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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 NTRS2026

A Review of Superconducting Electric Machines with On-Board Cryocoolers

This paper reviews the evolution and emerging direction of superconducting electric machines that employ onboard cryocoolers integrated directly into the rotor, eliminating the need for cryogenic fluid coupling and, in some cases, rotary seals. Traditional low-temperature superconducting (LTS) machines relied on external cryogenic systems and liquid helium transfer couplers, which introduced excessive complexity, poor reliability, and significant parasitic energy losses. The advent of high-temperature superconductors (HTS) has enabled compact, closed-cycle cryocoolers that support self-contained, fluid-free refrigeration architectures suitable for rotating applications. This paper examines the key technological challenges associated with on-board cryocooler integration and reviews three representative efforts by KAIST, NASA, and Hinetics, each illustrating distinct strategies and milestones toward practical implementation. KAIST demonstrated early proof-of-concept for rotating machines with on-board cryocoolers, NASA developed a shaft-integrated Stirling-type pulse tube cryocooler for a 1.4 MW hybrid-electric motor, and Hinetics achieved full-scale validation of a self-contained HTS rotor incorporating a commercial Stirling cryocooler and spoke-suspension torque tube. Collectively, these achievements confirm the technical feasibility of on-board cryogenic refrigeration and highlight steady progress toward compact and efficient superconducting rotating systems across various applications. Embedding cryocoolers directly within the rotor enables practical, efficient, and commercially viable superconducting propulsion technologies.

Cryogenics↗

NASA NTRS2026

Biobased Polybenzoxazine Derived from Furfurylamine and Piceol with Low Cure Temperature and Advanced Properties for Composite Matrices

A novel benzoxazine made from furfurylamine, paraformaldehyde, and piceol, Bz-FA-HA, is assessed for applications in fiber reinforced (FR) composites. Piceol is a biobased phenolic compound derived from the roots of Norwegian spruce trees and contains a methyl ketone group at the para position. Bz-FA-HA is a liquid at room temperature, has a viscosity of < 1 Pa.s at temperatures above 90 °C, and a Tonset of cure at 132 °C. The carbonyl is found to react with the furan ring, yielding a crosslinking reaction, when cured above 180 °C as indicated by differential scanning calorimetry and thermogravimetric analysis coupled with Fourier transform infrared spectroscopy. Poly(Bz-FA-HA) has a Tg > 350 °C, attributed to the crosslinking reaction. Furthermore, the storage modulus is > 3 GPa, regardless of cure temperature. Poly(Bz-FA-HA) has a char yield at 800 °C of 65.0 % (62.3 % at 1000 °C), and a Tonset of decomposition of 357 °C in nitrogen. The resulting carbon formed during pyrolysis shrinks during the carbonization reaction and scanning electron microscopy imaging shows a cross-section with micro cracks. The high processability, advanced mechanical properties, and exceptional char yield make it a promising candidate as the matrix for FR composites.

Benzoxazine↗

NASA NTRS1994

Surface Characterization Through Shape Oscillations of Drops in Microgravity and 1-g

The goal of these experiments is to determine the rheological properties of liquid drops of single or multiple components in the presence or absence of surface active materials by exciting drops into their quadrupole resonance and observing their free decay. The resulting data coupled with appropriate theory should give a better description of the physics of the underlying phenomena, providing a better foundation than earlier empirical results could. The space environment makes an idealized geometry available (spherical drops) so that theory and experiment can be properly compared, and allows a 'clean' environment, by which is meant an environment in which no solid surfaces come in contact with the drops during the test period. Moreover, by considering the oscillations of intentionally deformed drops in microgravity, a baseline is established for interpreting surface characterization experiments done on the ground by other groups and ours. Experiments performed on the United States Microgravity Laboratory Laboratory (USML-1) demonstrated that shape oscillation experiments could be performed over a wide parameter range, and with a variety of surfactant materials. Results, however, were compromised by an unexpected, slow drop tumbling, some problems with droplet injection, and the presence of bubbles in the drop samples. Nevertheless, initial data suggests that the space environment will be useful in providing baseline data that can serve to validate theory and permit quantitative materials characterization at 1-g.

Robert E Apfel↗

NASA NTRS1995

The Alpha-Proton-X-Ray Spectrometer Deployment Mechanism: an Anthropomorphic Approach to Sensor Placement on Martian Rocks and Soil

On July 4,1997, the Mars Pathfinder spacecraft lands on Mars and starts conducting technological and scientific experiments. One experiment, the Alpha-Proton-X-ray Spectrometer, uses a sensor head placed against rocks and soil to determine their composition. To guarantee proper placement, a deployment mechanism mounted on the Mars Rover aligns the sensor head to within 20 deg of the rock and soil surfaces. In carrying out its task, the mechanism mimics the action of a human hand and arm. Consisting of a flexible wrist, a parallel link arm, a brush dc motor actuator, and a revolutionary non-pyrotechnic fail-safe release device, the mechanism correctly positions the sensor head on rocks as high as 0.29 m and on targets whose surfaces are tilted as much as 45 deg from the nominal orientation of the sensor head face. The mechanism weighs less than 0.5 kg, can withstand 100 g's, and requires less than 2.8 N x m of actuation torque. The fail-safe coupler utilizes Cerrobend, a metal alloy that melts at 60 C, to fuse the actuator and the rest of the mechanism together. A film heater wrapped around the coupler melts the metal, and Negator springs drive the mechanism into its stowed position. The fail-safe actuates using 6.75 Watts for 5 minutes in the event of an actuator failure.

Richard S Blomquist↗

NASA NTRS2025

ISS Radiator Face Sheet Anomaly Investigation and Return to Function

Maintaining sufficient heat rejection on the International Space Station (ISS) is critical to the function of the Low-Earth Orbit station. The External Active Thermal Control System (EATCS) rejects the excess heat generated by the US On-Orbit Segment (USOS) modules. The system uses single-phase liquid ammonia to collect the heat and reject it to six radiators (three on the Starboard side, three on the Port side). Each radiator is made up of eight panels. In September 2008, imagery of the Starboard radiators was conducted and showed one of the panels’ face sheets had peeled up from the internal honeycomb core structure. Out of an abundance of caution, the radiator was isolated from the rest of the EATCS and the ammonia was vented to space. Since the radiator was vented, periodic imagery of all radiator panels was taken to monitor any changes in the face sheet and inspect for other radiator anomalies. In January 2025, after years of trending and inspections, the radiator was reintegrated into the system to increase heat rejection capabilities. This paper will document the multi-year investigation that took place to determine root cause and mitigations implemented to reduce risk to the system. A summary of the data since the investigation will show rationale for reintegrating the radiator even with the damaged panel. The goal of the paper is to document the investigation for historical purposes and provide future programs with findings discovered during the investigation.

Aaron Rodriguez↗

NASA NTRS2026

ISS Radiator Face Sheet Anomaly Investigation and Return to Function

Aaron Rodriguez↗

NASA NTRSDate not supplied

The Use of Immersion Rigs for High Temperature Hydrogen Exposure Testing Within the Nuclear Thermal Rocket Element Environmental Simulator (NTREES): NTREES-5 Hydrogen Heat Exchanger (N5HHX-01)

The Nuclear Thermal Rocket Element Environmental Simulator (NTREES) facility at NASA’s Marshall Space Flight Center (MSFC) subjects materials and components typically found on nuclear thermal propulsion (NTP) systems to non-nuclear simulations of prototypic NTP reactor thermohydraulic environments. With 1.2 MW of inductive power available, the currently employed methods to simulate nuclear heating in NTREES consist of 1) inductively heating a test specimen, which typically cannot be performed on ceramic materials, or 2) heating gas that envelops the test specimen. The latter of these has provided a basis for developing so-called “immersion rigs” to be used in NTREES. Furthermore, immersion rigs are especially useful in the case of smaller, technically challenging test specimens. One such device, the “NTREES-5 Hydrogen Heat Exchanger” (N5HHX-01), designed and deployed to test small material coupons to ~0.5 g/s of 2800 K, 500 psi Hydrogen, is discussed herein. To achieve this desired delivery temperature level, the most suitable material for the N5HHX’s construction was pure tungsten, which imposed budgetary and manufacturing challenges. Also discussed in this paper is the design of the N5HHX rig’s sample container, which became the first iteration of improving NTREES small material coupon test operations by permitting rapid changeout of different material samples.

Reactor Testing↗

NASA NTRS1993

Combustion for future supersonic transport propulsion

Even with it's marginal performance, Concorde has demonstrated that supersonic civil aircraft are a practical proposition. A second generation machine will need sufficiently good performance for a robust operating system that can provide reliable, frequent service with competitive economics. Additionally, the propulsion system must be acceptable environmentally. That is it must create acceptable noise levels around airports and have acceptable emissions throughout its mission including cruise. Whatever devices may be used to improve the acceptability at subsonic flight conditions, the high operating temperatures at cruise can create difficult targets for the operation of the combustion system both mechanically and in the combustion process itself. While the driving force is ever better fuel consumption and weight to achieve economic viability, a future supersonic transport engine will have cycle temperatures limited only by the mechanical integrity of the major components. The environment of the major components in modern gas turbine engines is dominated by the air delivered by the compressor system. Consequently the maximum compression temperature is governed by materials available for the turbine and compressor discs. The continued improvement of the disc material leads to combustion inlet temperatures beyond today's experience and sets difficult targets for combustion system emissions. This is worsened by the requirement being at cruise and therefore maintained for the major part of the mission. Problems such as creep and oxidation of metallic parts are also considered.

B. W. Lowrie↗

NASA NTRS2019

Physics-Based Modeling and Simulation of Emerging Battery Technologies for Aerospace

Recently there is a growing interest in the aviation sector to reduce air and noise pollution. Electrochemical energy storage devices such as batteries coupled with a distributed electric propulsion system can reduce noise concerns as well as emissions and allow the concept of Urban Air Mobility to come to fruition. The battery performance needs to improve considerably compared from current state-of-art Li-ion battery (about 200Wh/Kg) to realize all-electric passenger jet for short flights (up to 690 miles). NASA is exploring lithium-oxygen battery chemistry to power hybrid (battery powered electrical system) and all-electric aircraft for short distance and long-distance flights. Li-O2 is one of the advanced Li-ion technologies that promise to provide specific energy of more than 750Wh/Kg. For this presentation, we present our work on improving power density of Li-O2 batteries through the use of multiphysics simulations. Next, a path is outlined to port these model to simulate performance for a new battery chemistry for space application, Li-CO2. Li-CO2 uses carbon dioxide as the active material instead of oxygen. Although this technology is in its early development, the offers two benefits: it can be used as a CO2 scrubber, as oxygen is one of the by-products on charging, and as a backup or a standalone battery for various Mars or Venus missions, where the carbon dioxide content in the atmosphere is high and need battery to operate at higher temperatures.

Mehta, Mohit↗

NASA NTRS1999

Initial Test Firing Results for Solid CO/GOX Cryogenic Hybrid Rocket Engine for Mars ISRU Propulsion Applications

ORBITEC is developing methods for producing, testing, and utilizing Mars-based ISRU fuel/oxidizer combinations to support low cost, planetary surface and flight propulsion and power systems. When humans explore Mars we will need to use in situ resources that are available, such as: energy (solar); gases or liquids for life support, ground transportation, and flight to and from other surface locations and Earth; and materials for shielding and building habitats and infrastructure. Probably the easiest use of Martian resources to reduce the cost of human exploration activities is the use of the carbon and oxygen readily available from the CO2 in the Mars atmosphere. ORBITEC has conducted preliminary R&D that will eventually allow us to reliably use these resources. ORBITEC is focusing on the innovative use of solid CO as a fuel. A new advanced cryogenic hybrid rocket propulsion system is suggested that will offer advantages over LCO/LOX propulsion, making it the best option for a Mars sample return vehicle and other flight vehicles. This technology could also greatly support logistics and base operations by providing a reliable and simple way to store solar or nuclear generated energy in the form of chemical energy that can be used for ground transportation (rovers/land vehicles) and planetary surface power generators. This paper describes the overall concept and the test results of the first ever solid carbon monoxide/oxygen rocket engine firing.

Eric E Rice↗

NASA NTRSDate not supplied

Battery Failure Databank

The Battery Failure Databank contains thermal runaway results gathered from nearly 300 small format fractional thermal runaway calorimetry (S-FTRC) experiments. A majority of these experiments were conducted at synchrotron facilities where high-speed x-ray videography was conducted of the cell while tested inside of the S-FTRC. The databank is a two-component system which consists of a Microsoft ExcelTM spreadsheet which provides S-FTRC results in tabular format and a radiographic video library containing the high-speed x-ray videos. Overall, the databank provides thermal results from S-FTRC experiments conducted on a mixture of commercially available lithium-ion (Li-ion) cells and specialized Li-ion test cells with varying cell format (18650, 21700, and D-cell) and trigger mechanism (heaters, heaters plus internal short circuiting device, and nail penetration). The radiography video component provides insight into the initiation and propagation of TR in the cells, in addition to consequences of TR measured by the FTRC. Fractions of mass ejected for the cell types are separated into regimes based on the different failure modes of the cells, such as purely venting, partial ejection, and total ejection. With knowledge of the rate and characterization of the internal degradation of the cells during TR, and the amounts of mass ejected and unrecovered, the extent of TR, and therefore the mitigation of TR, is revealed relative to cell types and failure modes.

Lithium-ion battery↗

NASA NTRSDate not supplied

First-Principles Investigation of Phase Transitions in RuNb, RuTa, and Ru-Nb-Ta Ultrahigh Temperature Shape Memory Alloys

Ultrahigh temperature shape memory alloys (UHT-SMAs) have transition temperatures above 600 C, and they have found applications for sensing and actuating devices in aerospace industry. Among very few such UHT-SMAs currently known are Ru-based alloys such as RuNb and RuTa, whose martensite structures and phase transitions are totally different from those of NiTi-based SMAs and were poorly understood. In this work, we carried out a systematical study of RuNb using first-principles total energy calculations and molecular dynamics (MD) simulations. The transition paths and mechanisms in cubic → tetragonal →monoclinic transitions are revealed. and the transition sequence and martensitic transition temperatures are determined (MTTs) by evaluating the Gibbs free energies using thermodynamic integration. The calculated MTTs are in very good agreement with the experimental data. We found that the monoclinic phase at the second transition has the 𝑃21/m symmetry instead of experimentally identified 𝑃2/m. Our calculations demonstrate that RuTa has very similar phase transitions to those of RuTa. Furthermore, we studied the Ru0.5Nb0.25Ta0.25 ternary. Our results can explain the measured significant drop of MTT (~ 200 C) in the second transition for Ru0.5Nb0.25Ta0.25 compared with those of RuNb and RuTa, while in the first transition its MTT is between MTTs of RuNb and RuTa. The insights gained by this study and the verified ab initio methods for accurate MTT calculations can be applied to fast screen and quantitatively design novel UHT-SMAs having similar properties with desirable MTTs and much reduced cost.

Zhigang Wu↗

NASA NTRS1994

Protein Crystal Growth Results From the United States Microgravity Laboratory-1 Mission

Protein crystal growth experiments have been performed by this laboratory on 18 Space Shuttle missions since April, 1985. In addition, a number of microgravity experiments also have been performed and reported by other investigators. These Space Shuttle missions have been used to grow crystals of a variety of proteins using vapor diffusion, liquid diffusion, and temperature-induced crystallization techniques. The United States Microgravity Laboratory - 1 mission (USML-1, June 25 - July 9, 1992) was a Spacelab mission dedicated to experiments involved in materials processing. New protein crystal growth hardware was developed to allow in orbit examination of initial crystal growth results, the knowledge from which was used on subsequent days to prepare new crystal growth experiments. In addition, new seeding hardware and techniques were tested as well as techniques that would prepare crystals for analysis by x-ray diffraction, a capability projected for the planned Space Station. Hardware that was specifically developed for the USML-1 mission will be discussed along with the experimental results from this mission.

L J Delucas↗

NASA NTRSDate not supplied

A Parametric Battery Model for the Conceptual Design of Electric Aircraft

Electric aircraft conceptual designs usually have an assumed specific power and specific energy for the aircraft’s energy storage system that dictates the total capacity and the peak power available. The specific energy and power are inherently linked to the state-of-charge and discharge rate from which they were derived; therefore, they will not directly correspond to the diverse circumstances encountered in various aircraft missions and flight segments. These parameters turn the battery system into a black box, disregard potential electrical restrictions, and disallow the aircraft and battery to be optimized as a system. Peering into this box, this study highlights the importance of incorporating a parametric battery model into the conceptual design workflow by splitting high-level terms such as power into voltage and current and investigating their variability during the discharge process. Through the modeling of these more detailed parameters, this methodology shows the feasibility of using low states-of-charge for contingency operations, including the end of the reserve mission, expanding the amount of usable capacity for electric aircraft. Stark differences in aircraft capabilities can arise between varying fidelity battery models due to late-mission, high-power flight operations. This parametric battery model effectively captures these differences by evaluating the limitations that arise within the individual battery cells and the aircraft powertrain. This paper shows that the unusable charge of a battery is set by the balked landing power requirement and can realistically range from 5% to 44% based on assumptions. This sets the analog to unusable fuel capacity in aircraft with liquid fuel systems. Needing only aircraft- and mission-level inputs and only seconds of run time, this model is a prime fit for the fast, accurate exploration of the electric aircraft conceptual design space.

Battery↗

NASA NTRSDate not supplied

Spacecraft Fire Safety Predictions using Verified Saffire Model

A model developed using Fire Dynamics Simulator (FDS) that aimed to determine the effect of a fire in a spacecraft was validated by data collected during the Saffire campaign. The model used inlet and outlet temperatures and CO 2 concentrations of the Saffire payload where fire spread was taking place to determine the amount of heat and combustion products that made it into Northrop Grumman’s Cygnus vehicle. The model was then validated using six remote sensors in various places in the vehicle, as well as a far field device (FFD) in the open zenith section that was representative of average vehicle values. The current work focuses on using the model to predict fire safety scenarios. One simulation aimed to determine the fate of HCl, which sticks to surfaces. The model prediction showed that the HCl was removed from the atmosphere rapidly. This compared well against the FFD data in the Saffire VI campaign event where a bottle of 5% HCl was released into the vehicle. An additional simulation where the Environmental Control and Life Support System (ECLSS) was shut off once the FFD reached 5 ppm of HCl showed that HCl stayed in the atmosphere considerably longer. Continuing the simulation with the ECLSS activated and after temperatures returned to their initial conditions, resulted in a rapid removal of HCL similar to that observed in the original HCl release scenario model. Finally, a simulation that used the heat release rate from a lithium-ion battery test to determine the effect it would have on a spacecraft was performed. This simulation used a heat addition rate that is considerably higher than what was determined from the burning of solid fuels in the Saffire campaign and hence produced a non-trivial temperature increase in more locations within the vehicle.

Fire Safety↗

NASA NTRS1992

Effect of Microgravity on Several Visual Functions During STS Shuttle Missions

Many astronauts and cosmonauts have commented on apparent changes in their vision while on-orbit. Comments have included statements of supposed improved distance acuity to decreased near vision capability. The purpose of this study was to assess not only changes in visual acuity, but expand the assessment to several other visual functions for a comprehensive battery of tests. Vision was assessed using an innovative device, the Visual Function Tester - Model 1 (VFT-1), which presents the tests at optical infinity and includes critical flicker fusion, stereopsis to 10 seconds-of-arc, visual acuity in small steps to 20/7.7, cyclophoria, lateral and vertical phoria, and retinal rivalry. Vision was assessed 2 times prelaunch at L-14 days and L-7 days, 3-4 times while on-orbit, at landing, and 2 times postlanding at L+3 days and L+7 days. There were 26 STS astronauts that participated, with data on 20 astronauts used for analysis. There was a typical wide variability between subjects in baseline visual performance for each parameter at the prelaunch sessions. There was a slight but statistically significant decrease in visual acuity while on-orbit that was not clinically significant. For stereopsis (i.e. depth perception), there was a small improvement on-orbit that was not statistically significant. There were no changes during space flight for any of the other visual parameters tested. A few individuals showed apparent changes in acuity and stereopsis. The possibility exists that microgravity affects the visual system of some individuals differently, as with space adaptation syndrome. Repeat data on 2 astronauts showed good repeatability between the 2 flights. These results pertain to only short term space flight on the STS shuttle, and longer flights are necessary to determine if there is any relationship between mission duration and these visual functions.

Melvin R O'Neal↗

NASA NTRSDate not supplied

Experimental Characterization of Additively Manufactured Nickel-Titanium Shape Memory Alloy Heat Pipes

Shape memory alloys (SMA) have been identified for use in spacecraft components as replacement for conventional deployment mechanisms. They may be used in thermal management components such as radiators to create self-deploying radiators. One SMA, NiTi, has also been developed for additive manufacturing processes. Heat pipes are a common way to create highly effective and lightweight spaceflight radiators, and heat pipes can also be made from NiTi and related alloys. The wick is the critical element of a functioning heat pipe, and recent progress over the past years has led to the development of additively manufactured heat pipe wicks in various materials. The combination of these efforts is the focus of this project: creating an additively manufactured, shape memory alloy self-deploying heat pipe radiator. This paper will focus on the experimental characterization of these additively manufactured NiTi heat pipes. The heat pipe coupons were additively manufactured by direct metal laser sintering (DMLS), with an integral liquid cooled condenser. Heat is input to the heat pipe via a thin film heater. Thermocouples were spot welded to the heat pipes to measure temperature at several axial locations. The heat pipes were tested with two working fluids: water and ethanol. Ethanol is not an ideal working fluid for heat pipes but is useful in characterizing them because it wets well to a wide variety of surfaces. Water is in general a superior working fluid for heat pipes, but its contact angle and therefore wicking performance strongly depends on the surface chemistry of the surface it is in contact with. A particular measurement of interest in this test is the evaporator to condenser thermal conductance, which will be compared in the full paper to recently published correlations for additively manufactured heat pipes. Experimental results for two straight geometry and one bellows geometry heat pipe will be presented. The bellows geometry is of interest for condenser of the self-deploying radiator design.

Additive manufacturing↗

NASA NTRSDate not supplied

Performance of a Regenerative Fuel Cell System for the Lunar Surface

Regenerative fuel cells (RFCs) are an attractive energy storage solution for lunar missions as a technology capable of providing a higher specific energy (i.e., W∙h/kg) than state-of-the-art packaged Li-ion battery systems. An RFC consists of the (1 & 2) electrochemical stacks (chemical to electrical energy conversion to supply electricity to an external load, i.e. the fuel cell reaction, and electrical to chemical energy conversion of supplied electrical power to dissociate water into hydrogen and oxygen gases, i.e. water electrolysis), (3) fluidic conditioning, (4) reactant storage, (5) avionics, (6) power management and distribution (PMAD), and (7) thermal management. NASA’s Glenn Research Center has designed, assembled, and tested a breadboard RFC sys-tem capable of operating autonomously for multiple simulated lunar day/night cycles in a laboratory environment. The system is comprised of a non-flow through proton exchange membrane (PEM) fuel cell stack and a liquid-anode feed PEM electrolyzer (EZ) stack designed to electrochemically compress the reactants at balanced pressures up to 12.4 MPa (1800 psia). The fluidic conditioning, avionics, PMAD, and thermal management sub-systems are largely comprised of commercial-off-the-shelf components for this system-level development effort. The hardware is controlled by a CubeSat space processor running an operational program based on core flight architecture that can control the RFC hardware autonomously through a state machine with fault monitoring. The testing results highlighted here were completed with the system in an open-loop configuration such that reactants generated through water electrolysis were vented while gas cylinders supplied fuel cell operation. The breadboard operated autonomously, but there were five unplanned transitions to a safe state that required a manual restart after reviewing the data, determining a root cause, and implementing a solution. Four of the transitions were caused by the thermal management subsystem and the fifth was caused by a water management control issue in the EZ sub-system. The RFC system operated for over 550 hours with the final cycle being slightly abbreviated due to reasons unrelated to system performance.

Kerrigan Cain↗