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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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338 records · Page 10

Designing a Propylene-Glycol Coolant Servicer System for Gateway’s Internal Active Thermal Control System

A human spacecraft ATCS—especially one using single-phase coolant loops exposed to cabin atmospheric conditions—requires periodic degassing and refilling to support long-duration missions of 15 to 30 years. During initial fill operations, system maintenance, gas permeation, and quick-disconnect mating or de-mating, small amounts of gas can gradually enter the coolant system over time. This can lead to degraded heat transfer performance, pump cavitation, and potentially pump vapor lock if a significant gas volume accumulates over time. Additionally, system leaks and routine fluid sampling can gradually reduce accumulator volumes to unacceptable levels, requiring periodic refills. In more severe cases, catastrophic changes in fluid composition may necessitate emergency draining, refilling, and degassing to ensure continued system functionality. These risks were identified and mitigated on the ISS ITCS through the development of a dual-membrane degasser ORU and a Fluid Servicer System ORU for coolant refilling. These systems were developed for the fully water-based ISS ITCS Coolant[1]. The Gateway space station, the first permanent human habitat in lunar orbit, uses a propylene-glycol/water coolant mixture, which has significantly different fluid properties compared to pure water. Because microgravity degassing technologies are sensitive to fluid surface tension and viscosity, existing ISS hardware is not suitable for servicing a propylene-glycol-based TCS. Unlike the ISS, the Gateway will operate in a higher-radiation environment and must meet stricter mass constraints due to its location outside of low earth orbit. This Government Furnished Equipment (GFE) flight hardware project aims to develop a lightweight, radiation-resistant Coolant Servicer System (CSS) capable of degassing and refilling Gateway’s propylene-glycol water-based IATCS.

Propylene Glycol Water

Incremental Learning for Passive Microwave Precipitation Retrievals using Advanced Technology Microwave Sounder

Spaceborne passive microwave (PMW) radiometry is central to global precipitation monitoring, yet retrieval uncertainties remain substantial, particularly for cross-track sounders whose variable footprints and channel configurations are optimized for atmospheric temperature and moisture profiling rather than precipitation. Consequently, existing operational products often exhibit angular-dependent biases, limited effective swath utilization, unrealistic rainfall probability distributions, and systematic misclassification of precipitation phase. These limitations are further compounded by the scarcity of globally accurate and representative precipitation observations, as training data from the Dual-frequency Precipitation Radar (DPR) and the Cloud Profiling Radar (CPR) are spatially sparse, lack uniform global coverage, and exhibit heterogeneous error characteristics across precipitation regimes. To address these challenges, this study presents a supervised retrieval algorithm that incrementally trains an ensemble of extreme gradient-boosted decision trees by augmenting base learners with pre-training on reanalysis data and post-training on coincident DPR and CPR observations matched with the Advanced Technology Microwave Sounder (ATMS). By transferring prior information from reanalysis to posterior constraints from radar observations and adopting a sequential detection–estimation strategy for precipitation phase and rate retrieval, the proposed approach yields retrievals across the full ATMS swath that are largely free from persistent deficiencies in current Global Precipitation Measurement (GPM) passive microwave operational products. In particular, the method resolves bimodal artifacts in rainfall retrievals and mitigates systematic high-latitude snowfall biases, including overestimation across the Arctic and underestimation across the Antarctic. Validation against independent Multi-Radar Multi-Sensor (MRMS) data over the Contiguous United States (CONUS) further demonstrates improved performance in precipitation phase detection and rate estimation relative to both reanalysis and current GPM PMW products.

Mahyar Garshasbi

Designing a Propylene-Glycol Coolant Servicer System for Gateway’s Internal Active Thermal Control System

A human spacecraft ATCS—especially one using single-phase coolant loops exposed to cabin atmospheric conditions—requires periodic degassing and refilling to support long-duration missions of 15 to 30 years. During initial fill operations, system maintenance, gas permeation, and quick-disconnect mating or de-mating, small amounts of gas can gradually enter the coolant system over time. This can lead to degraded heat transfer performance, pump cavitation, and potentially pump vapor lock if a significant gas volume accumulates over time. Additionally, system leaks and routine fluid sampling can gradually reduce accumulator volumes to unacceptable levels, requiring periodic refills. In more severe cases, catastrophic changes in fluid composition may necessitate emergency draining, refilling, and degassing to ensure continued system functionality. These risks were identified and mitigated on the ISS ITCS through the development of a dual-membrane degasser ORU and a Fluid Servicer System ORU for coolant refilling. These systems were developed for the fully water-based ISS ITCS Coolant[1]. The Gateway space station, the first permanent human habitat in lunar orbit, uses a propylene-glycol/water coolant mixture, which has significantly different fluid properties compared to pure water. Because microgravity degassing technologies are sensitive to fluid surface tension and viscosity, existing ISS hardware is not suitable for servicing a propylene-glycol-based TCS. Unlike the ISS, the Gateway will operate in a higher-radiation environment and must meet stricter mass constraints due to its location outside of low earth orbit. This Government Furnished Equipment (GFE) flight hardware project aims to develop a lightweight, radiation-resistant Coolant Servicer System (CSS) capable of degassing and refilling Gateway’s propylene-glycol water-based IATCS.

Propylene Glycol Water

Mass Economy Evaluation for Integrated ECLSS and Propulsion Architecture

As missions in Low Earth Orbit (LEO) lengthen and extend to deep space, minimizing resupply needs becomes vital for sustaining crewed operations. Traditional life support systems depend on consumables resupplied from Earth, a method that is increasingly impractical for missions beyond LEO, such as lunar outposts or Mars transit. Long-duration missions require more efficient, autonomous systems that can recycle essential resources, particularly water and oxygen, to minimize the frequency and mass of resupply missions. The Environmental Control and Life Support System (ECLSS) is essential to such missions, with the International Space Station (ISS) serving as a testbed for advanced water recovery and partial oxygen recycling via physico-chemical methods. Yet, ECLSS and propulsion subsystems generally operate independently, despite overlapping requirements and potential areas for synergy. For instance, ECLSS byproducts, water, CO₂, and hydrogen, could be repurposed for propulsion, potentially reducing dedicated propellant mass and increasing overall system efficiency. One promising approach is to develop shared-resource architectures that integrate ECLSS with propulsion systems. This study examines the potential of such integration through the Sabatier CO₂ reduction process, focusing on water management as a key factor in system mass trade-offs. The Sabatier reaction produces water and methane from metabolic CO₂ and electrolytic hydrogen, partially closing the life support loop and providing methane, which could serve as a propellant. This integration could minimize waste, reduce resupply requirements, and enhance mission mass efficiency. A dynamic modeling framework will be used to simulate resource flows over long missions, capturing interactions between life support and propulsion. By comparing integrated versus separate system configurations, the study aims to quantify mass benefits and penalties, informing future habitat designs and trade studies for missions prioritizing autonomy and mass efficiency.

ECLSS

Mass Economy Evaluation for Integrated ECLSS and Propulsion Architecture

As missions in low Earth orbit (LEO) lengthen and extend to deep space, minimizing resupply needs becomes vital for sustaining crewed operations. Traditional life support systems depend on consumables resupplied from Earth, a method that is increasingly impractical for missions beyond LEO, such as lunar outposts or Mars transit. Long-duration missions require more efficient, autonomous systems that can recycle essential resources, particularly water and oxygen, to minimize the frequency and mass of resupply missions. The Environmental Control and Life Support System (ECLSS) is essential to such missions, with the International Space Station (ISS) serving as a testbed for advanced water recovery and partial oxygen recycling via physico-chemical methods. Yet, ECLSS and propulsion subsystems generally operate independently, despite overlapping requirements and potential areas for synergy. For instance, ECLSS byproducts, water, CO 2 , and hydrogen, could be repurposed for propulsion, potentially reducing dedicated propellant mass and increasing overall system efficiency. One promising approach is to develop shared-resource architectures that integrate ECLSS with propulsion systems. This study examines the potential of such integration through the Sabatier CO₂ reduction process, focusing on water management as a key factor in system mass trade-offs. The Sabatier reaction produces water and methane from metabolic CO 2 and electrolytic hydrogen, partially closing the life support loop and providing methane, which could serve as a propellant. This integration could minimize waste, reduce resupply requirements, and enhance mission mass efficiency. A dynamic modeling framework will be used to simulate resource flows over long missions, capturing interactions between life support and propulsion. By comparing integrated versus separate system configurations, the study aims to quantify mass benefits and penalties, informing future habitat designs and trade studies for missions prioritizing autonomy and mass efficiency.

ECLSS

RCA SATCOM Battery in Orbit Performance Update and Accelerated Life Test Results

No significant degradation of nickel cadmium battery performance in SATCOM F1 and F2 after almost 8 and 7-3/4 years in orbit was shown. Battery minimum discharge voltage data are presented for these spacecraft. In addition, 2 groups of nickel cadmium cells which are representative of those in orbit are undergoing real time eclipse-reduced suntime cycling in the laboratory. These groups of cells, which are being cycled at a maximum of 53% and 62% depth of discharge (based on actual capacity), have completed 14 and 15 eclipse seasons, respectively. Data for these groups of cells are presented and are compared with the in-orbit battery data.

Gaston, S. J.

Thermal expansion behavior of LDEF metal matrix composites

The effects of the space environment on the thermal expansion stability of metal matrix composites (graphite/Al and graphite/Mg) will be presented. A sample from each category of metal matrix composites mounted on the leading and trailing edge was chosen for analysis of the temperature-time-thermal strain histories. Typical thermal expansion curves over the same range of temperature were selected at the beginning, mid, and end of the recording duration. The thermal expansion of selected post-flight LDEF samples were measured over the same range of temperature in the laboratory using a Michelson laser interferometer. The thermal strains were monitored concurrently with a laser interferometer and a mounted strain gage.

T. D. Le

Reserve Li/SOC12 Battery Safety Testing

A reserve Lithium/Thionyl Chloride Battery concept is developed and undergoing feasibility testing in terms of performance, safety and abusive conditions. The feasibility of employing a battery of this type to replace thermal batteries in certain applications is demonstrated. Excellent performance of a Li/SOCl2 reserve battery is obtained across the temperature range from 0 C to +44 C. Performance improvement over the thermal battery usage is greater by a factor of 3 when discharge time and energy density are compared. Performance over an expanded temperature range is also possible. Safety and abusive testing is accomplished successfully on a series of five units. Further performance improvements can be achieved with regard to battery weight and volume reductions.

Dils, C. T.

User Interface Issues in Supporting Human-Computer Integrated Scheduling

A major problem in designing user interfaces for scheduling systems is one of allowing the human to become an integral part of the system. The human role in scheduling extends beyond the simple tasks of providing the input and accepting the output. Because of the inherent intractability of most real-world scheduling problems, intelligence must be incorporated into the scheduling process in order to reach an acceptable solution in a reasonable amount of time. Artificial Intelligence research has concentrated on identifying algorithms and heuristics for this purpose. However, interfaces which allow the scheduler to take advantage of human intelligence and allow the user insight into and influence over the planning process are also needed.

Lynne P Cooper

Ulysses navigation

Ulysses, a cooperative NASA and ESA project, measures charged and neutral particles, magnetic fields, and electromagnetic wave emissions from the Sun's polar regions and the out of elliptic heliospheric environment. ESA supplied the spacecraft and one half of the instruments, and is in control of the spacecraft and its attitude. NASA supplied the power supply, one half of the instruments, the launch vehicle, and tracks the spacecraft and performs the navigation. Orbit determination results mapped to the time of Jupiter's arrival show improved accuracy and consistency over the course of the mission to date. Solar radiation pressure model uncertainties are major contributors to orbit determination errors, but are being estimated more accurately as data are accumulated.

H. J. Gordon

Dynamic Regulation of Sub-Atmospheric Pressure for Constant and Cyclic Gas Loads During Testing of Spacesuit Components

New iterations of the various subsystems within the spacesuit will benefit from a new sorbent technology. For example, sorbents used in the Trace Contaminant Control (TCC) and the Rapid Cycle Amine (RCA) systems within the Exploration Portable Life Support System (xPLSS), part of the Extra-Vehicular Mobility Unit (xEMU). For proper validation, the sub-atmospheric pressure needs to be maintained within a simulated 2 ft 3 spacesuit volume. The traditional approach, which involves placing the entire vent loop within a hypobaric chamber, is not practical for the widespread testing of components and prototypes, as these specialized chambers are costly and not widely available. A two-stage regulator based sub-atmospheric pressure system is presented in this work. The method regulates the pressure based on pressure differentials between the pressure regulation pump, the test system, and the ambient environment. The performance of this system is demonstrated using data collected during a 150+ hour non-regenerative TCC sorbent evaluation, several 24-hour regenerative TCC sorbent evaluations with different regeneration cycles, and an 8-hour RCA sorbent evaluation, all under xEMU operating conditions. For regulation, the inlet regulator was set to propagate a small leak to increase the stability of the system as the gas load from the testing system changes. It was also found that controlling the input flow rate that replaces the material lost during regeneration is critical for ensuring the stability of the system. This system provided excellent pressure regulation, without adjustments, for constant loads during shorter time evaluations (hours), while longer time evaluations (days) are easily obtainable with periodic regulator adjustments. A second method is under development to address longer-term stability and to automate pressure regulation. It will incorporate flow and pressure measurements to dynamically control a set of electronically controlled proportional valves for adjusting the pumping speed and air bleed supply.

Nicholas F Materer

In-suit CO2 Washout Test System (ICWTS) for CO2 Washout Verification in Spacesuits

Since the time of Mercury, Gemini, and Apollo, NASA has been performing CO 2 washout verification of spacesuits with Human in the Loop (HITL) test methods. Classically, the only instrumentation both with the accuracy and response time necessary was that of external mass spectrometers or medical gas analyzers fed by a long capillary line from the oro-nasal region within the suit. The helmet CO 2 washout configuration including the challenges posed by variation of a suited human subject frequently created difficulty in capturing adequate breath by breath data. For example, a nasal cannula could be worn with reasonable comfort however it posed the following challenges: (1) impeded the test subject’s ability to do a proper Valsalva maneuver; (2) frequently provided a corrupted waveform with relative movement; (3) precluded the ability to evaluate the Flow Weighted Average (FWA) at subject interface. A mouthpiece could be used in lieu of a cannula but posed challenges as well: (1) created potential disturbances of the flow field; (2) precluded the test subject from speaking during usage; and (3) presented comfort issues limiting the duration of test points. These challenges made it impractical to use a mouthpiece for anything other than short lab ambient environment tests. Technology development and NASA investment have afforded new capabilities to address some of these measurements providing improved data collection and are implemented in the In-suit CO 2 Washout Test System (ICWTS) which provides suit inlet/outlet pressure, temperature, relative humidity, partial pressure of oxygen, partial pressure of CO 2 , and flow measurement coupled with the acquisition of the inspired PPCO 2 including the ability for FWA measurement. This test system, coupled with use of the In-suit Respiration Mannequin Assembly (IRMA) and Computational Fluid Dynamics (CFD) combine to provide a full picture of the in-suit oro-nasal flow field and effectiveness of CO 2 washout in a spacesuit design.

Colin Campbell

Beyond Melting: Amorphous Bonding for Joining and Consolidation

Crystallization may be the hidden constraint in thermoplastic composite manufacturing. It requires tightly controlled cooling, induces residual stresses through shrinkage, and introduces path-dependent behavior that complicates predictive modeling yet remains essential for structural performance. This work asks: can bonding be achieved without relying on melt-driven crystallization? To address this, thin (5–20 μm) polyetherimide (PEI) interlayers are pre-healed to slow-cooled polyaryletherketone (PAEK) in two contexts. The first, Thermabond®, is sub-melt joining of low melt-PAEK laminates. Results show that bond quality is governed primarily by processing (i.e., adequate healing and film handling) rather than modest changes in interlayer thickness. This concept is then extended to laminate-scale manufacturing through an architecture known as OATMEAL (Out-of-autoclave Amorphous/semicrystalline Thermoplastic Material for Energy-efficient Aerospace-grade Laminates). PEI is healed to carbon fiber reinforced polyetheretherketone (PEEK) at the prepreg and excess PEI is then ablated from the surface. Crystallinity is developed off-line during prepreg fabrication, while subsequent consolidation occurs below the melt temperature to preserve it. Cross-ply warpage experiments show that, contrary to intuition, repeated amorphous interfaces reduce global curvature by lowering the effective stress lock-in temperature and eliminating crystallization shrinkage from the lamina response. Correspondingly, laminate behavior is accurately predicted using classical laminate theory (CLT) with a single effective stress-free temperature, whereas conventional CF/PEEK requires accounting for crystallization-driven effects. By decoupling interfacial healing from crystallization, OATMEAL enables sub-melt consolidation, reduces energy consumption by up to 75%, and increases manufacturing throughput by fivefold. These results demonstrate that amorphous bonding is not only a joining strategy, but a pathway to more predictable and scalable thermoplastic composite manufacturing.

solidification

In-suit CO 2 Washout Test System (ICWTS) for CO 2 Washout Verification in Spacesuits

Since the time of Mercury, Gemini, and Apollo, NASA has been performing CO 2 washout verification of spacesuits with Human in the Loop (HITL) test methods. Classically, the only instrumentation both with the accuracy and response time necessary was that of external mass spectrometers or medical gas analyzers fed by a long capillary line from the oro-nasal region within the suit. The helmet CO 2 washout configuration including the challenges posed by variation of a suited human subject frequently created difficulty in capturing adequate breath by breath data. For example, a nasal cannula could be worn with reasonable comfort however it posed the following challenges: (1) impeded the test subject’s ability to do a proper Valsalva maneuver; (2) frequently provided a corrupted waveform with relative movement; (3) precluded the ability to evaluate the Flow Weighted Average (FWA) at subject interface. A mouthpiece could be used in lieu of a cannula but posed challenges as well: (1) created potential disturbances of the flow field; (2) precluded the test subject from speaking during usage; and (3) presented comfort issues limiting the duration of test points. These challenges made it impractical to use a mouthpiece for anything other than short lab ambient environment tests. Technology development and NASA investment have afforded new capabilities to address some of these measurements providing improved data collection and are implemented in the In-suit CO 2 Washout Test System (ICWTS) which provides suit inlet/outlet pressure, temperature, relative humidity, partial pressure of oxygen, partial pressure of CO 2 , and flow measurement coupled with the acquisition of the inspired PPCO 2 including the ability for FWA measurement. This test system, coupled with use of the In-suit Respiration Mannequin Assembly (IRMA) and Computational Fluid Dynamics (CFD) combine to provide a full picture of the in-suit oro-nasal flow field and effectiveness of CO 2 washout in a spacesuit design.

Colin Campbell

Dynamics and Structure of Weakly-Strained Flames In Normal- and Micro-Gravity

Strained laminar flames have been systematically studied, as the understanding of their structure and dynamic behavior is of relevance to turbulent combustion. Most of these studies have been conducted in opposed-jet, stagnation-type flow configurations. Flame studies in stagnation flows also allow for the determination of fundamental flame properties such as laminar flame speeds and extinction states that can be also conveniently modeled in detail. Studies at high strain rates are important in quantifying and understanding the response of vigorously-burning flames under conditions in which the transport time scales become comparable to the chemical time scales. Studies of weakly-strained flames can be of particular interest for all stoichiometries. For example, the laminar flame speeds for any equivalence ratio, phi, can be accurately determined by using the counterflow technique only if measurements are obtained at very low strain rates. Furthermore, near-limit flames can be only stabilized by weak strain rates. Previous studies have shown that weakly-burning flames are particularly sensitive to chain mechanisms, thermal radiation, and unsteadiness. The stabilization and study of weakly-strained flames is complicated by the presence of buoyancy that can render the flames unstable to the point of extinction. Such instabilities are caused either by the induced natural convection or the fact that higher density fluid can find itself on top of a lower density fluid. Thus, the use of microgravity (mu-g) becomes essential in order to provide meaningful insight into this important combustion regime. In view of the foregoing considerations, the main objectives of the program are to: (1) Experimentally determine the laminar flame speed at near-zero strain rates; (2) Experimentally determine the extinction limits of near-limit flames; (3) Experimentally determine the response of near-limit flames to unsteadiness and heat loss; (4) Introduce Digital Particle Image Velocimetry (DPIV) in microgravity; (5) Conduct detailed numerical simulations of the experiments; and (6) Provide physical insight into the underlying physico-chemical mechanisms.

Hai Zhang

Sulfur outgassing and in-gassing in lunar orange glass beads and implications for 33S “Anomaly” in the Moon

Our recent investigations have discovered inward diffusion (in-gassing) of moderately volatile elements (MVEs; e.g., Na, K and Cu) from volcanic gas into volcanic beads/droplets. In this work, we examine the distribution of sulfur in lunar orange glass beads. Our analyses reveal that sulfur exhibits a non-uniform distribution across the beads, forming “U” or “W” shaped profiles typical of in-gassing. A model developed to assess sulfur contributions from different sources (original magmatic sulfur versus atmospheric in-gassed sulfur) in the orange beads indicates that atmospheric sulfur in-gassed during eruption contributes approximately 9–24 % to the total sulfur content of an orange bead, averaging around 16 %. This in-gassed sulfur is derived from the eruption plume, where atmospheric sulfur could undergo photochemical reactions induced by UV light, leading to mass independent fractionation and a distinct sulfur isotope signature. Interestingly, a recent study discovered a small mass independent isotope fractionation of sulfur in lunar orange glass beads in drive tube 74002/1 and a lack of such mass independent isotope fractionation in black glass beads in the same lunar sample. This finding contrasts with sulfur in lunar basalts, which typically exhibit mass dependent fractionation. With our work, the observed mass independent fractionation signal in sulfur isotopes of orange beads can be attributed to the in-gassing of photolytic sulfur in the optically thin part of the eruption plume where UV light can penetrate. Using the sulfur isotope data of lunar orange beads, we estimate that the Δ33S value of atmospheric sulfur is approximately −0.18 ‰. Our study provides new insights into the complex dynamics of volatile elements in lunar volcanic processes, highlighting the role of in-gassing in shaping sulfur isotope signatures in volcanic glass beads.

Xue Su

A computerized aircraft battery servicing facility

The latest upgrade to the Aerospace Energy Systems Laboratory (AESL) is described. The AESL is a distributed digital system consisting of a central system and battery servicing stations connected by a high-speed serial data bus. The entire system is located in two adjoining rooms; the bus length is approximately 100 ft. Each battery station contains a digital processor, data acquisition, floppy diskette data storage, and operator interfaces. The operator initiates a servicing task and thereafter the battery station monitors the progress of the task and terminates it at the appropriate time. The central system provides data archives, manages the data bus, and provides a timeshare interface for multiple users. The system also hosts software production tools for the battery stations and the central system.

Glover, Richard D.

Evaluation of Long-Term Storage Stability and Operational Efficiency of Rapid Cycle Amine Adsorbents

With the recent incorporation of Mars Extravehicular Activity (EVA) into the 2025 NASA roadmap, Rapid Cycle Amine (RCA) technology advancement within the Exploration Extravehicular Mobility Unit (xEMU) applies to both the upcoming Lunar Artemis missions and future human exploration of Mars. The incorporation of commercial spacesuit vendors to service NASA’s crewed-space programs since 2021 has increased the demand for regenerable, RCA-based carbon dioxide (CO2) and humidity control adsorbents. The regenerable RCA subunit is the most advanced, long-term solution for CO2 removal and humidity control, enabling both lunar and Martian EVAs. The adsorbent selected for use within the RCA unit must exhibit sufficient storage stability and operational efficiency for prolonged missions. As XploSafe worked to simultaneously develop both a recirculating sub-atmospheric test rig and adsorbents for the RCA system within the xEMU, several novel adsorbents were evaluated for long-term storage stability in support of future extended-duration missions. The chosen materials were periodically evaluated by nuclear magnetic resonance (NMR) spectroscopy, thermal desorption-coupled with gas chromatography/mass spectrometry (TD-GC/MS), and CO2 adsorption to assess long-term storage efficacy across various environmental storage conditions. NMR spectroscopy was utilized by extracting the active CO2 adsorbing chemical from the solid support with deuterated solvent and comparing the spectra over time for degradation and change. The solid adsorbents were also analyzed via TD-GC/MS to reveal any potential off-gassing chemicals over time. Additionally, XploSafe’s breakthrough test rig was utilized to dose the solid adsorbents with a 585 BTU/h metabolic rate flow-equivalent CO2 stream and monitored for 0–99% CO2 breakthrough. The performance metrics from the breakthrough analysis were compared over the storage study duration for CO2 removal and humidity control. Xplo-SA9T was evaluated for 24 months, whereas two additional adsorbent variants, MMPA-Sorbent and LPEI-Sorbent, were each evaluated for 12 months.

John R Tidwell