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Effective thermal management and removal of the waste heat generated at diode arrays is critical to the development of high-power solid-state lasers. Thermal design must be considered in the packaging of these arrays. Two different packages with heat dissipation through spray cooling are evaluated experimentally and numerically. Their overall performance is compared with other packaging configurations using different heat removal approaches. A novel packaging design is proposed that can fulfill the requirements of low thermal resistance, temperature uniformity among emitters in the diode array, low coolant flow rate, simplicity and low assembly cost. The effect of temperature uniformity on the pumping efficiency for gain media is examined for our novel packaging design. The thermal stress induced by temperature variation within an emitter is also considered.

An innovative nonlinear simulation approach for high power density synchronous generator systems is developed and implemented. Due to high power density, the generator operates in nonlinear region of the magnetic circuit. Magnetic Finite Element Analysis (FEA) makes nonlinear simulation possible. Neural network technique provides nonlinear functions for system level simulation. Dynamic voltage equation provides excellent mathematical model for system level simulations. Voltage, current, and flux linkage quantities are applied in Direct-Quadrature (DQ) rotating frame. The simulated system includes main machine, exciter, rectifier bridge, bang-bang control, and PI control circuitry, forming a closed loop system. Each part is modeled and then integrated into the system model.

This paper presents the concept of a dual latent heat sink for thermal management of pulse heat generating electronic systems. The focus of this work is to verify the effectiveness of the concept during charging through experimentation. Accordingly, custom components were built and a prototype version of the heat sink was fabricated. Experiments were performed to investigate the implementation feasibility and heat transfer performance. It is shown that this heat sink is practicable and helps in arresting the system temperature rise during charging (period of pulse heat load).

A power electronics module was equipped with an evaporative spray cooling nozzle assembly that served to remove waste heat from the silicon devices. The spray cooling nozzle assembly took the place of the standard heat sink, which uses single phase convection. The purpose of this work was to test the ability of spray cooling to enable higher power density in power electronics with high temperature coolant, and to be an effective and lightweight system level solution to the thermal management needs of aerospace vehicles. The spray cooling work done here was with 95 °C water, and this data is compared to 100 °C water/ propylene glycol spray cooling data from a previous paper so as to compare the spray cooling performance of a single component liquid to that of a binary liquid such as WPG. The module used during this work was a COTS module manufactured by Semikron, Inc., with a maximum DC power input of 180 kW (450 VDC and 400 A).

The aircraft electromechanical actuator (EMA) cooling fan is a critical component because an EMA failure caused by overheating could lead to a catastrophic failure in aircraft. Fault tree analysis (FTA) is used to access the failure probability of EMA fans with the goal of improving their mean time to failure (MTTF) from ∼O(5×104) to ∼ O(2.5×109) hours without incurring heavy weight penalty and high cost. The dual-winding and dual-bearing approaches are analyzed and a contra rotating dual-fan design is proposed. Fan motors are assumed to be brushless direct current (BLDC) motors. To have a full understanding of fan reliability, all possible failure mechanisms and failure modes are taken into account. After summarizing the possible failure causes and failure modes of BLDC fans by focusing on each failure mechanism, the life expectancy of fan ball bearings based on a major failure mechanism of lubricant deterioration is calculated and compared to that provided in the literature.

Data mining is defined as the discovery of useful, possibly unexpected, patterns and relationships in data using statistical and non-statistical techniques in order to develop schemes for decision and policy making. Data mining can be used to discover the sources and causes of problems in complex systems. In addition, data mining can support simulation strategies by finding the different constants and parameters to be used in the development of simulation models. This paper introduces a framework for data mining and its application to complex problems. To further explain some of the concepts outlined in this paper, the potential application to the NASA Shuttle Reinforced Carbon-Carbon structures and genetic programming is used as an illustration.

With the development and licensing of inland, state-owned spaceports, and the ongoing development of several new reusable launch vehicles (RLV), the space launch industry is undergoing a significant transformation. As a result, there is a need to reevaluate current launch risk analysis methodologies and practices, which so far have revolved around the conservative casualty expectation analysis developed in the 1950s. Furthermore, an important aspect of launch risk analysis which gives rise to its complexity is its multidisciplinary nature. In analyzing such risk, the physics of and interactions between the varieties of hazards produced by launch vehicles breakups must be captured, modeled and, their effects analyzed. In this paper we discuss how a well-designed multidisciplinary modeling and analysis platform could be a significant step toward reducing the complexity just mentioned.

In this paper, we address the thermal management issues which limit the lifespan, specific power and overall efficiency of an air-cooled rotary Wankel engine used in Unmanned Air Vehicles (UAVs). Our goal is to eliminate the hot spots and reduce the temperature gradients in the engine housing and side plates by aggressive heat spreading using heat pipes. We demonstrate by simulation that, for a specific power requirement, with heat spreading and more effective heat dissipation, thermal stress and distortion can be significantly reduced, even with air cooling. The maximum temperature drop was substantial, from 231°C to 129°C. The temperature difference (measure of temperature uniformity) decreased by 8.8 times (from 159°C to 18°C) for a typical UAV engine. Our heat spreaders would not change the frontal area of the engine and should have a negligible impact on the installed weight of the propulsion assembly.