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NASA NTRS2017

New Global Electron Density Observations from GPS-RO in the D- and E-Region Ionosphere

A novel retrieval technique is developed for electron density (N(sub e)) in the D- and E-region (80-120 km) using the high-quality 50-Hz GPS radio occultation (GPS-RO) phase measurements. The new algorithm assumes a slow, linear variation in the F-region background when the GPS-RO passes through the D- and E-region, and extracts the N(sub e) profiles at 80-130 km from the phase advance signal caused by N(sub e). Unlike the conventional Abel function, the new approach produces a sharp N(sub e) weighting function in the lower ionosphere, and the N(sub e) retrievals are in good agreement with the IRI (International Reference Ionosphere) model in terms of monthly maps, zonal means and diurnal variations. The daytime GPS-RO N(sub e) profiles can be well characterized by the alpha-Chapman function of three parameters (N(sub mE), h(sub mE) and H), showing that the bottom of E-region is deepening and sharpening towards the summer pole. At high latitudes the monthly GPS-RO N(sub e) maps at 80-120 km reveal clear enhancement in the auroral zones, more prominent at night, as a result of energetic electron precipitation (EEP) from the outer radiation belt. The D-/E-region auroral N(sub e) is strongly correlated with K(sub p) on a daily basis. The new N(sub e) data allow further comprehensive analyses of the sporadic E (E(sub s)) phenomena in connection with the background N(sub e) in the E-region. The layered (2-10 km) and fluctuated (less than 2 km) E(sub s) components, namely N(sub e_Layer) than N(sub e_Pert), are extracted with respect to the background N( sub e_Region) on a profile-by-profile basis. The N(sub e_Layer) component has a strong but highly-refined peak at approximately 105 km, with an amplitude smaller than N(sub e_Region) approximately by an order of magnitude. The N(sub e_Pert) component, which was studied extensively in the past, is approximately 2 orders of magnitude weaker than N(sub e_Layer). Both N(sub e_Layer) and N(sub e_Pert) are subject to significant diurnal and semidiurnal variations, showing downward progression with local time in amplitude. The 11-year solar cycle dominates the N(sub e) interannual variations, showing larger N(sub e_Region) and N(sub e_Layer) but smaller N(sub e_Pert) amplitudes in the solar maximum years. Enhanced Ne profiles are often observed in the polar winter, showing good correlation with solar proton events (SPEs) and geomagnetic activity. The new methodology offers great potential for retrieving low N(sub e) in the D-region, where radio propagation and communication blackouts can occur due to enhanced ionization. For space weather applications it is recommended for GPSRO operations to raise the top of high-rate data acquisition to approximately 140 km in the future.

GSP-R↗

NASA NTRS2018

NASA SPLICE Project: Development and Testing of Precision Landing GN&C Technologies

NASA's technology advancement needs for entry, descent and landing call for high-precision, high-rate sensors that can improve navigation accuracy and vehicle control performance. Higher landing accuracy is required for any future human lander missions, and likely, for most robotic missions 1,2. Sensors and algorithms that significantly reduce navigation errors and can image the local terrain will enable landing at locations of high scientific interest that would otherwise pose significant risk to the vehicle. The Safe and Precise Landing-Integrated Capabilities Evolution project, or SPLICE, is developing precision landing and hazard avoidance (PL&HA) technologies for NASA and for potential commercial space flight missions. SPLICE technologies include sensors, algorithms, advanced space flight computing capabilities, and simulation tools used to integrate and study guidance, navigation, and control (GN&C) system performance. SPLICE efforts include hardware-in-the-loop (HWIL) simulation testing, ground testing, and flight testing, including reuse of hardware from the CoOperative Blending of Autonomous Landing Technologies (COBALT) suborbital flight-test payload3,4. Two of the precise navigation sensors that are being developed and matured within SPLICE are LiDARs. Since 2006, NASA Langley has been developing a Navigation Doppler LiDAR (NDL) for precise velocity measurements, and SPLICE is building an NDL engineering test unit (ETU) that will be brought up to TRL 6 following environmental and high-speed1,2 testing. NASA Goddard is developing a Hazard Detection LiDAR (HD LiDAR) engineering development unit (EDU) for SPLICE that has relevance to future human and robotic lander missions. The HD LiDAR will be flight test and matured to TRL 5.

Restrepo, Carolina I.↗

NASA NTRS2019

Challenges and Solutions for Precision Solar Pointing on the ISS for the TSIS Instrument

The International Space Station offers an attractive platform for external payloads in many regards, but its large, complex structure is challenging for payloads that require precise, unobstructed pointing. As an instrument that measures solar irradiance on a continual basis, the TSIS payload was designed to robustly account for these ISS challenges and is now performing its mission on the ISS with great success.This paper first describes how TSIS was able to measure the ISS background jitter using High-rate Fine Sun Sensor data that was taken during passive solar transits through its field of view. The measurements showed that ISS jitter at the TSIS location on ELC-3 Site 5 is relatively benign with less than 4 arcseconds 1 at frequencies less than 0.5 Hz. This value is lower than previous estimates but agrees well with recent measurements from other external payloads, including OPALS and SAGE III. Because TSIS was designed to be robust to base motion jitter, it has achieved less than 4 arcseconds 1 of pointing error, which provides an extremely precise pointing platform for the solar irradiance measurements. The other challenging ISS characteristic is its large, complex structure that obscures solar viewing at sunrise and sunset from the zenith-facing location of TSIS. Although TSIS was able to predict solar viewing durations during the design phase with relatively high accuracy, the exact timing and causes of obscuration were difficult to predict and understand after TSIS began operating on the ISS. To aid in the understanding of blockage by ISS structure, detailed obscuration maps were created using HFSS measurements that clearly show the exact gimbal angles where blockage occurs and the specific structural features of the ISS that cause the blockage. These maps have helped TSIS to maximize its solar tracking durations each orbit, which has supported the mission in meeting its science objectives.

background jitter↗

NASA NTRS2016

Characterization of Operational Performance of Ka-Band Links in Deep Space Network

This paper presents a characterization of performance of 32-GHz Ka-band link in an operational environment. The data come from tracking of Kepler spacecraft by the NASA Deep Space Network (DSN) in the past few years. Ka-band link offers a significant signal-to-noise advantage compared to the more common X- or S-band; however, it is subject to more signal fluctuation caused by the weather. Kepler is the first mission supported by the DSN that solely rely on the higher deep space Ka-band communications link to return its high-rate science data. A well characterization of the operational performance of Kepler would benefit future Ka-band missions, especially for those operating with smaller link margin. The study examines how weather conditions at the DSN facilities (e.g., winds, clouds, rains) affect the received signal, particularly on telemetry data. It addresses questions such as how often the weather affects the link and how much degradation the link could suffer. Among the 22 Ka-band passes in 2012, heavy clouds affected one pass and two passes were impacted by high winds. The adverse weather caused at time as much as 3-dB instantaneous change in the signal to noise ratio (SNR). Estimates of degradation to the SNR as a function of wind speeds are captured based on observations. This study also quantifies the probability distribution of the variation of received signal power. With such information, future missions can better plan their link design. An optimal link design aims for just having enough margin to realize the data return with a targeted probability, with neither having too much margin that it reduces the downlink data rate nor insufficient reserve that causes frequent data outages. The study tries to provide some answers to the questions such as how much does SNR vary from one tracking pass to the next, and what is the cumulative distribution of signal fluctuation. Regarding the signal variation over many tracking passes, we found that the averaged symbol SNR (SSNR) for each pass changed by as much as 4 dB. Some variations were due to geometry such as the changing distance between spacecraft and Earth and different antenna pointing elevations. Other variations seem to be random in nature, reflecting the randomness of operational environments. Some passes were found to be quite stable, with a standard deviation of symbol SNR around 0.25 dB while others had greater variation, up to 1.4 dB. Overall, the cumulative distribution of the symbol SNR reflects that 50% of the fluctuations was less than 0.6 dB, 90% of fluctuation was within 1.6 dB and 95% within 2.2 dB. Some of the challenges in data processing, validation and modeling were captured in this paper. We observed some inconsistent measurements where operational data significantly deviate from a normal expectation. These inconsistent measurements made it hard to develop an accurate and consistent performance model, such as the degradation of signal SNR as a function of high wind. The difficulty was compounded by the fact that there were only a few Ka-band passes observed in high winds.

Pham, Timothy↗

NASA NTRS2019

Operations of the Optical Communications Demonstration for the Orion EM-2 Mission

The GSFC implementation of an Optical Communication System to demonstrate an operational optical communication link for Orion EM-2. It will serve as a base for providing an operational optical communications capability for future Orion missions. GSFC plans to maintain a development path for the optical communication flight terminal to allow commercialization and implementation on future Orion missions. The Orion optical module part of the optical communications flight terminal and its control electronics have a common architecture with the ILLUMA-T optical terminal provided by GSFC for use on the ISS. The plan is to flow data from Orion through the Optical Communication Fight Terminal to the Optical Communication Ground Terminal and reverse. NASA's Orion spacecraft is an exploratory vehicle designed for longer-duration flights beyond the Moon. Following Orion's Exploration Mission-1 (EM-1), during which the spacecraft will travel beyond the Moon, enter a distant retrograde orbit around the Moon and return to Earth unmanned, Exploration Mission-2 (EM-2) will see a crewed spacecraft complete a slightly different flight path. First crewed test flight of the Orion spacecraft, currently targeting a June 30, 2022 launch. The mission involves: One revolution in Low Earth Orbit (LEO) parking orbit to verify basic Orion systems functionality and deploy solar arrays. A single 42-hour Highly Elliptical Orbit (HEO) intermediate checkout orbit allows characterization of the Orion vehicle system performance prior to committing to a cis-lunar flight. Trans Lunar Injection (TLI) burn using Orion Service Module (SM) main engine, which sends Orion on a lunar flyby and free return. Skip reentry at lunar return velocities to splashdown off the coast of San Diego. Total mission duration is approximately 10 days. EM-2 is the first crewed mission of the Orion Spacecraft that crew brings more video up/downloads, file transfers, and real-time chats with family back home and high-rate communications enables live HD streaming for Crew conferences, Public Affairs Office (PAO) events, and significant mission events. Also still collecting vehicle data on numerous Orion subsystems via Development Flight Instrumentation (DFI) allows large data volume returns sooner for DFI and future science payloads, as opposed to waiting for end-of-mission. O2O is a demonstration of operational utility system tested as a Developmental Test Objective (DTO) and not required to meet mission requirements/success/ Flight Test Objectives (FTO). EM-2 architecture is as close to future mission operational architecture as possible.Orion subsystems (video, DFI, etc.) expected to generate ~250 GB of data in the first 24 hours of flight. Total data generated over the mission estimated to be more than 400 GBUsing S-Band alone, Orion limited to ~ 6GB of data downlink per day. Because of this limitation, Orion is planning to limit live video downlinks on EM-1 in order to downlink high priority fileswith 1 hour/day of Optical Communication, Orion could downlink ~6x more data per day (~ 36GB/day).The optical communication system is capable of multiple data rates up to at least 80 Mbps downlink for the transfer of Orion data to Earth while Orion is operating in the lunar vicinity.

Optical Communication↗

NASA NTRSDate not supplied

Testing of ACC-6 Carbon-Carbon at High Strain Rates and High Temperatures

Some materials, such as steel, titanium, and tungsten, have a yield stress that depends on the strain rate, and actually are stronger at high rates of load or deformation. The increase in strength is relevant; and if not taken into account, the computer models will not match the experimental behavior observed in typical shock loading, ordnance, or ballistic tests. For higher velocity (hypervelocity impacts), an equation of state that accounts for non-linearities and temperature in the pressure-volume relation, may also be needed. This rate-dependent behavior of the strength has also been observed in some composite materials. Southwest Research Institute® (SwRI®) has started an internal research effort to measure and better model the behavior of materials, in particular carbon/carbon composites like ACC-6, at ultra-high temperatures for both static and high rates of deformation. The ultimate objective is to obtain reliable computer models of carbon/carbon material under hypersonic flight conditions, hypervelocity impacts, shock-loading situations such as booster-vehicle separation, and munition operation events. SwRI® has successfully modeled in the past ballistic impact on other composites, namely S-2 glass/epoxy, Kevlar/resin, polyethylene fibers/resin, and carbon fiber composites. This presentation will show test results relevant to the strength properties of the ACC-6 C/C material which were measured at quasistatic, medium, and the moderately high strain rates (~103 s—1) achievable in a conventional Split Hopkinson bar apparatus. Some of the tests were performed at both high-rates and high temperatures typical of hypersonic flight, something that, to the authors’ knowledge, has never been published in the past for this particular material. The test method will be presented, as well as the comparison of the stress-strain curves for the different temperatures and strain-rates of interest. A discussion of how the results can be used in the typical hydrocodes of interest will be included.

carbon/carbon↗

NASA NTRSDate not supplied

A Novel RF Architecture for Simultaneous Communication, Navigation, and Remote Sensing with Software-Defined Radio

The rapid growth of SmallSat and CubeSat missions at NASA has necessitated a re-evaluation of communication and remote-sensing architectures. Novel designs for CubeSat-sized single-board computers can now include larger Field-Programmable Gate Arrays (FPGAs) and faster System-on-Chip (SoCs) devices. These components substantially improve onboard processing capabilities so that varying subsystems no longer require an independent processor. By replacing individual Radio Frequency (RF) systems with a single software-defined radio (SDR) and processor, mission designers have greater control over reliability, performance, and efficiency. The presented architecture combines individual processing systems into a single design and establishes a modular SDR architecture capable of both remote-sensing and communication applications. This new approach based on a multi-input multi-output (MIMO) SDR features a scalable architecture optimized for Size, Weight, Power, and Cost (SWaP-C), with sufficient noise performance and phase-coherence to enable both remote-sensing and navigation applications, while providing a communication solution for simultaneous S-band and X-band transmission. This SDR design is developed around the NASA CubeSat Card Standard (CS2) that provides the required modularity through simplified backplane and interchangeable options for multiple radiation-hardened/tolerant processors. This architecture provides missions with a single platform for high-rate communication and a future platform to develop cognitive radio systems.

Advanced Avionics, Hybrid Processing, Data Process↗

NASA NTRS2021

Atoms to Aircraft to Spacecraft

The next generation of aerospace systems requires materials and structures that combine high performance at high utilization in short missions with the possibility of high rate production, without excessive non-recurring cost, to allow for rate flexibility and shorter structural life cycles. The development of materials and structures that offer this flexibility in rate without negatively influencing performance and economic viability will require a matching and overlapping experimental and computational design approach. The objective is to go from Atom to Airframe to Spaceframe for thermoplastic unidirectional tape based fastener-free assemblies. Thermoplastic composites are chosen as the focus because these materials allow for reversible fusion bonding in every stage of their life cycle after synthesis. Our strategy is to combine multi-scale computational approaches with multi-scale experimental activities to develop an understanding of and capabilities to manufacture custom unidirectional thermoplastic tape. This tape will be the basis for our high-rate multiple-technology manufacturing approach validated by the production of two representative demonstrators for urban air mobility vehicle structures. The multi-disciplinary team will work in an integrated manner to effectively combine computational approaches with experimental approaches at each stage of characteristic manufacturing flows. The team aims for tools and technology to quantify the thermo-rheological aspects of unidirectional tape-based production and assembly of aerospace quality thermoplastic components as well as for validated tools for unidirectional tape-based thermoplastic preform and part design and manufacture. The work will be used to design and build two demonstration structural parts characteristic for urban air mobility vehicles.

Paul Ziehl↗

NASA NTRS2005

Optical vector receiver operating near the quantum limit

An optical receiver concept or binary signals with performance approaching the quantum limit at low average signal background photons has been devised by Dolinar, however this receiver requires ideal optical combining and complicated real-time shaping of the local field, hence tends to be difficult to implement at high data rates. A simpler nulling receiver that approaches the quantum limit without complex optical processing, suitable for high-rate operation has been suggested earlier by Kennedy. Here we formulate a vector receiver concept that incorporates the Kennedy receiver together with a physical beamsplitter, but also utilizes the reflected signal component to improve signal detection. It is found that augmenting the Kennedy receiver with classical coherent detection at the auxiliary beamsplitter output, and optimally processing the vector observations, always improves on the performance of the Kennedy receiver alone, significantly so at low average photon rates. This is precisely the region of operation where modern codes approach channel capacity. It is also shown that the addition of background radiation has little effect on the performance of the coherent receiver component, suggesting a viable approach for near quantum-limited performance in high background environments

Lau, Chi-Wung↗

NASA NTRS2006

High-capacity communications from Martian distances part 4 : assessment of spacecraft pointing accuracy capabilities required for large Ka-band reflector antennas

Improved surface accuracy for deployable reflectors has brought with it the possibility of Ka-band reflector antennas with extents on the order of 1000 wavelengths. Such antennas are being considered for high-rate data delivery from planetary distances. To maintain losses at reasonable levels requires a sufficiently capable Attitude Determination and Control System (ADCS) onboard the spacecraft. This paper provides an assessment of currently available ADCS strategies and performance levels. In addition to other issues, specific factors considered include: (1) use of "beaconless" or open loop tracking versus use of a beacon on the Earth side of the link, and (2) selection of fine pointing strategy (body-fixed/spacecraft pointing, reflector pointing or various forms of electronic beam steering). Capabilities of recent spacecraft are discussed.

Bassily, Samir (Sam)↗

NASA NTRS2006

Solving Cassini's data glitch problem during coherency mode transition for Titan radar observations

We describe the problem of regular small telemetry losses incurred during coherency mode transitions in Cassini’s telecommunication. The project did not originally plan any corrective steps for avoiding these data losses, because of 1) the disparity between the small durations of the transitions (1-2 min) and large playback capability losses (15 min) needed for bracketing the transition time spans and 2) the unpredictable content of data downlinking during the transitions. However, as the intense science data return from the tour began, it became apparent that the impact of these small losses can sometimes be significant. We provide two examples of the impact on Radar-dedicated Titan flybys. In general, the impacts are larger for high-rate data and for data acquired during a targeted flyby of Titan and other icy satellites. Although the content of data during a transition for every downlink pass is unpredictable, we are certain that some important data will be lost on downlink passes dedicated to transmit the flyby data and it does not matter what part of the data will be hit by the transitions. We collected more than 200 days of data from Cassini tour operations between June 2004 and February 2005 to analyze the distributions of the start time and duration of the transitions. We found that the occurrence of a transition can be predicted within a 5-min window, with 95 percent confidence. Given that, it is possible to eliminate the data losses by pausing playback at the beginning of a transition for 5 minutes and resuming playback after transition completion. We briefly describe three operational fixes as to how to implement the playback pause, with the pros and cons for each method. Finally, we report the results of the method chosen by the project and implemented on the spacecraft for several Titan and icy satellites flybys between September and October, 2005.

Weld, K. R.↗

NASA NTRSDate not supplied

An Augmented Ground Station Architecture for Spacecraft-Initiated Communication Service Requests

Spacecraft performing science and exploration missions have increasingly complex and event-driven objectives, making communication needs difficult to predict in advance. Additional flexibility is required in space communication provider networks to effectively meet time-varying demand. We envision a framework for automated resource allocation in which requests for communications service are initiated by spacecraft based on current mission needs. We propose an augmented ground station configuration featuring a wide field-of-view antenna to receive transmissions from spacecraft requesting high-rate communications. A software suite to automate the service fulfillment process, including interfacing with external scheduling systems such as NASA’s Near Space Network, is described. Experimental results characterizing the physical-layer link between the wide field-of-view antenna and a software-defined radio testbed on the International Space Station are presented. We also discuss long-duration software testing on a ground-based testbed. Taken together, these proof-of-concept results demonstrate the feasibility of the concept to improve the responsiveness of space communications.

user-initiated service↗

NASA NTRSDate not supplied

A Prototype Early Planetary Organic Processor Assembly (OPA) Based on Dual-Stage Anaerobic Membrane Bioreactor (AnMBR) for Fecal and Food Waste Treatment and Resource Recovery

Long-duration, deep-space exploration and habitation missions demand robust and reliable technologies to ensure crew health, safety, and mission success. Local food production will be essential for crew nutrition and morale. However, at $10,000/lb, the payload costs and mass/volume limitations to transport and provide the necessary resources, including fertilizer, for an anticipated 30-month mission become challenging over time. For mission success and sustainability, the Environmental Control and Life Support System (ECLSS) of the near future will need to recover resources from all “waste” sources and be near-closed loop. Organic wastes (e.g., fecal and food) offer a renewable source of C, N, P, water and other trace elements necessary to sustain crop production. However, these high solidwastes are often difficult to treatdue to factors includingheterogeneity, complexity, high organic strength, and the presence of pathogens. To date, there is no flight-ready technology capable of treating mixed organic wastes, creating a technology gap for future space missions. To address this need, a prototype Organic Processor Assembly (OPA) was developed through collaboration between the University of South Florida (USF) and NASA’s Kennedy Space Center (KSC). The OPA is based on the anaerobic membrane bioreactor (AnMBR), a hybrid technology coupling high-rate anaerobic digestion with membrane filtration. The system is designed for an early planetary base (EPB) scenario to aid in closing the resource recovery loop and decreaseresupply dependence. This presentation discusses initial research pertaining to: 1) design challenges in maximizing hydraulic/organic throughputandReliability, Availability, Maintainability, and Safety(RAMS)while minimizingmass and volume; 2) create capabilities for treating simulated high solids waste under steady and non-steady state conditions; and 3) measuresolids performance parameter(s). Future research and development pertaining to further optimization on system operation, performance, and expanded treatment capabilities arepresented.

Bioreactor↗

NASA NTRSDate not supplied

Modeling Electro-Optic Frequency Comb Generation as a Pump Source for Quantum Communications

The Quantum Communications group at NASA GRC is focused on developing technologies and system architectures to enable future space-based quantum networks. High-repetition rate pulsed pump lasers are needed because the signal on the quantum channel cannot be amplified, hence entanglement generation rates can only be increased through high-rate pumping. Additionally, tunability in center frequency, pulse width, and repetition rate allows for a wider parameter space over which to optimize quantum channel frequency conversion efficiency, joint spectral engineering, and channel synchronization for high-fidelity entanglement swapping –a necessary stepping-stone towards quantum repeater development. One of the most flexible methods for high-repetition rate pulse generation is through spectral shaping–generating a frequency comb from a continuous-wave(CW)laser using electro-optic modulators (EOMs). As a result, this project focuses on analytically modeling and simulating the effects various EOMs such as phase and intensity modulators have on a CW source. Generating a tunable frequency comb as the pump source allows us to conveniently fine-tune the central frequency, repetition rate, and the spectral shape of our source to match the strict optimal parameters for any given entanglement source considered in the future. These models and simulations are to be used for comparison purposes for future experiments as well as for providing the Quantum Communications group a convenient tool to understand the effects of manipulating various parameters have on the outgoing frequency comb.

Electro-optic modulator↗

NASA NTRS2021

NASA-ISRO SAR (NISAR) Mission Status

The National Aeronautics and Space Administration (NASA) in the United States and the Indian Space Research Organisation (ISRO) are developing the NASA-ISRO Synthetic Aperture Radar (NISAR) mission, now planned for launch toward the end of 2022. The mission will exploit synthetic aperture radar to map Earth’s surface every 12 days, persistently on ascending and descending portions of the orbit, over all land and ice-covered surfaces. The mission’s primary objectives will be to study Earth land and ice deformation, and ecosystems, in areas of common interest to the US and Indian science communities. This single observatory solution with an L-band (24 cm wavelength) and S-band (10 cm wavelength) radar has a swath of over 240 km at fine resolution, using full polarimetry where needed. To achieve these unprecedented capabilities, both radars use a reflector-feed system, whereby the feed aperture elements are individually sampled to allow a scan-on-receive (“SweepSAR”) capability at both L-band and S-band. The L-band and S-band electronics and feed apertures, provided by NASA and ISRO respectively, share a common 12-m diameter deployable reflector/boom system, provided by NASA. These two radars, which can operate simultaneously, even with FPGA-based on-board digital beamforming and filtering to reduce data rates, produce prodigious amounts of data. Given the high data rates and ambitious coverage requirements, new technologies for high-rate Ka-band downlink complement these first-of-a-kind radar systems.

Kumar, Raj↗

NASA NTRS2021

Tunable Pseudocapacitive Intercalation of Chloroaluminate Anions into Graphite Electrodes for Rechargeable Aluminum Batteries

Rechargeable aluminum-graphite batteries using chloroaluminate-containing electrolytes have been the focus of significant research, particularly due to their high-rate capabilities. Engineered graphite electrodes have been shown to exhibit supercapacitor-like rate performance, despite the fact they store charge via the electrochemical intercalation of polyatomic AlCl4− anions. However, the origins of such rate capabilities are not well understood. Here, using electrochemical techniques, we disentangle quantitatively the diffusion-limited Faradaic, pseudocapacitive, and capacitive contributions to charge storage, revealing that AlCl4− anions intercalate into graphite with significant pseudocapacitive characteristics due to low ion diffusion limitations. Pristine and mildly exfoliated graphites are compared, where exfoliation resulted in significantly higher pseudocapacitive AlCl4− intercalation at the highest potential redox pair as well as higher galvanostatic capacity retention at faster discharge rates. The relationships between graphite structure, ion mass transport, and the overall rate of electrochemical AlCl4− intercalation are discussed. Ion diffusion within the electrolyte phase of the porous electrode is shown to play a key role in controlling the rate of intercalation at higher potentials and faster rates, which can be enhanced by reducing electrode tortuosity. The results establish that chloroaluminate anion intercalation into graphite exhibits non-diffusion-limited pseudocapacitive contributions that are tunable by modifying the graphite structure.

Jeffrey H. Xu↗

NASA NTRS2026

Manufacturing Process Development of a Carbon Fiber Reinforced Polymer Composite Shaft for Electric Motors

Electric aircraft applications require electric motors with increased specific power and efficiency. Composite structural components in motors are a potential solution for reducing motor mass, reducing magnetic losses, and limiting undesired conduction paths for fault, electromagnetic interference, or common-mode currents. In this report, manufacturing trials for a high-speed carbon fiber reinforced polymer composite motor shaft are presented. Four prototype shafts were produced using a hybrid biaxial/triaxial fabric that was circumferentially wrapped onto an additively manufactured high-temperature washout mandrel. An additional traditional overbraid approach was also evaluated and shows promise for high-rate, high-performance parts using automated manufacturing. This paper discusses the shaft design, manufacturing methods explored, material selection, the manufacturing trials, and the lessons learned. The results of this manufacturing investigation show feasibility for manufacturing composite shafts for electric motors.

Electric moto shaft↗

NASA NTRS2026

Fatigue Life of Flow-Formed Aluminum 2195 and 6061 Alloys

The successful design and fabrication of metallic cryotanks for commercial aviation applications require lightweight, durable materials capable of withstanding high pressures and cryogenic temperatures through tens of thousands of thermomechanical refueling cycles. Flow forming is an advanced manufacturing technique that offers high-rate production and scalability for fabricating integrally stiffened cylinders suitable for cryotank applications. This work establishes the durability of flow-formed aluminum alloys by characterizing their fatigue life performance under conditions that mimic cryotank refueling cycles. Residual stresses in flow-formed aluminum-lithium (Al-Li) 2195-T6 cylinders were assessed using the contour method and found to be minimal. Fatigue life testing was conducted on flow-formed Al-Li 2195-T6 at room temperature and cryogenic temperatures (-321°F [-196°C]), with wrought Al-Li 2195-T6 serving as a baseline for comparison. Results showed that flow-formed materials exhibited fatigue performance comparable to or better than wrought materials, with no statistically significant differences observed between different specimen orientations relative to processing directions. Fractography revealed reduced delaminations in the flow-formed Al-Li 2195 samples as compared to wrought, indicating potential improvement to the microstructure that could result in improved service properties. Texture analysis using electron backscattered diffraction (EBSD) indicated recrystallization during heat treatment, potentially contributing to reduced delamination susceptibility. These findings demonstrating flow-formed material durability coupled with the high manufacturing efficiency of flow forming, makes flow forming an attractive process to produce aircraft cryotanks.

EBF3↗