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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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At least 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

Testing of Flexible Ballutes in Hypersonic Wind Tunnels for Planetary Aerocapture

Studies were conducted for the In-Space Propulsion (ISP) Ultralightweight Ballute Technology Development Program to increase the technical readiness level of inflatable decelerator systems for planetary aerocapture. The present experimental study was conducted to develop the capability for testing lightweight, flexible materials in hypersonic facilities. The primary objectives were to evaluate advanced polymer film materials in a high-temperature, high-speed flow environment and provide experimental data for comparisons with fluid-structure interaction modeling tools. Experimental testing was conducted in the Langley Aerothermodynamics Laboratory 20-Inch Hypersonic CF4 and 31-Inch Mach 10 Air blowdown wind tunnels. Quantitative flexure measurements were made for 60 degree half angle afterbody-attached ballutes, in which polyimide films (1-mil and 3- mil thick) were clamped between a 1/2-inch diameter disk and a base ring (4-inch and 6-inch diameters). Deflection measurements were made using a parallel light silhouette of the film surface through an existing schlieren optical system. The purpose of this paper is to discuss these results as well as free-flying testing techniques being developed for both an afterbody-attached and trailing toroidal ballute configuration to determine dynamic fluid-structural stability. Methods for measuring polymer film temperature were also explored using both temperature sensitive paints (for up to 370 C) and laser-etched thin-film gages.

Buck, Gregory M.↗
NASA NTRS2008

Multiscale Computer Simulation of Failure in Aerogels

Aerogels have been of interest to the aerospace community primarily for their thermal properties, notably their low thermal conductivities. While such gels are typically fragile, recent advances in the application of conformal polymer layers to these gels has made them potentially useful as lightweight structural materials as well. We have previously performed computer simulations of aerogel thermal conductivity and tensile and compressive failure, with results that are in qualitative, and sometimes quantitative, agreement with experiment. However, recent experiments in our laboratory suggest that gels having similar densities may exhibit substantially different properties. In this work, we extend our original diffusion limited cluster aggregation (DLCA) model for gel structure to incorporate additional variation in DLCA simulation parameters, with the aim of producing DLCA clusters of similar densities that nevertheless have different fractal dimension and secondary particle coordination. We perform particle statics simulations of gel strain on these clusters, and consider the effects of differing DLCA simulation conditions, and the resultant differences in fractal dimension and coordination, on gel strain properties.

Good, Brian S.↗
NASA NTRS2010

A One-Dimensional Synthetic-Aperture Microwave Radiometer

A proposed one-dimensional synthetic- aperture microwave radiometer could serve as an alternative to either the two-dimensional synthetic-aperture radiometer described in the immediately preceding article or to a prior one-dimensional one, denoted the Electrically Scanned Thinned Array Radiometer (ESTAR), mentioned in that article. The proposed radiometer would operate in a pushbroom imaging mode, utilizing (1) interferometric cross-track scanning to obtain cross-track resolution and (2) the focusing property of a reflector for along-track resolution. The most novel aspect of the proposed system would be the antenna (see figure), which would include a cylindrical reflector of offset parabolic cross section. The reflector could be made of a lightweight, flexible material amenable to stowage and deployment. Other than a stowage/deployment mechanism, the antenna would not include moving parts, and cross-track scanning would not entail mechanical rotation of the antenna. During operation, the focal line, parallel to the cylindrical axis, would be oriented in the cross-track direction, so that placement of receiving/radiating elements at the focal line would afford the desired along-track resolution. The elements would be microwave feed horns sparsely arrayed along the focal line. The feed horns would be oriented with their short and long cross-sectional dimensions parallel and perpendicular, respectively, to the cylindrical axis to obtain fan-shaped beams having their broad and narrow cross-sectional dimensions parallel and perpendicular, respectively, to the cylindrical axis. The interference among the beams would be controlled in the same manner as in the ESTAR to obtain along-cylindrical- axis (cross-track) resolution and cross-track scanning.

Doiron, Terence↗
NASA NTRS2003

Organic/Inorganic Hybrid Polymer/Clay Nanocomposites

A novel class of polymer/clay nanocomposites has been invented in an attempt to develop transparent, lightweight, durable materials for a variety of aerospace applications. As their name suggests, polymer/ clay nanocomposites comprise organic/ inorganic hybrid polymer matrices containing platelet-shaped clay particles that have sizes of the order of a few nanometers thick and several hundred nanometers long. Partly because of their high aspect ratios and high surface areas, the clay particles, if properly dispersed in the polymer matrix at a loading level of 1 to 5 weight percent, impart unique combinations of physical and chemical properties that make these nanocomposites attractive for making films and coatings for a variety of industrial applications. Relative to the unmodified polymer, the polymer/ clay nanocomposites may exhibit improvements in strength, modulus, and toughness; tear, radiation, and fire resistance; and lower thermal expansion and permeability to gases while retaining a high degree of optical transparency.

Park, Cheol↗
NASA NTRS2011

Optical Coating Performance for Heat Reflectors of the JWST-ISIM Electronic Component

A document discusses a thermal radiator design consisting of lightweight composite materials and low-emittance metal coatings for use on the James Webb Space Telescope (JWST) structure. The structure will have a Thermal Subsystem unit to provide passive cooling to the Integrated Science Instrument Module (ISIM) control electronics. The ISIM, in the JWST observatory, is the platform that provides the mounting surfaces for the instrument control electronics. Dissipating the control electronic generated-heat away from JWST is of paramount importance so that the spacecraft s own heat does not interfere with the infrared-light gathering of distant cosmic sources. The need to have lateral control in the emission direction of the IEC (ISIM Electronics Compartment) radiators led to the development of a directional baffle design that uses multiple curved mirrorlike surfaces. This concept started out from the so-called Winston non-imaging optical concentrators that use opposing parabolic reflector surfaces, where each parabola has its focus at the opposite edge of the exit aperture. For this reason they are often known as compound parabolic concentrators or CPCs. This radiator system with the circular section was chosen for the IEC reflectors because it offers two advantages over other designs. The first is that the area of the reflector strips for a given radiator area is less, which results in a lower mass baffle assembly. Secondly, the fraction of energy emitted by the radiator strips and subsequently reflected by the baffle is less. These fewer reflections reduced the amount of energy that is absorbed and eventually re-emitted, typically in a direction outside the design emission range angle. A baffle frame holds the mirrors in position above a radiator panel on the IEC. Together, these will direct the majority of the heat from the IEC above the sunshield away towards empty space.

Rashford, Robert A.↗
NASA NTRS2012

Mars Sample Return Using Solar Sail Propulsion

Many Mars Sample Return (MSR) architecture studies have been conducted over the years. A key element of them is the Earth Return Stage (ERS) whose objective is to obtain the sample from the Mars Ascent Vehicle (MAV) and return it safely to the surface of the Earth. ERS designs predominantly use chemical propulsion [1], incurring a significant launch mass penalty due to the low specific impulse of such systems coupled with the launch mass sensitivity to returned mass. It is proposed to use solar sail propulsion for the ERS, providing a high (effective) specific impulse propulsion system in the final stage of the multi-stage system. By doing so to the launch mass of the orbiter mission can be significantly reduced and hence potentially decreasing mission cost. Further, solar sailing offers a unique set of non-Keplerian low thrust trajectories that may enable modifications to the current approach to designing the Earth Entry Vehicle by potentially reducing the Earth arrival velocity. This modification will further decrease the mass of the orbiter system. Solar sail propulsion uses sunlight to propel vehicles through space by reflecting solar photons from a large, mirror-like surface made of a lightweight, reflective material. The continuous photonic pressure provides propellantless thrust to conduct orbital maneuvering and plane changes more efficiently than conventional chemical propulsion. Because the Sun supplies the necessary propulsive energy, solar sails require no onboard propellant, thus reducing system mass. This technology is currently at TRL 7/8 as demonstrated by the 2010 flight of the Japanese Aerospace Exploration Agency, JAXA, IKAROS mission. [2]

Johnson, Les↗
NASA NTRS2008

NASA Subsonic Rotary Wing Project - Structures and Materials Discipline

The Structures & Materials Discipline within the NASA Subsonic Rotary Wing Project is focused on developing rotorcraft technologies. The technologies being developed are within the task areas of: 5.1.1 Life Prediction Methods for Engine Structures & Components 5.1.2 Erosion Resistant Coatings for Improved Turbine Blade Life 5.2.1 Crashworthiness 5.2.2 Methods for Prediction of Fatigue Damage & Self Healing 5.3.1 Propulsion High Temperature Materials 5.3.2 Lightweight Structures and Noise Integration The presentation will discuss rotorcraft specific technical challenges and needs as well as details of the work being conducted in the six task areas.

Halbig, Michael C.↗
NASA NTRS2014

Lightweight Radiator for in Space Nuclear Electric Propulsion

Nuclear electric propulsion (NEP) is a promising option for high‐speed in‐space travel due to the high energy density of nuclear fission power sources and efficient electric thrusters. Advanced power conversion technologies may require high operating temperatures and would benefit from lightweight radiator materials. Radiator performance dictates power output for nuclear electric propulsion systems. Game‐changing propulsion systems are often enabled by novel designs using advanced materials. Pitch‐based carbon fiber materials have the potential to offer significant improvements in operating temperature, thermal conductivity, and mass. These properties combine to allow advances in operational efficiency and high temperature feasibility. An effort at the NASA Marshall Space Flight Center to show that woven high thermal conductivity carbon fiber mats can be used to replace standard metal and composite radiator fins to dissipate waste heat from NEP systems is ongoing. The goals of this effort are to demonstrate a proof of concept, to show that a significant improvement of specific power (power/mass) can be achieved, and to develop a thermal model with predictive capabilities making use of constrained input parameter space. A description of this effort is presented.

Craven, Paul↗
NASA NTRS2014

An Analysis of the FY-1C, Iridium 33, and Cosmos 2251 Fragments

The beginning of the year 2013 marks the sixth anniversary of the destruction of the Fengyun-1C (FY-1C) weather satellite as the result of an anti-satellite test conducted by China in January 2007 and the fourth anniversary of the accidental collision between Cosmos 2251 and the operational Iridium 33 in February 2009. These two events represent the worst satellite breakups in history. A total of 5579 fragments have been cataloged by the U.S. Space Surveillance Network (SSN), and almost 5000 of them were still in orbit in January 2013. In addition to these cataloged objects, hundreds of thousands (or more) of fragments down to the millimeter size regime were also generated during the breakups. These fragments are too small to be tracked by the SSN, but are large enough to be a safety concern for human space activities and robotic missions in low Earth orbit (LEO, the region below 2000 km altitude). Like their cataloged siblings, many of them remain in orbit today. These two breakup events dramatically changed the landscape of the orbital debris environment in LEO. The spatial density of the cataloged population in January 2013 is shown as the top blue curve. The combined FY-1C, Iridium 33, and Cosmos 2251 fragments (black curve) account for about 50 percent of the cataloged population below an altitude of 1000 km. They are also responsible for the concentrations at 770 km and 850 km, altitudes at which the collisions occurred. The effects of the FY-1C, Iridium 33, and Cosmos 2251 fragments will continue to be felt for decades to come. For example, approximately half of the generated FY-1C fragments will remain in orbit 20 years from now. In general, the Iridium 33 and Cosmos 2251 fragments will decay faster than the FY-1C fragments because of their lower altitudes. Of the Iridium 33 and Cosmos 2251 fragments, the former have much shorter orbital lifetimes than the latter, because lightweight composite materials were heavily used in the construction of the Iridium vehicle, leading to the higher area-to-mass ratios of the fragments.

Liou, J.-C.↗
NASA NTRSDate not supplied

ANALYSIS OF THE MSL/MEDLI ENTRY DATA WITH COUPLED CFD AND MATERIAL RESPONSE.

The Mars Science Laboratory (MSL) was protected during its atmospheric entry by an instrumented heat-shield using NASA's Phenolic Impregnated Carbon Ablator (PICA) material. PICA is a lightweight carbon fiber/polymeric resin material that offers out-standing performances for protecting probes during planetary entry. The Mars Entry Descent and Landing Instrument (MEDLI) suite on MSL offers unique in-flight validation data for models of material response and atmospheric entry. MEDLI recorded, among other things, time-resolved in-depth temperature data of PICA using thermocouple sensors assembled in the MEDLI Integrated Sensor Plugs (MISP). The objective of this work is to showcase and analyze the coupling between the material response and the aerothermal environment. As shown in Figure 1, the workflow is divided into the following steps. First, the aerothermal properties are computed in the Data Parallel Line Relaxation (DPLR) code [3] and used with the Nonequilibrium air radiation (NEQAIR) program [8] to compute radiative heating. Second, the thermal response inside the material is computed in the Porous material Analysis Toolbox based on Open-FOAM (PATO) using a fixed blowing correction parameter. Third, the pyrolysis gases computed in PATO are used as inputs to a blowing boundary condition within DPLR. Fourth, the new environment properties from DPLR are used in NEQAIR to provide an updated solution, then both the updated aerothermal environment and radiative heating are used in PATO without blowing correction. The third and fourth steps are then repeated until convergence in surface temperature is obtained. Convergence in the radiative heating is generally achieved before surface temperature, at which point the radiative heating is no longer updated. Char mass loss rates are forced to zero to produce a non-receding surface condition. For early time points in the trajectory, where flow around the MSL aeroshell is rarefied, the Direct Simulation Monte Carlo (DSMC) code, SPARTA, is used to compute the aerothermal environment. Iteration between PATO and SPARTA is not performed due to the computational cost of DSMC simulations. Preliminary results of the coupling between PATO and DPLR for the MSL heatshield atmospheric entry model are presented in Figures 2-4 at 65 seconds after entry interface. Figure 2 shows the surface temperature results from an uncoupled simulation in PATO with the blowing correction parameter applied (left) along with the coupled surface temperature after iteration (right). Figure 3 shows the surface temperature along the centerline from windward to leeward for easier comparison. Figure 4 shows the coupled and uncoupled pyrolysis gas blowing rate. Mars 2020 used a similar heatshield consisting of PICA for thermal protection during entry, descent, and landing. In preparation for Mars 2020 post-flight analysis, the predictive material response capability is benchmarked against flight data from MEDLI. This work represents an important milestone toward the development of validated predictive capabilities for designing thermal protection systems for planetary probes.

Mars Science Laboratory↗
NASA NTRS2022

Novel Processing, Testing and Characterization of Copper/Carbon Nanotube (Cu/CNT) Yarn Composite Conductor

Sustainable electrified aircraft propulsion (EAP) is likely to lead to an increase in the electrical wiring contained within a single aircraft. Since the electrical resistance and mass of copper (Cu) conductors are associated with power losses, it is desirable to design high-conductivity lightweight conductor materials, thus reducing the mass of components like motor windings, low-voltage signal cables, and transmission cables for data and power to improve the overall energy efficiency. This paper describes a unique framework for manufacturing metalized carbon nanotube (CNT) composite conductors, measuring their electrical conductivity and strength, and modeling the overall conductivity and current sharing within such composites. Tensile testing was conducted on the processed composite conductor cables with the use of acoustic emission and electrical resistivity to determine stress-dependent-failure mechanisms while monitoring the electrical conductivity. The average of measured electrical conductivities of annealed Cu/CNT samples from batch 5 was greater than theoretical predictions by 9.8 percent and was also greater than the conductivity of pure annealed Cu by 4.8 percent and had comparable ultimate tensile strengths. Additionally, those Cu/CNT samples provide a 13.5% weight saving over current state of the art copper wires. Theories explaining improved intrinsic conductivity are discussed.

Metalized CNT↗
NASA NTRSDate not supplied

Recent Advances in Structural Carbon Nanotube Composites

Carbon nanotubes (CNT) have been a subject of investigation for more than two decades. Part of the interest in CNTs was driven by CNT tensile mechanical properties at the nanoscale that suggest their potential to outperform state-of-the-art (SOA) lightweight structural materials. Early work on the development of CNT nanocomposites involved the dispersion of CNT powder into polymer matrices. Although low levels of CNT doping resulted in meaningful increases in electrical conductivity to enable applications such as electrostatic charge dissipation, the highest concentrations of CNTs in these lightly doped nanocomposites did not yield mechanical properties that could compete with SOA carbon fiber composites. The maximum concentration of CNTs in lightly doped nanocomposites was limited to about 5% due to increases in viscosity that prevent the fabrication of good quality nanocomposites. At the lower concentrations, properties of the resulting nanocomposites were analogous to those of composites made with very short, chopped carbon fibers. About ten years ago, CNTs became available in continuous fiber form, allowing the investigation of processing methods to incorporate much higher CNT content into composites. Recent developments in CNT composite fabrication have yielded improved mechanical properties and indicate that while some standard carbon fiber composite processing methods can be used, CNTs have unique microstructural features that require techniques tailored to access the hierarchical features of CNTs. This presentation will discuss the evolution of structural CNT mechanical property advancements and collaboration mechanisms for research across federal labs, academia, and industry that accelerated the maturation of structural CNTs.

Carbon Nanotubes↗
NASA NTRSDate not supplied

P-band Antenna Array for NASA's Space Exploration Synthetic Aperture Radar (SESAR) Instrument

A dual-polarized, wideband, lightweight P-band (435 MHz) antenna element and array for spaceborne radar applications has been developed for NASA’s SESAR (Space Exploration Synthetic Aperture Radar) instrument for planetary synthetic aperture radar (SAR) applications. The antenna array is based on lightweight, low-profile antenna elements that form the building blocks of configurable “array panels” that can in turn be used to build larger arrays consisting of multiple panels. The element design combines a novel, mostly planar conductor antenna element geometry with a robust lightweight composite material construction.

Synthetic Aperture Radar↗
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↗
NASA NTRS2025

The Shape Effect: Influence of 1D and 2D Boron Nitride Nanostructures on the Radiation Shielding, Thermal, and Damping Properties of High-Temperature Epoxy Composites

In space exploration, lightweight multifunctional materials capable of shielding neutron radiation, dissipating heat, and providing damping are essential. Polymer composites reinforced with boron nitride (BN) nanomaterials—specifically one-dimensional boron nitride nanotubes (BNNTs) and two-dimensional boron nitride nanoplatelets (BNNPs)—offer promising solutions. This study investigates how BN nanomaterial morphology influences the performance of high-temperature (HT) epoxy composites. We developed ultralightweight, three-dimensional BN foams comprising 1D BNNTs, 2D BNNPs, and hybrid 1D BNNT/2D BNNP structures via freeze-drying, then infiltrated them with HT epoxy to form dense composites. The BNNT foam exhibited the highest neutron radiation shielding, with a mass absorption coefficient of 26.64 cm2 g −1 , outperforming the hybrid foam (18.18 cm 2 g −1 ) and the BNNP foam (11.12 cm 2 g −1 ). A similar trend was observed in the HT epoxy composites; incorporating these foams at least doubled the mass absorption coefficient compared to the neat polymer. In terms of thermal conductivity, the BNNT/BNNP foam-epoxy composite achieved the highest value of 0.34 W m −1 K −1 , a 2.13-fold increase over neat HT epoxy. The BNNT/BNNP foam-epoxy composites also improved by 1.88 and 1.75 times, respectively. Mechanical testing revealed that BNNP foams withstood the highest loads during nanoindentation (3.53 kN), followed by BNNT/BNNP foams (1.93 kN) and BNNT foams (1.56 kN). All BN foam-epoxy composites exhibited enhanced damping properties, with tan δ increasing by at least 30 % compared to neat HT epoxy. These findings elucidate the impact of BN nanomaterial morphology on the multifunctional performance of HT epoxy composites, offering insights for developing high-performance, tailorable materials for demanding environments.

Kazue Orikasa↗
DOE OSTI2024

Leverage modern artificial intelligence (AI) enabled systems for waste reduction

Manufacturing industries continue to face challenges in reducing waste, as upstream strategies such as source reduction and product redesign require a deeper understanding of processes compared to conventional recycling methods. Recent advancements in artificial intelligence (AI) and machine learning (ML) have opened new opportunities to integrate modern computational techniques with traditional waste minimization strategies. This paper explores AI-enabled approaches for product redesign, source reduction, and recycling that can significantly reduce waste generation while improving efficiency and sustainability. AI-driven material substitution and lightweighting in product design enable discovery of novel materials with optimized properties, reducing waste without compromising performance. Reinforcement learning models optimize process parameters, raw material specifications, and machine sequencing to minimize production losses, while Industrial Internet of Things (IIoT) systems paired with AI analytics enhance real-time waste tracking, predictive maintenance, and quality inspection. Furthermore, AI-based demand forecasting and production planning reduce overproduction and excess inventory, as demonstrated in industrial applications. In recycling, ML-powered pattern recognition and robotic sorting technologies achieve higher accuracy in waste segregation, directly improving recycling efficiency. Complementary solutions such as smart bins and AI-enabled waste pickup scheduling optimize collection logistics, reducing both costs and emissions. Although implementation requires upfront investment in infrastructure and training, the long-term benefits include higher material efficiency, reduced waste, improved product quality, and stronger sustainability outcomes across the supply chain. By leveraging AI-enabled systems, manufacturers can align waste minimization efforts with circular economy principles, creating scalable solutions for both industry and society.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗