Steven M. Geng

An Overview of Long Duration Sodium Heat Pipe Tests

High temperature heat pipes are being evaluated for use in energy conversion applications such as fuel cells, gas turbine re‐combustors, and Stirling cycle heat sources; with the resurgence of space nuclear power, additional applications include reactor heat removal elements and radiator elements. Long operating life and reliable performance are critical requirements for these applications. Accordingly long‐term materials compatibility is being evaluated through the use of high temperature life test heat pipes. Thermacore, Inc. has carried out several sodium heat pipe life tests to establish long term operating reliability. Four sodium heat pipes have recently demonstrated favorable materials compatibility and heat transport characteristics at high operating temperatures in air over long time periods. A 316L stainless steel heat pipe with a sintered porous nickel wick structure and an integral brazed cartridge heater has successfully operated at 650C to 700C for over 115,000 hours without signs of failure...

A 3-D magnetic analysis of a linear alternator for a Stirling power system

The NASA Glen Research Center and the Department of Energy (DOE) are developing advanced radioisotope Stirling convertors, under contract with Stirling Technology Company (STC), for space applications. Of critical importance to the successful development of the Stirling convertor for space power applications is the development of a lightweight and highly efficient linear alternator. This paper presents a 3-D finite element method (FEM) approach for evaluating Stirling convertor linear alternators. Preliminary correlations with open-circuit voltage measurements provide an encouraging level of confidence in the model. Spatial plots of magnetic field strength (H) are presented in the region of the exciting permanent magnets. These plots identify regions of high H, where at elevated temperature and under electrical load, the potential to alter the magnetic moment of the magnets exists. This implies the need for further testing and analysis.

Comparison of GLIMPS and HFAST Stirling engine code predictions with experimental data

Predictions from GLIMPS and HFAST design codes are compared with experimental data for the RE-1000 and SPRE free-piston Stirling engines. Engine performance and available power loss predictions are compared. Differences exist between GLIMPS and HFAST loss predictions. Both codes require engine-specific calibration to bring predictions and experimental data into agreement.

Overview of NASA Supported Stirling Thermodynamic Loss Research

NASA is funding research to characterize Stirling machine thermodynamic losses. NASAs primary goal is to improve Stirling design codes to support engine development for space and terrestrial power. However, much of the fundamental data is applicable to Stirling cooling and heat pump applications. The research results are reviewed. Much was learned about oscillating flow hydrodynamics, including laminar/turbulent transition, and tabulated data was documented for further analysis. Now, with a better understanding of the oscillating flow field, it is time to begin measuring the effects of oscillating flow and oscillating pressure level on heat transfer in heat exchanger flow passages and in cylinders.

Overview of NASA Magnet and Linear Alternator Research Efforts

The Department of Energy, Lockheed Martin, Stirling Technology Company, and NASA Glenn Research Center are developing a high‐efficiency, 110 watt Stirling Radioisotope Generator (SRG110) for NASA Space Science missions. NASA Glenn is conducting in‐house research on rare earth permanent magnets and on linear alternators to assist in developing a free‐piston Stirling convertor for the SRG110 and for developing advanced technology. The permanent magnet research efforts include magnet characterization, short‐term magnet aging tests, and long‐term magnet aging tests. Linear alternator research efforts have begun just recently at GRC with the characterization of a moving iron type linear alternator using GRC’s alternator test rig. This paper reports on the progress and future plans of GRC’s magnet and linear alternator research efforts.

Results from baseline tests of the SPRE I and comparison with code model predictions

The space power research engine (SPRE), a free-piston Stirling engine with a linear alternator, is being tested as a candidate high-capacity power supply for space systems. Results of baseline engine tests at design and off-design operating conditions are presented. The test results are compared with HFAST code model predictions and show fairly good agreement. The trends in measured data generally follow the same trends as the code predictions. The code, however, does not account for effects of gas bearing flows and mass transport between volumes of the engine.<<ETX>>

Design, fabrication and test of a high efficiency refractive secondary concentrator for solar applications

Common to many of the space power applications that utilize solar thermal energy such as electric power conversion, thermal propulsion and furnaces, is a need for highly efficient, solar concentration systems. An effort is underway to develop the refractive secondary concentrator, which uses refraction and total internal reflection to efficiently concentrate and direct solar energy. When used in combination with advanced primary concentrators, the refractive secondary concentrator enables very high system concentration ratios (10,000 to 1) and very high temperatures (>2000 K). Presented is an overview of the effort at the NASA Glenn Research Center to evaluate the performance of a prototype single crystal sapphire refractive secondary concentrator and to compare the performance with analytical models. The effort involves the design and fabrication of a secondary concentrator, design and fabrication of a calorimeter and its support hardware, calibration of the calorimeter, testing of the secondary concentrator in NASA Glenns Tank 6 solar thermal vacuum facility, and comparing the test results with predictions. Test results indicate an average throughput efficiency of 87%. It is anticipated that reduction of a known reflection loss with an antireflective coating would result in a secondary concentrator throughput efficiency of approximately 93%.

Transient Thermal Analysis of a Refractive Secondary Solar Concentrator

A secondary concentrator is an optical device that accepts solar energy from a primary concentrator and further intensifies and directs the solar flux. The refractive secondary is one such device; fabricated from an optically clear solid material that can efficiently transmit the solar energy by way of refraction and total internal reflection. When combined with a large state-of-the-art rigid or inflatable primary concentrator, the refractive secondary enables solar concentration ratios of 10,000 to 1. In support of potential space solar thermal power and propulsion applications, the NASA Glenn Research Center is developing a single-crystal refractive secondary concentrator for use at temperatures exceeding 2000K. Candidate optically clear single-crystal materials like sapphire and zirconia are being evaluated for this application. To support this evaluation, a three-dimensional transient thermal model of a refractive secondary concentrator in a typical solar thermal propulsion application was developed. This paper describes the model and presents thermal predictions for both sapphire and zirconia prototypes. These predictions are then used to establish parameters for analyzing and testing the materials for their ability to survive thermal shock and stress.

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.

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 lowtemperature 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 sodiumpotassium (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.