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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRSDate not supplied

Design, Build, and Testing of the Roman Space Telescope’s Wide Field Instrument Optical Stimulus System (SORC)

The Stimulus Of Ray Cones (SORC) is an optical stimulus system developed to verify, characterize, and calibrate the Roman Space Telescope’s (RST) Wide Field Instrument (WFI) under simulated operational conditions. SORC provides several critical test modes, the primary being point-source mode, which projects an image anywhere on the Focal Plane Assembly (FPA) detectors. This mode provides precise position knowledge of the FPA within WFI. Additional modes enable capturing WFI pupil alignment, evaluation of WFI’s selectable optical elements, and verification of focal plane fiber operation for higher-level system testing. The light source system incorporates a suite of narrowband and broadband fiber fed sources spanning the visible to near-infrared range, with options for pulsed or continuous wave illumination. SORC was designed and built at NASA’s Goddard Spaceflight Center (GSFC). Initial system-level testing occurred under ambient conditions in GSFC’s Spacecraft Systems Development and Integration Facility (SSDIF), followed by vacuum testing at operational temperatures (SORC at 214-222 K) in the Space Environment Simulator (SES). The system was then shipped to BAE Systems in Boulder, CO for post-shipment ambient and cryogenic testing before integration with WFI for two thermal vacuum test campaigns at cryogenic temperatures. This presentation will focus on design, development, and performance of SORC. Details of WFI verification and calibration using SORC, along with test results, have been published previously and will be referenced only as needed to describe SORC. The SORC ground test capability is critical to ensuring WFI meets stringent optical performance requirements, directly supporting the mission’s science objectives.

Stimulus of Ray Cones↗

NASA NTRS1990

Solar Array Automation Limitations

Significant progress in the automation of the spacecraft electrical power systems has been made within the past few years. This is especially important with the development of the space station and the increasing demand on the electrical power systems for future satellites. The key element of the spacecraft power system, the solar arrays which supply the power, will have to grow to supply many tens of kilowatts of power within the next twenty years. This growth will be accompanied by the problems associated with large distributed power systems. The growth of the arrays, the on-array management problems and potential solutions to array degradation or failure are discussed. Multilowatt arrays for unmanned spacecraft with comments on the implications of array degradation for manned spacecraft are discussed.

Terry M Trumble↗

NASA NTRSDate not supplied

Motor Configuration Selection for A New Technical Challenge to Develop A 5 MW Cryogenic Motor and Drive

Due to aviation’s appreciable and growing share of humanity’s impact on our environment and estimates that CO2emissions only account for 34% of aviation’s total effective radiative forcing [1], there is a need to reach beyond climate goals that focus only on CO2emissions, such as the US Aviation Climate Action Plan’s [3] goal to reach net-zero carbon emissions by 2050.There is motivation to develop technology that pushes toward future large transport aircraft with net zero climate impact that are highly electrified (i.e., have higher power electrical propulsion system components). This paper describes a new, 6-year technical challenge to address this need by developing a 5 MW superconducting motor and cryogenic drive. Section 1 will detail the motivation for this work. Section 2 will describe the technical challenge and the selected specifications for the motor. Section 3 will present the results of a motor configuration trade study and the down selection of one configuration to develop a detailed design for. The technical challenge focuses on the design of a5 MW superconducting motor and cryogenic drive and demonstration of it at a 2+ MW scale to achieve TRL 3. Both fully superconducting (superconducting stator and rotor) and fully cryogenic (superconducting rotor and cryogenic stator) machine configurations will be explored. An emphasis will be placed on addressing the key tall poles for high power superconducting machines. Further details will be included in the full paper. The requirements and goals of the motor will be detailed. The rated speed (2,000 to 3,000 rpm) is defined to be appropriate for directly driving multi-MW fans or propellers. A range of rated speed is permitted because the motor is not designed for a specific aircraft and to provide design flexibility if AC losses in the stator winding are found to be a significant constraint (i.e., a lower speed can be selected to reduce electrical frequency). Relatively conservative requirements for efficiency (99%) and specific power (20 kW/kg) are defined, because TRL advancement and pushing toward flight readiness is emphasized over performance optimization. However, more aggressive efficiency and specific power goals are specified (99.9% and 40 kW/kg). The 3rd section will present the results of a motor configuration trade study. The study started with a qualitative assessment of sixteen motor configurations based on geometric, mechanical, thermal, and electromagnetic criteria. This assessment has been completed with three evaluators scoring all nine criteria. A configuration down select was made by prioritizing the sixteen configurations into four tiers based on each configuration’s total score and consideration of manufacturability, complexity, and support hardware (e.g., rotary vacuum seals, bearings). Configurations in priority A and B will be further evaluated through quantitative assessments, whereas those in priority C will only be further evaluated if time permits and priority D will not be further evaluated. Eight of the sixteen configurations were down selected for quantitative assessment, which will include analytical calculations and low-to moderate-fidelity finite element analysis to produce a preliminary Pareto front of efficiency versus specific power for each configuration. This assessment emphasizes the calculation of AC losses in the stator winding and an exploration of thermal management approaches to remove that heat and maintain cryogenic temperature. The final paper will include a description of each motor configuration that was considered. The quantitative assessments are underway, and an assessment of one configuration is complete for multiple stator conductor options. The remaining assessments are scheduled to be completed by late March so that the final down select to one configuration can be included in this paper.

Net Zero↗

NASA NTRS1992

Design of A CVD Reactor for the Deposition of Diamond in A Microgravity Environment

There is a growing body of theoretical and experimental evidence suggesting that the uniformity, rate, adhesion, quality, and other key properties of Chemical Vapor Deposition (CVD) diamond coatings are influenced by the gas mixing kinetics in the thermal plasma environment of the reaction chamber. The implementation of, for example, Microwave Plasma Enhanced Chemical Vapor Deposition (MPECVD) process in microgravity has, thus, been suggested. Such a diamond deposition system, which overcomes the limitations of present systems and which is distiguishable from them by the use of high pressure MPECVD and recirculation of the would be effluent hydrogen and carbon, is described. Given the key fact that there is nothing in the effluent of the MPECVD process that is truly a byproduct or 'waste', the system can, at least in principle, lend itself to being closed loop yet dynamic. The exhaust contains hydrogen and carbon species which can be recirculated to the plasma reactor, that is, since there are no unusable reaction byproducts, the effluent can be fed back to the reaction chamber with no detriment, thus allowing deployment in a microgravity environment.

M L Languell↗

NASA NTRSDate not supplied

Battery Relevant Cell Side Wall Rupture Characterization

The propensity for a cell design to experience can side wall rupture (SWR) during thermal runaway is highly influenced by how a battery design mechanically constrains its cells. Testing cells while unsupported has been found to yield false negative results that don't represent this risk in a battery configuration. This talk addresses how to verify the adequacy of battery design measures used to control SWR and how to get results relevant, accurate, and statistically defendable for a proposed battery design.

thermal runaway↗

NASA NTRS2026

Spacecraft Water Impurity Monitor, a System for Water Quality Analysis on Exploration Missions Beyond Low Earth Orbit

Exploration missions beyond low-earth-orbit (LEO) will require advanced instrumentation to monitor water quality. Traveling beyond LEO means the transfer of water samples to an Earth-based laboratory for detailed analysis is not feasible. Detailed analysis of water composition during exploration is still necessary, because having the capability to determine the specific organic chemical causing a change in total organic carbon (TOC) or the specific metal or ionic species causing a change in conductivity has the potential to inform the crew health and system management decisions. On a new vehicle such as a lunar or Mars surface habitat or a Mars transit vehicle, finding “new” impurities not seen on ISS should be expected. The key is to identify the impurity so the correct action can be taken. On ISS we can measure TOC, conductivity, and other physical properties but do not have the capability for detailed analysis using vehicle instrumentation. This is acceptable because ISS can send samples down to Earth for further analysis and obtain the detailed composition. The Spacecraft Water Impurity Monitor (SWIM) will provide detailed water quality analysis for missions in which sample down mass is not available. SWIM is a system comprising organic and inorganic analysis modules. For organic chemicals, a gas chromatograph mass spectrometer (GCMS) detects and identifies organic impurities. For inorganic species, a capillary electrophoresis capacitively coupled contactless conductivity detection (CE-C4D) system as well as ion specific electrodes detect and identify metal ions and other inorganic salts / acids. The SWIM technology demonstration project has completed a System Requirements Review (SRR) to finalize detection requirements and is currently working to refine vehicle interface requirements for a future technology demonstration. The project also has begun preliminary flight design activities for the core analyzers in the instrument suite.

Water Monitoring↗

NASA NTRS2024

Wave Rotor Enhanced Nuclear (WREN) Propulsion: NASA Innovative Advanced Concepts (NIAC) - Phase I Final Report

Nuclear Thermal Propulsion (NTP) is identified as one of the preferred propulsion technologies for manned missions throughout the solar system (NASA MSFC).[1, 2] The state-ofthe-art NTP cycle is based on a solid core Nuclear Engine for Rocket Vehicle Application (NERVA)[3] class technology (Fig. 1) that is envisioned to provide a specific impulse of 900 seconds doubling chemical rocket performance (450 seconds). Even with this impressive increase, the NTP NERVA designs still have issues providing adequate initial to final mass fractions for high ΔV missions.[4] Nuclear Electric Propulsion (NEP) can provide extremely high Isp (2,000 to over 10,000 seconds) but with only low thrust and limits on mass to power ratios. The need for an electric power source also adds the issue of heat rejection in space where thermal energy conversion is at best 30-40% under ideal conditions. NASA Space Technology Mission Directorate (STMD) has recently expressed interest in finding advanced nuclear propulsion technology through the NASA Go:Thrust RFI.[5, 6] A novel Wave Rotor (WR) topping cycle has been proposed for our NASA NIAC concept. It promises to deliver similar thrust as NERVA class NTP propulsion, but with Isp in the 1,200-2,000 second range. Coupled with an NEP cycle, the duty cycle Isp can further be increased (1,800-4,000 seconds) with minimal addition of dry mass. This bimodal design enables fast transit trajectories for manned missions to Mars and revolutionizes the deep space exploration of our solar system.

Nuclear Thermal Propulsion↗

NASA NTRSDate not supplied

Battery Pack Shape Optimization using Transient Heat Conduction Coupled with Cell-Discharge Analysis

Battery electric systems exhibit significant time-dependence, especially when evaluated in the context of an aircraft mission profile with continually changing power demands. Additionally, when evaluating battery-powered aircraft concepts, it is important to accurately compute the temperature of the batteries and properly characterize the thermal response of the system. The temperature of the batteries has a significant impact on cell performance, in addition to safety considerations of maintaining battery temperatures below their operating limit. Because of these considerations, battery models for preliminary design and optimization of aircraft should include the capability to accurately compute the temperature distribution within the battery pack. Furthermore, battery pack designs should be as light-weight as possible to maximize the pack energy density, while also considering battery temperature limits. Here, we demonstrate a simultaneous trajectory and shape optimization of a battery pack concept, using a transient heat transfer finite element model coupled with a time-varying cell-discharge battery model to provide this capability. Including the transient finite element problem in the loop enables accurate temperatures that can be passed back to the cell discharge model, while the cell discharge model can supply the finite element model with time-varying heat boundary conditions to the finite element problem, further benefiting the fidelity of the thermal response of the batteries. We first demonstrate the coupling capability between the battery cell-discharge model and the transient finite-element heat transfer through an optimization which computes the optimal current profile for the battery pack while ensuring the battery temperatures remain below their operational limit. We then build on this optimization by adding shape optimization to the problem, which allows us to consider a composite objective function which also minimizes the mass of the battery pack, while also producing an optimal current discharge profile.

Optimization↗

NASA NTRS2026

Spacecraft Water Impurity Monitor, a System for Water Quality Analysis on Exploration Missions Beyond Low Earth Orbit

Water Monitoring↗

NASA NTRSDate not supplied

Preliminary Findings of the Experimental Development Unit Cold Flow Test for a Generation Zero Nuclear Propulsion Engine

Nuclear thermal propulsion (NTP) technology will greatly benefit human travel to Mars by significantly shortening transit times, improving crew safety, and providing more mission flexibility than traditional chemical rockets. As part of DRACO follow-on work to develop, build, and fly a generation zero NTP engine, a full scale flight-like experimental design unit (EDU) reactor was constructed to collect sufficient on-ground performance data to characterize flow induced vibrations (FIV) of critical reactor structures/components, inform development of the engine and reactor control algorithm, and collect pressure drop and flow distribution data across the reactor. The fluid conditions for the test program were designed to achieve system responses equivalent to that of an operational engine through all phases of engine operation including reactor startup, mainstage operation, reactor shutdown, and reactor cooldown. Over 100 tests were executed, flowing either GN2 or GHe through the EDU at varying flow rates and pressures. This experiment provided early validation of flow behavior and vibration risks before nuclear testing, boosted critical subsystem TRLs, informed design iterations, and reduced future test costs. The steady-state flow parameters for the experiment were modeled in Ansys Thermal Desktop, allowing rapid tuning and experiment-informed updates to a flight-like test matrix. The EDU dynamic environment was characterized with accelerometers, strain gauges, and high-frequency pressure transducers all sampled at 20 kHz. While many narrow-band oscillations were identified, no significant FIV occurred; the reactor structural responses tend to be enveloped by typical launch vehicle ascent vibration environments (defined up to 2 kHz), although significant energy is also present at higher frequencies.

Flow Induced Vibration↗

NASA NTRS2026

NASA Agile Community of Practice 2024-2026 Report

This 2024-2026 report provides a summary of the products and activities executed by the NASA Agile Community of Practice (CoP) during its second and third years. Building on the foundation established in its inaugural year, the CoP continued to advance Agile values and principles across NASA centers. The report highlights key initiatives, including specialized framework training, AI integration in Agile toolkits, and active participation in agency-wide project management and systems engineering workshops.

Agile↗

NASA NTRSDate not supplied

Advances in Design Capabilities for Planetary Missions from the NASA Entry Systems Modeling and Instrumentation Portfolio

The Entry Systems Modeling project (ESM) is supported by both the NASA Space Technology and the Science Mission Directorates and focuses on developing simulation tools and validated models for characterizing the performance of entry systems tailored to planetary destinations across the Solar System. ESM is organized into six technical capability areas that together address all relevant factors related to spacecraft entry, as well as some aspects of descent: Thermal Protection System (TPS) Materials; Aerothermodynamics; Entry & Descent Vehicle Dynamics; Guidance, Navigation, and Control; Vehicle Systems Analysis; and Advanced Tools and Numerical Methods. Development within the capability areas is undertaken explicitly with a focus on transition and infusion to science missions, human exploration missions, and commercial space activities. The present talk details developments that specifically impact science missions, including simulation tool capabilities that aid in mission design and model development to understand entry system performance at a given destination. Examples of the successful infusion and transition of such project outcomes to science missions also are provided. Several simulation tool development efforts within ESM have resulted in new design capabilities for missions. One such outcome is improved toolsets for mission trajectory and concept of operations design. Specifically, an initiative to couple a leading tool for entry, ascent/descent, and orbital trajectory optimization (Program to Optimize Simulated Trajectories II or POST2) to those used within the Agency for interplanetary trajectory optimization (Copernicus and Monte) has made substantial progress, with the outcomes to date promising to allow efficient trajectory optimization across mission phases. Additionally, toolchains for the evaluation of vehicle performance during entry and descent have been developed that allow assessment of multi-dimensional aeroheating on detailed vehicle geometries, characterization of deployment and inflation of parachutes, and assessment of vehicle dynamic stability during descent. These capabilities are achieved by coupling diverse sets of physics together – material response, computational fluid dynamics, radiation, and vehicle dynamics – to suitably describe complex entry and descent phenomena. Several model development and validation efforts for specific destinations and entry regimes also are underway within the ESM project. For instance, new experimental capabilities to validate radiation models at low densities/high altitudes recently have been established with project support, specifically the Low-Density Shock Tube (LDST) at the NASA Ames Research Center Electric Arc Shock Tube (EAST) facility. The LDST is being leveraged to develop improved models of shock layer kinetics and radiation in Titan atmospheres, while future studies will be conducted in the LDST and the existing high velocity shock tube to provide validation data for radiation models of Venus, Ice Giants, and Mars atmospheres. Models describing the aerothermal and thermo-structural performance of Thermal Protection System (TPS) materials has been another focus, with multiscale modeling activities on-going for the two leading TPS materials applicable to a range of entry conditions and science missions: the Phenolic-Impregnated Carbon Ablator (PICA) and woven materials like 3D Mid-Density Carbon Phenolic (3MDCP). A continual effort is made to infuse and transition outcomes from ESM simulation tool and model development activities into relevant science missions. Significant progress has been made on this front, with missions such as Dragonfly, DAVINCI, and Mars Missions benefitting from project outcomes. The groundwork also is being laid to provide insights into forward looking missions to Gas/Ice Giants as well as for potential sample returns.

Justin Haskins↗

NASA NTRS2026

Turbofan Engine Power Extraction Demonstration Final Report

As GE Aerospace advances toward a revolutionary step change in propulsion efficiency, the integration and demonstration of new engine architectures and technology systems are essential. The NASA Turbofan Engine Power Extraction Demonstration (PEx), conducted through the Hybrid Thermally Efficient Core (HyTEC) project, aims to develop and demonstrate megawatt-class hybrid electric capability on a modern commercial turbofan engine. The hybrid electric system is critical to meeting the needs of the U.S. aviation industry for next-generational propulsion systems with greater efficiency, durability, and range. This supports energy independence and helps ensure the security and resilience of one of America's largest export industries. The PEx project specifically targets three key objectives: mechanically integrating hybrid electric capability into a commercial turbofan engine, integrating electric machine control with turbofan control for advanced power management, and de-risking performance modeling of future hybrid electric architectures. To mature these technologies to Technology Readiness Level (TRL) 6, a series of electric power system component tests and a baseline engine performance test campaign were conducted. These efforts culminated in an integrated hybrid electric turbofan test campaign demonstrating power extraction, power insertion, and power transfer between spools. Tests of the electric power system were completed at GE Aerospace’s Electrical Power Integrated Systems Center in Dayton, Ohio and engine tests were completed at Peebles Test Operation in Peebles, Ohio. Hybrid electric trade studies extended the demonstrated capability to altitude using the validated cycle model from the PEx test campaigns, allowing for comments on expanded mission benefits not demonstrated in the ground campaign. The knowledge gained from PEx also supports GE Aerospace’s Compact Core Demonstrator as part of HyTEC Phase 2 and ultimately informs the implementation of hybrid electric systems in the next generation of GE Aerospace commercial engine products. This report provides a summary of the program background, test campaigns, trade studies, and insights into the technical maturation required to support future commercial products.

Hybrid Electric↗

NASA NTRSDate not supplied

Battery Pack Shape Optimization using Transient Heat Conduction Coupled with Cell-Discharge Analysis

Battery electric systems exhibit significant time-dependence, especially when evaluated in the context of an aircraft mission profile with continually changing power demands. Additionally, when evaluating battery-powered aircraft concepts, it is important to accurately compute the temperature of the batteries and properly characterize the thermal response of the system. The temperature of the batteries has a significant impact on cell performance, in addition to safety considerations of maintaining battery temperatures below their operating limit. Because of these considerations, battery models for preliminary design and optimization of aircraft should include the capability to accurately compute the temperature distribution within the battery pack. Furthermore, battery pack designs should be as light-weight as possible to maximize the pack energy density, while also considering battery temperature limits. Here, we demonstrate a simultaneous trajectory and shape optimization of a battery pack concept, using a transient heat transfer finite element model coupled with a time-varying cell-discharge battery model to provide this capability. The transient finite-element analysis is done using TACS, and the cell-discharge battery model uses OpenMDAO and dymos. Including the transient finite element problem in the loop enables accurate temperatures that can be passed back to the cell discharge model, while the cell discharge model can supply the finite element model with time-varying heat boundary conditions, further benefiting the fidelity of the thermal response of the batteries. We first demonstrate the coupling capability between the battery cell-discharge model and the transient finite-element heat transfer through an optimization which computes the optimal current profile for the battery pack while ensuring the battery temperatures remain below their operational limit. We then build on this optimization by adding shape optimization to the problem, which allows us to consider a composite objective function which also minimizes the mass of the battery pack, while also producing an optimal current discharge profile.

Optimization↗

NASA NTRS1973

Mariner Mars 1971 battery design, test, and flight performance

The design, integration, fabrication, test results, and flight performance of the battery system for the Mariner Mars spacecraft launched in May 1971 are presented. The battery consists of 26 20-Ah hermetically sealed nickel-cadmium cells housed in a machined magnesium chassis. The battery package weighs 29.5 kg and is unique in that the chassis also serves as part of the spacecraft structure. Active thermal control is accomplished by louvers mounted to the battery baseplate. Battery charge is accomplished by C/10 and C/30 constant current chargers. The switch from the high-rate to low-rate charge is automatic, based on terminal voltage. Additional control is possible by ground command or onboard computer. The performance data from the flight battery is compared to the data from various battery tests in the laboratory. Flight battery data was predictable based on ground test data.

Bogner, R. S.↗

NASA NTRS1991

Nickel hydrogen battery expert system

The Hubble Telescope Battery Testbed at MSFC uses the Nickel Cadmium (NiCd) Battery Expert System (NICBES-2) which supports the evaluation of performance of Hubble Telescope spacecraft batteries and provides alarm diagnosis and action advice. NICBES-2 provides a reasoning system along with a battery domain knowledge base to achieve this battery health management function. An effort is summarized which was used to modify NICBES-2 to accommodate Nickel Hydrogen (NiH2) battery environment now in MSFC testbed. The NICBES-2 is implemented on a Sun Microsystem and is written in SunOS C and Quintus Prolog. The system now operates in a multitasking environment. NICBES-2 spawns three processes: serial port process (SPP); data handler process (DHP); and the expert system process (ESP) in order to process the telemetry data and provide the status and action advice. NICBES-2 performs orbit data gathering, data evaluation, alarm diagnosis and action advice and status and history display functions. The adaptation of NICBES-2 to work with NiH2 battery environment required modification to all of the three component processes.

Shiva, Sajjan G.↗

NASA NTRS1995

Performance of the Satellite Test Assistant Robot in JPL's Space Simulation Facility

An innovative new telerobotic inspection system called STAR (the Satellite Test Assistant Robot) has been developed to assist engineers as they test new spacecraft designs in simulated space environments. STAR operates inside the ultra-cold, high-vacuum, test chambers and provides engineers seated at a remote Operator Control Station (OCS) with high resolution video and infrared (IR) images of the flight articles under test. STAR was successfully proof tested in JPL's 25-ft (7.6-m) Space Simulation Chamber where temperatures ranged from +85 C to -190 C and vacuum levels reached 5.1 x 10 -6 torr. STAR's IR Camera was used to thermally map the entire interior of the chamber for the first time. STAR also made several unexpected and important discoveries about the thermal processes occurring within the chamber. Using a calibrated test fixture arrayed with ten sample spacecraft materials, the IR camera was shown to produce highly accurate surface temperature data. This paper outlines STAR's design and reports on significant results from the thermal vacuum chamber test.

Douglas McAffee↗

NASA NTRSDate not supplied

The Roman Space Telescope Optical System: Status, Test, and Verification Update

The Nancy Grace Roman Space Telescope (“Roman”) is NASA’s next flagship observatory. Launching in 2026, Roman will explore the nature of dark energy as well as expand the census of exoplanets in our galaxy via microlensing. Roman’s large field of view, agile survey capabilities, and excellent stability enable these scientific objectives, yet present unique challenges for the design, test, and verification of its optical system. Roman recently completed a comprehensive thermal vacuum test of the Spacecraft bus + Integrated Payload Assembly (SCIPA), followed by integrating the Outer Barrel Assembly (OBA), Solar Array Sunshield (SASS), and Deployable Aperture Cover (DAC) with SCIPA to complete the Observatory. This paper will present an overview of the thermal vacuum optical testing as well as a status of the optical system performance and verification.

Matthew Bolcar↗