EA6B SPRAY COOL TECHNOLOGY INSERTION

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EA-6B SPRAY COOLTECHNOLOGY INSERTION
Advanced Liquid Cooling Workshop DSPO / VITA
Sponsored Scottsdale, AZ 13 May 2003
DISTRIBUTION STATEMENT A Approved for public
release distribution is unlimited.
CIV Richard Woodruff NSWC Crane
C8022 woodruff_r_at_crane.navy.mil 812-854-6334 (DSN
482)
PEO TACTICAL AIRCRAFT RADM J.B. GODWIN PEO(T)
PROGRAM MANAGER CAPT JOHN SCHEFLER PMA-234
IPT LEVEL II CIV RICHARD WOODRUFF PMA-23457
IPT LEVEL I CIV JEFF RUSHER PMA-2345
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SPRAY COOL TECHNOLOGY PROSPECTIVE
DISTRIBUTION STATEMENT A Approved for public
release distribution is unlimited.
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EA-6B PROWLERBACKGROUND
PRIMARY MISSION Suppression of
Enemy Air Defenses INVENTORY 100 Navy 25
Marine WEAPON SYSTEMS ALQ99 Electronic
Countermeasures USQ113 Radio Countermeasures AGM
88 High speed Anti-Radiation Missile SERVICE
LIFE 1971 to 2015 OPERATING
ENVIRONMENT Subsonic Tactical Air, 40K
Altitude Carrier Expeditionary Deployment
ALQ99 Aft Power Supply Supplies DC voltages to
ALQ99 Surveillance Receivers 2.8 lb/min cooling
airflow provided by aircraft ECS Electronics
cooling by thermal conduction to air plenum Size
12 x 8 x 12.5 / 54 lbs 225 Watts heat
dissipation
EA-6B PROWLER
DISTRIBUTION STATEMENT A Approved for public
release distribution is unlimited.
APS130 Radar Power Supply Supplies DC voltages
to Radar subsystems 0.9 lb/min cooling airflow
provided by aircraft ECS Electronics cooling by
thermal conduction to air plenum Size 7.5 x 12
x 11.5 / 32 lbs 165 Watts heat dissipation
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Spray Cool Aft Power Supply Development Program
ACQUIRING ACTIVITY NAVAIR PMA234, Paxtuxent
River MD PRIME CONTRACTOR Isothermal Systems
Research, Clarkston WA ACCEPTANCE AGENT NSWC
Crane Division, Crane IN
DISTRIBUTION STATEMENT A Approved for public
release distribution is unlimited.
Legacy Power Supply SpraycoolTM Power Supply
Spray Cool ALQ99 Aft Power Supply Development
(SC-APS) SBIR Contract 1.8M Deliver 4 EDM
Units RD Objectives Tactical Aircraft
Suitability Reliability Impacts
Maintainability Impacts Size Weight Impacts
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Spray Cool Aft Power Supply Design Principles
Aux. Fan and Aux. Heat Exchanger
Wet Chassis
DISTRIBUTION STATEMENT A Approved for public
release distribution is unlimited.
Primary Heat Exchanger
Ambient Air ground maint. only
VME Card Cage Assembly
Aircraft ECS Airflow
Heat Rejection
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Spray Cool Aft Power Supply Test Evaluation
Tactical Aircraft Suitability (EA-6B) Shock
and Vibration 20Gs shock impulse 34Grms
random vibration Temperature, Altitude and
Pressurization 0 to 40Kft operating 0 to
40Kft rapid decent -40C to 71C operating
-40C to 71C thermal shock -54C to 85C
storage double airflow at 40Kft
Electromagnetic Compatibility box level EMI
tests aircraft installation tests
Humidity, Dust, Salt Fog and Fungus evaluated
by analysis Dynamic Flight Conditions (fluid
circulation) spatial reorientation
airfoil turbulence simulation catapult and
arrestment simulation push-up maneuver
simulation pullover maneuver simulation
Reliability and Maintainability evaluated by
analysis
DISTRIBUTION STATEMENT A Approved for public
release distribution is unlimited.
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Spray Cool Radar Power Supply Development Program
ACQUIRING ACTIVITY NAVAIR PMA234, Paxtuxent
River MD PRIME CONTRACTOR Isothermal Systems
Research, Clarkston WA ACCEPTANCE AGENT NSWC
Crane Division, Crane IN
DISTRIBUTION STATEMENT A Approved for public
release distribution is unlimited.
Legacy Power Supply SpraycoolTM Power Supply
Spray Cool APS130 Radar Low Voltage Power Supply
Development (SC-LVPS) SBIR Contract
2.1M Deliver 2 EDM Units Reliability
Development Test RD Objectives Reliability
Impacts Reduced Parts Count
Maintainability Impacts Dry Chassis w/ Modules
Contract Award SRR PDR CDR Design
Verification Environment Qual Deliver First
Article Reliability Dev Test Contract Complete
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Spray Cool Radar Power Supply Design Principles
Dry Chassis
Spray Cooled AC/DC Module
DISTRIBUTION STATEMENT A Approved for public
release distribution is unlimited.
Pump Module
Conduction Cooled Power Entry Module
Blind-mate Connections
Aircraft ECS Airflow
Heat Rejection
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Take Away

• Evaporative Cooling in General
• Solves Thermal Challenges
• tremendous heat acquisition capability
• heat rejection to remote location
• A Quickly Maturing Technology
• simple concept and intricate design
• high interest and concerted effort
• An Enabler for Future Electronics
• COTS survivability at high temperature
• high performance microprocessors
• solid state laser and s.s. microwave
• densified electronic packaging
• Widespread Military Use ?
• Only for its cooling performance
• Unit cost is still relatively high
• Reliability issues need work
• Maintainability issues need work

• EA-6B Spray Cool Technology Insertion
• Tactical Aircraft Suitability par
• military environment
• flight operability
• Reliability Impacts bogie
• functional electronics
• spray cooling subsystem
• Maintainability Impacts bogie
• fault isolation
• field repair
• Size Weight Impacts par
• chassis dimensions
• overall weight
• Cooling Performance eagle
• heat dissipation
• temperature stability

DISTRIBUTION STATEMENT A Approved for public
release distribution is unlimited.