Testing and Failure Mechanisms of Ice Phase Change Material Heat Exchangers

Phase change materials (PCM) may be useful for thermal control systems that involve cyclical heat loads or cyclical thermal environments such as Low Earth Orbit (LEO) and Low Lunar Orbit (LLO). Thermal energy can be stored in the PCM during peak heat loads or in adverse thermal environments. The stored thermal energy can then be released later during minimum heat loads or in more favorable thermal environments. One advantage that PCM s have over evaporators in this scenario is that they do not use a consumable. The use of water as a PCM rather than the more traditional paraffin wax has the potential for significant mass reduction since the latent heat of formation of water is approximately 70% greater than that of wax. One of the potential drawbacks of using ice as a PCM is its potential to rupture its container as water expands upon freezing. In order to develop a space qualified ice PCM heat exchanger, failure mechanisms must first be understood. Therefore, a methodical experimental investigation has been undertaken to demonstrate and document specific failure mechanisms due to ice expansion in the PCM. A number of ice PCM heat exchangers were fabricated and tested. Additionally, methods for controlling void location in order to reduce the risk of damage due to ice expansion were investigated. This paper presents the results of testing that occurred from March through September of 2010 and builds on testing that occurred during the previous year

Development, Fabrication, and Testing of a Liquid/Liquid Microchannel Heat Exchanger for Constellation Spacecrafts

Minimizing mass and volume is critically important for space hardware. Microchannel technology can be used to decrease both of these parameters for heat exchangers. Working in concert with NASA, Pacific Northwest National Laboratories (PNNL) has developed a microchannel liquid/liquid heat exchanger that has resulted in significant mass and volume savings. The microchannel heat exchanger delivers these improvements without sacrificing thermal and pressure drop performance. A conventional heat exchanger has been tested and the performance of it recorded to compare it to the microchannel heat exchanger that PNNL has fabricated. The microchannel heat exchanger was designed to meet all of the requirements of the baseline heat exchanger, while reducing the heat exchanger mass and volume. The baseline heat exchanger was designed to have an transfer approximately 3.1 kW for a specific set of inlet conditions. The baseline heat exchanger mass was 2.7 kg while the microchannel mass was only 2.0 kg. More impressive, however, was the volumetric savings associated with the microchannel heat exchanger. The microchannel heat exchanger was an order of magnitude smaller than the baseline heat exchanger (2180cm3 vs. 311 cm3). This paper will describe the test apparatus designed to complete performance tests for both heat exchangers. Also described in this paper will be the performance specifications for the microchannel heat exchanger and how they compare to the baseline heat exchanger