fuel cell

This paper was presented at the 3rd Micro and Nano Flows Conference (MNF2011), which was held at the Makedonia Palace Hotel, Thessaloniki in Greece. The conference was organised by Brunel University and supported by the Italian Union of Thermofluiddynamics, Aristotle University of Thessaloniki, University of Thessaly, IPEM, the Process Intensification Network, the Institution of Mechanical Engineers, the Heat Transfer Society, HEXAG - the Heat Exchange Action Group, and the Energy Institute.In the constantly growing market of fuel cells, the heat management of the system is a crucial area of research, since it affects the efficiency, operability and lifetime of the fuel cell. The CFD simulations performed for a plate heat exchanger (PHE) with flat plates clearly demonstrate temperature non-uniformity across the membrane of the unit cell. The CFD code was successfully validated with experimental data acquired from a setup that reproduces the geometry and simulates the thermal behaviour of a typical unit PEMFC. Additionally, the performance of a novel PHE, with micro-structured corrugations on its plates, was studied with the previously validated CFD code. The results clearly show that the proposed plate modifications can increase temperature uniformity across the membrane more than 20% compared to that of the flat plate

Microgravity noncontact temperature requirements at NASA Lewis Research Center

NASA Lewis Research Center is currently supporting 66 microgravity science and applications projects. The 66 projects are separated into 23 flight projects and 43 ground-based projects. The part of the NASA Lewis program dealing with flight experiments is divided into six areas: Combustion Science, Materials Science, Fluid Physics, Instrumentation/Equipment, Advanced Technology Development, and Space Station Multi-User Facility studies. The part of the NASA Lewis program dealing with ground-based experiments is coincidentally also divided into six areas: Electronic Materials, Combustion Science, Fluid Dynamics and Transport Phenomena, Metals and Alloys, Glasses and Ceramics, and Physics and Chemistry Experiments. Several purposes exist for ground-based experimenting. Preliminary information is necessary before a decision can be made for flight status, the short low gravity durations available in ground facilities are adequate for a particular study, or extensive ground-based research must be conducted to define and support the microgravity science endeavors contemplated for space. Not all of the 66 microgravity science and application projects at NASA Lewis have temperature requirements, but most do. Since space allocation does not permit a review of all the pertinent projects, a decision was made to restrict the coverage to the science flight projects, flight projects minus the advanced technology development, and multiuser facility efforts. Very little is lost by this decision as the types of temperature requirements for science flight projects can be considered representative of those for the ground-based projects. The noncontact temperature needs at NASA Lewis, as represented by the science flight projects are discussed by describing briefly the experiments themselves, by displaying an illustration of each experimental setup, and by specifying their temperature requisites

Single-phase laminar flow heat transfer from confined electron beam enhanced surfaces

An experimental investigation of the thermal-hydraulic characteristics for single-phase flow through three electron beam enhanced structures was conducted with water at mass flow rates from 0.005 kg/s to 0.045 kg/s. The structures featured copper heat transfer surfaces, approximately 28 mm wide and 32 mm long in the flow direction, with complex three-dimensional (3D) electron beam manufactured pyramid-like structures. The channel height varied depending on the height of the protrusions and the tip clearance was maintained at 0.1-0.3 mm. The average protrusion densities for the three samples S1, S2, and S3 were 13, 11, and 25 per cm2 with protrusion heights of 2.5, 2.8, and 1.6 mm, respectively. The data gathered were compared to those for a smooth channel surface operating under similar conditions. The results show an increase up to approximately three times for the average Nusselt number compared with the smooth surface. This is attributed to the surface irregularities of the enhanced surfaces, which not only increase the heat transfer area but also improve mixing, disturb the thermal and velocity boundary layers, and reduce thermal resistance. The increase in heat transfer with the enhanced surfaces was accompanied by an increase of pressure drop, which has to be considered in design.The authors would like to acknowledge Dr Anita Buxton and Dr Bruce Dance of TWI for their contribution to this project and also EPSRC and TSB for funding the EngD programme and sponsoring the ASTIA collaborative research project that helped to develop the Electron Beam enhanced surfaces respectively

Thermal analysis of a plastic helical coil heat exchanger for a domestic water storage tank

In the present study, the heat transfer coefficients of helically coiled corrugated plastic tube heat exchanger inside of the solar boiler vessel were investigated experimentally. The metal coil of the conventional solar boiler for domestic usage was replaced by a plastic tube and the results were compared with the numerical simulation and the technical documentation of the initial solar boiler. All the required parameters like inlet and outlet temperatures of tubeside and stratified temperatures, flow rate of fluids, etc. were measured using appropriate instruments. The test runs were performed for different temperatures inside the tank ranging from 30-60°C and different flow rates from which the heat transfer coefficients were calculated

Numerical modelling of heat transfer and experimental validation in Powder-Bed Fusion with the Virtual Domain Approximation

Among metal additive manufacturing technologies, powder-bed fusion features very thin layers and rapid solidification rates, leading to long build jobs and a highly localized process. Many efforts are being devoted to accelerate simulation times for practical industrial applications. The new approach suggested here, the virtual domain approximation, is a physics-based rationale for spatial reduction of the domain in the thermal finite-element analysis at the part scale. Computational experiments address, among others, validation against a large physical experiment of 17.5 $\mathrm{[cm^3]}$ of deposited volume in 647 layers. For fast and automatic parameter estimation at such level of complexity, a high-performance computing framework is employed. It couples FEMPAR-AM, a specialized parallel finite-element software, with Dakota, for the parametric exploration. Compared to previous state-of-the-art, this formulation provides higher accuracy at the same computational cost. This sets the path to a fully virtualized model, considering an upwards-moving domain covering the last printed layers

Determination of heat transfer coefficient for hot stamping process

© 2015 The Authors.The selection of the heat transfer coefficient is one of the most important factors that determine the reliability of FE simulation results of a hot stamping process, in which the formed component is held within cold dies until fully quenched. The quenching process could take up to 10. seconds. In order to maximise the production rate, the optimised quenching parameters should be identified to achieve the highest possible quenching rate and to reduce the quenching time. For this purpose, a novel-testing rig for the Gleeble 3800 thermo- mechanical simulator was designed and manufactured, with an advanced control system for temperature and contact pressure. The effect of contact pressure on the heat transfer coefficient was studied. The findings of this research will provide useful guidelines for the selection of the heat transfer coefficient in simulations of hot stamping processes and useful information for the design of hot stamping processes