Reusable high-temperature heat pipes and heat pipe panels

A reusable, durable heat pipe which is capable of operating at temperatures up to about 3000 F in an oxidizing environment and at temperatures above 3000 F in an inert or vacuum environment is produced by embedding a refractory metal pipe within a carbon-carbon composite structure. A reusable, durable heat pipe panel is made from an array of refractory-metal pipes spaced from each other. The reusable, durable, heat-pipe is employed to fabricate a hypersonic vehicle leading edge and nose cap

Development of higher-order modal methods for transient thermal and structural analysis

A force-derivative method which produces higher-order modal solutions to transient problems is evaluated. These higher-order solutions converge to an accurate response using fewer degrees-of-freedom (eigenmodes) than lower-order methods such as the mode-displacement or mode-acceleration methods. Results are presented for non-proportionally damped structural problems as well as thermal problems modeled by finite elements

A Return to Innovative Engineering Design, Critical Thinking and Systems Engineering

I believe we are facing a critical time where innovative engineering design is of paramount importance to the success of our aerospace industry. However, the very qualities and attributes necessary for enhancing, educating, and mentoring a creative spirit are in decline in important areas. The importance of creativity and innovation in this country was emphasized by a special edition of the Harvard Business Review OnPoint entitled: "The Creative Company" which compiled a series of past and present articles on the subject of creativity and innovation and stressed its importance to our national economy. There is also a recognition of a lack of engineering, critical thinking and problem-solving skills in our education systems and a trend toward trying to enhance those skills by developing K-12 educational programs such as Project Lead the Way, "Science for All Americans", Benchmarks 2061 , etc. In addition, with respect to spacecraft development, we have a growing need for young to mid-level engineers with appropriate experience and skills in spacecraft design, development, analysis, testing, and systems engineering. As the Director of Engineering at NASA's Johnson Space Center, I realized that sustaining engineering support of an operational human spacecraft such as the Space Shuttle is decidedly different than engineering design and development skills necessary for designing a new spacecraft such as the Crew Exploration Vehicle of the Constellation Program. We learned a very important lesson post Columbia in that the Space Shuttle is truly an experimental and not an operational vehicle and the strict adherence to developed rules and processes and chains of command of an inherently bureaucratic organizational structure will not protect us from a host of known unknowns let alone unknown unknowns. There are no strict rules, processes, or procedures for understanding anomalous results of an experiment, anomalies with an experimental spacecraft like Shuttle, or in the conceptual design of a spacecraft. Engineering design is as much an art as it is a science. The critical thinking skills necessary to uncover lurking problems in an experimental design and creatively develop solutions are some of the same skills necessary to design a new spacecraft. Thus, I believe engineers unfamiliar with or removed from design and development need time to transition and develop the required skill set to be effective spacecraft designers. I believe the creative process necessary in design can be enhanced and even taught as early as grades K-12 and should continue to be nurtured and developed at the university level and beyond. I am going to present a strategy for developing learning teams to address complex multidisciplinary problems and to creatively develop solutions to those problems rapidly at minimal cost. I will frame a real problem, the development of on-orbit thermal protection system repair of the Space Shuttle, and step through the series of skills necessary to enhance the creative process. The case study I will illustrate is based on a real project, the R&D Reinforced Carbon-Carbon (RCC) Repair Team's development of on-orbit repair concepts for damaged Space Shuttle RCC nose cap and/or leading edges

Application of formal optimization techniques in thermal/structural design of a heat-pipe-cooled panel for a hypersonic vehicle

Nonlinear mathematical programming methods are used to design a radiantly cooled and heat-pipe-cooled panel for a Mach 6.7 transport. The cooled portion of the panel is a hybrid heat-pipe/actively cooled design which uses heat pipes to transport the absorbed heat to the ends of the panel where it is removed by active cooling. The panels are optimized for minimum mass and to satisfy a set of heat-pipe, structural, geometric, and minimum-gage constraints. Two panel concepts are investigated: cylindrical heat pipes embedded in a honeycomb core and an integrated design which uses a web-core heat-pipe sandwich concept. The latter was lighter and resulted in a design which was less than 10 percent heavier than an all actively cooled concept. The heat-pipe concept, however, is redundant and can sustain a single-point failure, whereas the actively cooled concept cannot. An additional study was performed to determine the optimum number of coolant manifolds per panel for a minimum-mass design

Heat exchanger with oscillating flow

Various heat exchange apparatuses are described in which an oscillating flow of primary coolant is used to dissipate an incident heat flux. The oscillating flow may be imparted by a reciprocating piston, a double action twin reciprocating piston, fluidic oscillators, or electromagnetic pumps. The oscillating fluid flows through at least one conduit in either an open loop or a closed loop. A secondary flow of coolant may be used to flow over the outer walls of at least one conduit to remove heat transferred from the primary coolant to the walls of the conduit

Development of advanced modal methods for calculating transient thermal and structural response

Higher-order modal methods for predicting thermal and structural response are evaluated. More accurate methods or ones which can significantly reduce the size of complex, transient thermal and structural problems are desirable for analysis and are required for synthesis of real structures subjected to thermal and mechanical loading. A unified method is presented for deriving successively higher-order modal solutions related to previously-developed, lower-order methods such as the mode displacement and mode-acceleration methods. A new method, called the force-derivative method, is used to obtain higher-order modal solutions for both uncoupled (proportionally-damped) structural problems as well as thermal problems and coupled (non-proportionally damped) structural problems. The new method is called the force-derivative method because, analogous to the mode-acceleration method, it produces a term that depends on the forcing function and additional terms that depend on the time derivatives of the forcing function

A simplified method for thermal analysis of a cowl leading edge subject to intense local shock-wave-interference heating

Type IV shock wave interference heating on a blunt body causes extremely intense heating over a very localized region of the body. An analytical solution is presented to a heat transfer problem that approximates the shock wave interference heating of an engine cowl leading edge of the National Aero-Space Plane. The problem uses a simplified geometry to represent the leading edge. An analytical solution is developed that provides a means for approximating maximum temperature differences between the outer and inner surface temperatures of the leading edge. The solution is computationally efficient and, as a result, is well suited for conceptual and preliminary design or trade studies. Transient and steady state analyses are conducted, and results obtained from the analytical solution are compared with results of 2-D thermal finite element analyses over a wide range of design parameters. Isotropic materials as well as laminated composite materials are studied. Results of parametric studies are presented to indicate the effects of the thickness of the cowl leading edge and the width of the region heated by the shock wave interference on the thermal response of the leading edge

An evaluation of higher-order model methods for calculating transient structural response

A higher-order modal method proposed by Leung for transient structural analysis entitled the force-derivative method is evaluated. This method repeatedly integrates by parts with respect to time the convolution-integral form of the structural response to produce successively better approximations to the contribution of the higher modes which are neglected in the modal summation. Comparisons are made of the force-derivative, the mode-displacement, and the mode-acceleration methods for several numerical example problems for various times, levels of damping, and forcing functions. The example problems include a tip-loaded cantilevered beam and a simply-supported multispan beam. The force-derivative method is shown to converge to an accurate solution in fewer modes than either the mode-displacement or the mode-acceleration methods. In addition, for problems in which there are a large number of closely-spaced frequencies whose mode shapes have a negligible contribution to the response, the force-derivative method is very effective in representing the effect of the important, but otherwise neglected, higher modes

Six-year evolution of a space-inspired collaborative problem-solving study program in Finland

This paper presents the results of the six-year qualitative longitudinal case-study of the Epic Challenge study program in Finland. Created in 2008 for NASA engineers, the Epic Challenge program has grown and evolved to teach collaborative problem solving that reaches across different disciplines and ages. The paper presents an overview and evolution of program features and teaching methodologies. In the program, students learn a challenge-based methodology called Innovative Conceptual Engineering Design (ICED) and use this methodology to develop innovative solutions connected to the overarching challenge of sustainable human habitation of Mars. The program is built around the assumption that space exploration as a complex, multidisciplinary challenge provides the inspiration, a driving force and integrated curriculum for teaching Science, Technology, Engineering and Math (STEM) concepts and problem-solving techniques in four key areas: teamworking, networking, systems thinking and innovation. In 2015 the program was adopted and fused with a phenomenon-based learning curriculum in Finland, and it grew to be taught to students of various backgrounds from high-school to doctoral level. The course delivery and content were modified annually based on lessons learned and more than 500 students have gone through the program in Finland. The paper presents the evolution of key program features and concludes by presenting the most robust features of the program implementations that could benefit space agencies, companies and faculty interested in promoting space and STEM related competences

Method for producing micro heat panels

Flat or curved micro heat pipe panels are fabricated by arranging essentially parallel filaments in the shape of the desired panel. The configuration of the filaments corresponds to the desired configuration of the tubes that will constitute the heat pipes. A thermally conductive material is then deposited on and around the filaments to fill in the desired shape of the panel. The filaments are then removed, leaving tubular passageways of the desired configuration and surface texture in the material. The tubes are then filled with a working fluid and sealed. Composite micro heat pipe laminates are formed by layering individual micro heat pipe panels and bonding them to each other to form a single structure. The layering sequence of the micro heat pipe panels can be tailored to transport heat preferentially in specific directions as desired for a particular application