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Oscillating heat pipes (OHPs) represent a promising advancement over traditional heat pipes, yet their operational boundaries, especially for long OHPs, remain insufficiently understood. This study investigates the impact of varying adiabatic length, channel diameter, and fill ratio on thermal performance, crucial for assessing their suitability for engineering applications like spacecraft thermal management. Three long OHPs, ranging from 451 mm to 770 mm in total length, were subjected to multiple performance tests, employing channel diameters of 1.1 mm and 1.9 mm, along with adiabatic lengths of 305 mm and 610 mm. The experimental setup involved mounting the OHPs onto a testbed, monitored by nine K-type thermocouples. The tests, conducted horizontally to eliminate gravity-assistance, revealed that thermal performance is significantly influenced by channel diameter, adiabatic length, and fill ratio. Notably, optimal performance was observed at a 50% fill ratio, while reductions in diameter hindered start-up at a 70% fill ratio and failed to start-up at 30% fill ratio. These findings highlight the limitations of long OHPs, which is crucial to determine the limits of their applicability and dimensional constraints. 

Abstract High-power small satellites will play an important role in reducing the cost of space missions. High power levels are required to satisfy high bandwidth communication needs, as well as to accommodate other critical systems such as propulsion and high-power electronics. One of the current high-power limitations is the need to overcome the thermal challenges associated with high thermal loads. While substantial work has been done in the development of deployable solar arrays, relatively little attention has been given to small satellite deployable radiators. Previous deployable small satellite radiators rely on a mechanical hinge to conduct heat from spacecraft to radiator. However, this presents a thermal choke point and limits heat flow. Thus, a deployable radiator design concept is currently being explored as a thermal solution for high powered electronics in CubeSats. This Additively Manufactured Deployable Radiator Oscillating Heat Pipes (AMDROHP) design concept combines the function of a deployable radiator with high performance Oscillating Heat Pipes in this compact thermal solution. In this project, significant efforts have gone into developing the mechanical, deployable aspect of this design while maximizing its thermal performance, and this joint development has been discussed in previous publication. This initial design was additively manufactured and thermally tested at the Jet Propulsion Laboratory. The results of the thermal testing of the initial AMDROHP design are discussed and presented in this work. The device is tested across a range of heat inputs under “micro-gravity” and “gravity-assisted” orientations for the working fluids R134a and Ammonia. The performance and behavior of the AMDROHP device are characterized by transient temperature measurement data under these different conditions. The results were interpreted to determine the feasibility of the design. Although AMDROHP did operate under “gravity-assisted” orientation, it did not start-up under “micro-gravity” orientation. Furthermore, the range of operation under “gravity-assisted” orientation was less than expected. Based on these results, possible design changes have been identified to improve AMDROHP performance under space-like conditions. These changes include creating a shorter adiabatic length by decreasing the path length of the helical joint, as well as increasing the inner channel diameter. These changes will allow for better thermal performance and to better avoid any imperfections in the additive manufacturing process to cause negative effects on OHP operation. In this study, experimental testing provided actionable information about the initial design of AMDROHP to lead to design improvements. These design improvements will be implemented in the next design iteration of AMDROHP. 

Abstract Oscillating Heat Pipes (OHPs) are unique two-phase heat transfer devices with many advantages over standard and more widely adopted thermal control devices. Specifically, OHPs are able to operate passively, over a wide temperature range, and under high heat fluxes, with few design constraints. OHPs operate based on the process of evaporating and condensing a working fluid on opposite ends of a series of serpentine channels. The pressure difference causes an oscillating behavior of the fluid to travel along the direction of the channels enabling a high heat transfer rate. The capability of this technology has garnered much attention and interest for a variety of applications in different fields. While as a thermal management device, OHP technology shows much promise, there is still much to be understood about the fundamental principles of its operation. One of the most important aspects of OHP operation that is still not well understood is the phenomena known as “start-up”. Start-up is when the proper conditions of an OHP are created such that the operating, oscillatory process of an OHP is enabled to begin. In this work, experimental testing is performed to investigate the relationship between evaporator and condenser length on OHP start-up. In this study, combinations of small, medium, and large length evaporators and condensers were used on a 42-turn OHP with 1 mm square channels, charged with R134a to 50% fill ratio with the goal to quantify the minimum heat that would initiate start-up. Before this test could be performed, issues in consistency of the start-up of OHP had to be resolved. A method to “reset” the liquid-vapor distribution to overcome any adverse history from previous OHP operation developed is discussed. Then, a zero-heat input method of confirming a liquid-vapor distribution favorable to start-up is outlined. After developing this method to achieve a consistent start-up heat input in the OHP, tests were performed for nine different configurations of large, medium, and small evaporator and condensers, to determine their relationship with the minimum heat required to start-up an OHP. It was observed that both the size of the evaporator and condenser both influence the start-up heat load. That is, a large condenser and evaporator can reduce the heat load required to start-up. Additionally, the size of a condenser is much more influential than the size of the evaporator. The overarching discovery is that the process of start-up relies heavily on the history of the OHP i.e., the initial liquid-vapor distribution of the working fluid in the channels. In measuring start-up, it is important to recognize and address how the current state of the OHP can lead to inconsistent results. 

Abstract As small spacecraft technologies develop, thermal management devices need to meet the growing demands of high-powered electronics. Currently being developed to meet this demand in CubeSats is the Additively Manufactured Deployable Radiator Oscillating Heat Pipes (AMDROHP). AMDROHP seeks to implement the high thermal conductivity and two-phase technology of Oscillating Heat Pipes into a unique deployable radiator design for a 3U CubeSat, taking advantage of additive manufacturing capabilities. While much consideration has been put into designing the AMDROHP on its own as a heat exchanger, there is also the need for it to be evaluated thermally at a system-level with the rest of the CubeSat while in orbit. In this study, thermal orbital spacecraft simulations, through the Thermal Desktop software, were performed to analyze how AMDROHP thermally integrates and interacts with the rest of the CubeSat and evaluate the survivability of temperature-sensitive components on the spacecraft. The simulations in this study included an 11th-orbit beta angle sweep for a tumbling orientation of the spacecraft in Low Earth Orbit (LEO). These simulations were performed with two AMDROHP devices in the CubeSat bus, each under a direct 25W heat input and performing with a thermal conductance of 6 W/K, which corresponds to the projected performance of the AMDROHP device while in operation. In this paper, the Thermal Desktop model of the AMDROHP CubeSat includes all major physical components, connections, heat loads, and thermal and optical materials. Then, steps are taken to improve the computational speed of the model. Furthermore, the means of addressing the modeling of the complex two-phase behavior of the OHP is outlined. Then, a number of test cases considering various operating conditions were simulated. From these simulations, orbital temperatures of sensitive components, primarily electronics, were collected and analyzed to find the minimum and maximum operating temperatures across all potential orbits. These temperatures were then evaluated to determine the component’s survivability in a worst-case scenario in orbit. From the results, it was found that, with the projected conductance of AMDROHP, all components operate under safe temperature conditions for any beta angle while in Low Earth Orbit. The evaporator is consistently the hottest component of the spacecraft and electronics boards all maintain survivable temperatures and are not at risk of over or underheating, even at worst case temperatures for all orbits tested. Based on the results and analysis of this conceptual study, it is suggested that AMDROHP will perform as an effective management device for small satellites.