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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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347 records · Page 14

Reliability Assessment of Solid-State Circuit Breakers (CRADA CRD-21-21469, Project 4 Final Report)

Growth in power requirements and the complexity of emerging distribution systems are creating the need for new solid-state products for many applications. The qualification requirements, testing standards and life-cycle management practices of solid-state devices used in protection applications is not established. The project will leverage newly developed accelerated testing capabilities design specifically for protection applications to generate large data sets that will enable advanced digital techniques for data analysis and embedded health monitoring.

14 SOLAR ENERGY

Space Station battery system design and development

The Space Station Electric Power System will rely on nickel-hydrogen batteries in its photovoltaic power subsystem for energy storage to support eclipse and contingency operations. These 81-Ah batteries will be designed for a 5-year life capability and are configured as orbital replaceable units (ORUs), permitting replacement of worn-out batteries over the anticipated 30-year Station life. This paper describes the baseline design and the development plans for the battery assemblies, the battery ORUs and the battery system. Key elements reviewed are the cells, mechanical and thermal design of the assembly, the ORU approach and interfaces, and the electrical design of the battery system. The anticipated operational approach is discussed, covering expected performance as well as the processor-controlled charge management and discharge load allocation techniques. Development plans cover verification of materials, cells, assemblies and ORUs, as well as system-level test and analyses.

Haas, R. J.

Space Electrochemical Research and Technology

Individual papers presented at the conference address the following topics: development of a micro-fiber nickel electrode for nickel-hydrogen cell, high performance nickel electrodes for space power application, bending properties of nickel electrodes for nickel-hydrogen batteries, effect of KOH concentration and anions on the performance of a Ni-H2 battery positive plate, advanced dependent pressure vessel nickel hydrogen spacecraft cell and battery design, electrolyte management considerations in modern nickel hydrogen and nickel cadmium cell and battery design, a novel unitized regenerative proton exchange membrane fuel cell, fuel cell systems for first lunar outpost - reactant storage options, the TMI regenerable solid oxide fuel cell, engineering development program of a closed aluminum-oxygen semi-cell system for an unmanned underwater vehicle, SPE OBOGS on-board oxygen generating system, hermetically sealed aluminum electrolytic capacitor, sol-gel technology and advanced electrochemical energy storage materials, development of electrochemical supercapacitors for EMA applications, and high energy density electrolytic capacitor.

Richard M Wilson

Evaluation of Anomaly Detection Capability for Ground-Based Pre-Launch Shuttle Operations

This chapter will provide a thorough end-to-end description of the process for evaluation of three different data-driven algorithms for anomaly detection to select the best candidate for deployment as part of a suite of IVHM (Integrated Vehicle Health Management) technologies. These algorithms were deemed to be sufficiently mature enough to be considered viable candidates for deployment in support of the maiden launch of Ares I-X, the successor to the Space Shuttle for NASA's Constellation program. Data-driven algorithms are just one of three different types being deployed [3],[5]. The other two types of algorithms being deployed include a "rule-based" expert system, and a "model-based" system. Within these two categories, the deployable candidates have already been selected based upon qualitative factors such as flight heritage. For the rile-based system, SHINE (Spacecraft High-speed Inference Engine) has been selected for deployment, which is a component of BEAM (Beacon-based Exception Analysis for Multimissions) [4], a patented technology developed at NASA's JPL (Jet Propulsion Laboratory) and serves to aid in the management and identification of operational modes. For the "model-based" system, a commercially available package developed by QSI (Qualtech Systems, Inc.), TEAMS (Testability Engineering and Maintenance System) [1] has been selected for deployment to aid in diagnosis. In the context of this particular deployment, distinctions among the use of the terms "data-driven," "rule-based," and "model-based," call found in [5]. Although there are three different categories of algorithms that have been selected for deployment, our main focus in this chapter will be on the evaluation of three candidates for data-driven anomaly detection. These algorithms will be evaluated upon their capability for robustly detecting incipient faults or failures in the ground-based phase of pre-launch space shuttle operations, rather than based oil heritage as performed in previous studies [5]. Robust detection will allow for the achievement of pre-specified minimum false alarm and/or missed detection rates in the selection of alert thresholds. All algorithms will also be optimized with respect to all of these same criteria. Our study relies upon the use of Shuttle data to act as was a proxy for and in preparation for application to Ares I-X data, which uses a very similar hardware platform for the subsystems that are being targeted (TVC - Thrust Vector Control subsystem for the SRB (Solid Rocket Booster)).

False Alarms

Fuel Heating System Design and Thermal Modeling for Aviation Combustion Research

Aviation fuels offer substantial heat-sink capability that can be applied to aircraft thermal-management strategies and advanced propulsion-system concepts. Accurate control of fuel temperature is critical for understanding combustion behavior and supporting high temperature fuel experimental studies. This work describes the modeling and experimental validation of a portable, high temperature fuel-conditioning system designed for multiple NASA Glenn Research Center’s combustion facilities. The system utilizes a circulating-oil heating unit and modular tube-in-tube heat exchangers capable of conditioning Jet-A to temperatures approaching 600 K. A Thermal Desktop model was created to analyze heat exchanger configurations and predict performance across a range of operating conditions. Model predictions were compared with measurements collected in the CE-13C test facility, showing good agreement across the tested flow range except at low fuel flow rate around 2 kg/hr. Results provide guidance for sizing future fuel heating system for combustion research applications.

Jet fuel heating system

Nickel hydrogen battery expert system

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

Shiva, Sajjan G.

Impact of Advances in Anion Exchange Membranes and Ionomers on Alkaline Fuel Cells

Abstract The operation of low‐temperature electrochemical energy conversion systems (fuel cells, electrolyzers) at high pH values is of perennial interest due to the possibility of moving away from expensive platinum group metal catalysts and reducing cost. Historically, the anion exchange membranes (AEMs) and ionomers have been hampered by performance (ionic conductivity, mechanical strength) and chemical stability issues. In this context, select developments over the past decade in alternate AEM chemistries, water management methods, and production of membrane electrode assemblies (MEAs) that have enabled a significant leap in performance of alkaline fuel cells are examined. These developments are linked to performance improvements in alkaline H 2 /O 2 fuel cells and also consider developments in alkaline fuel cells using nitrogen‐containing fuels (ammonia, hydrazine), carbon‐containing fuels (alcohols, glycols), and boron‐containing fuels (sodium borohydride, ammonia borane). Finally, current challenges and bottlenecks are identified, and potential solutions are proposed.

Chemistry

Power performance and loads characterization of laboratory-scale cross-flow rotors fabricated using additive manufacturing

Tidal energy conversion is a relatively new application for additive manufacturing (AM), where the focus has been on fabricating axial-flow turbine blades. AM techniques add material precisely where it is needed, creating more complex shapes with less waste. Cross-flow rotor geometry presents an opportunity for AM to improve rotor performance by fabricating features that cannot be created economically via conventional manufacturing. The challenges associated with using AM in cross-flow design include water resistance and degradation over time while retaining a level of quality equivalent to conventionally machined parts. In this work, AM materials were tested by environmentally conditioning samples in a seawater tank for 5 months, followed by performance and phase-resolved load testing of laboratory-scale rotors in a hydraulic flume. We found that while metals like titanium and Inconel have excellent performance in marine environments, achieving the desired geometry and performance is difficult. Thermoplastics degraded in seawater but were easier to form into desired geometries and could exceed the performance of an aluminum control rotor. Warping and surface finish were significant detractors from AM rotor performance. These results suggest that the primary benefits of using AM for cross-flow rotors is to quickly fabricate and test unconventional rotor geometries.

16 TIDAL AND WAVE POWER

Enhancing Battery Safety with Fractional Thermal Runaway Calorimetry

Effective thermal management systems, designed to handle the impacts of thermal runaway (TR) and to prevent cell-to-cell propagation, are key to safe operation of lithium-ion (Li-ion) battery assemblies. Critical factors for optimising these systems include the total energy released during a single cell TR event and the fraction of the total energy that is released through the cell casing versus through the ejecta material. A unique fractional thermal runaway calorimeter (FTRC), designed to characterise said critical factors, was utilised to examine the TR behaviour of Li-ion cells). Delegates will be provided with an in-depth discussion on what fractional thermal runaway calorimetry is and how it benefits the development of safe and optimised battery assemblies that protect against thermal runaway. Delegates will see calorimetry data associated with a variety of Li-ion cells. Data presented is relevant to any industry that utilises high-energy Li-ion cells in closed environments and has a need to focus on safety.

Walker, William

NASA Talks: Space Shuttle Columbia - Lessons Learned: Columbia Launch and Recovery

On February 25, 2026, this NASA Talk was held regarding the Space Shuttle Columbia (Columbia Launch & Recovery). Crew & Thermal System Division (EC) partnered with Kennedy Space Center (KSC) and Engineering Directorate (EA) to bring this talk to Johnson Space Center (JSC) centering on what led up to and transpired after the Space Shuttle Columbia accident. Some recovered debris was on exhibit during the talk. Retired NASA Columbia Vehicle Manager Scott Thurston presented this talk. Mr. Thurston brings a wealth of knowledge from his mission experience. This talk was timely and a solemn reminder of the critical importance of diligence, safety, and excellence in our work. EA Director Julie Kramer White welcomed the 400+ center-wide in-person audience, and EC Division Chief Rubik Sheth introduced the speakers. This event was held in the JSC Teague Auditorium, recorded, and executed by the EC in-house STAR Productions team. This record includes an mp4 video presentation with a run time of 36 min. 20 sec.; in color; with sound.

NASA Talks

Boron Coordination in Multicomponent Glasses: Analytical Models and Machine Learning With Uncertainty

Borosilicate glasses are extensively used in a variety of applications from kitchenware to nuclear waste immobilization due to the strong network formed by the Si-O-B bond that makes it resistant to chemical corrosion and gives it a low thermal expansion. Boron, however, exists in both trigonal BO3 and tetrahedral BO4 bonds in glass systems, which impacts the chemical durability and thermal resistance of the glass, amongst other properties. Boron coordination (N4), or the ratio of the amount of BO4 to BO3 within a glass, may aid in predicting these properties but is difficult to derive without experimental data due to the complexity of impacts from varied glass compositions and processing factors. For this reason, compositional models have been developed to predict boron coordination, but the models typically include a limited number of glass components. To help fill this gap in the models, in this work, a diverse multicomponent glass dataset of 809 glasses is compiled from a literature search, and then a number of analytical and machine learning (ML) models are trained on the dataset. Previously developed modified Bernstein and modified Du Stebbins analytical models were fitted to update parameters with the new dataset. Then, partially Bayesian neural networks, Gaussian process regressor, and heteroskedastic deterministic neural networks were evaluated. The ML models examined all have different strategies to overcome the potential for overfitting as a result of a limited training dataset, and return results that account for model uncertainty, which can be valuable for understanding model reliability. For the first time, cooling rate is introduced as an input parameter for ML models, showing consistent improvements in performance and solidifying the importance of including parameters outside of composition alone for N4 prediction. The machine learning models examined here show promise in accurate predictions of boron coordination in borosilicate glasses, all achieving R2 values of 0.91.

boron coordination

Test Results of a Ten Cell Bipolar Nickel-hydrogen Battery

A study was initiated to design and evaluate a new design concept for nickel-hydrogen cells. This concept involved constructing a battery in a bipolar stack with cells consisting of a one plate for each nickel and hydrogen electrode. Preliminary designs at the system level of this concept promised improvements in both volumetric and gravimetric energy densities, thermal management, life extension, costs, and peak power capability over more conventional designs. Test results were most encouraging. This preprototype battery, built with less than ideal components and hardware, exceeded expectations. A total of 2000 LEO cycles at 80 percent depth of discharge were accrued. A cycle life goal of 30,000 cycles appears achievable with minor design changes. These improvements include advanced technology nickel electrodes, insulated bipolar plates and specifically designed frames to minimize shunt currents. The discharge rate capability of this design exceeds 25C. At the 10C discharge rate, 80% of the battery capacity can be withdrawn in six minutes. This data shows that the bipolar design is well suited for those applications requiring high peak power pulses.

Cataldo, R. L.

Lessons learned from the development and implementation of a workforce training curriculum for advanced controls for high performance HVAC systems

Over the past decade, academic research on advanced controls has slowly transitioned into new software platforms, giving rise to various companies developing and deploying these innovative products, including solutions for light commercial HVAC systems. However, the current workforce remains widely unprepared to install, maintain and operate these systems, particularly complex software-based control platforms, as most workforce training programs still focus on traditional building automation for large commercial buildings. This paper presents the development and piloting of curriculum for three key types of professionals: ● Technicians (trade-level): installing and maintaining modern high-performance HVAC systems and controls ● Programmers (undergrad-level): developing and implementing advanced controls ● Engineers and energy professionals (undergrad/grad-level): managing and evaluating system performance We share details of the material developed including training videos, open-source software, instruction manuals. We also present the results of a pilot implementation of the training materials with real students.

Casillas, Armando

Experimental investigation of a closed vapour box module for a divertor-like configuration in Magnum-PSI

Efficient management of extreme heat fluxes in the divertor region to extend the lifetime of the components remains a critical challenge for the realization of nuclear fusion-based power plants. Among the alternative concepts explored for the divertor region, the use of liquid metals, particularly lithium, is of interest due its ability to dissipate the incoming plasma heat flux through the vapour shielding effect (VS). In this work, we experimentally investigated a ‘closed’ configuration of a dedicated Vapour Box Module (VBM) in the linear plasma device Magnum-PSI. The goal of the experiments is to simulate the vapour box divertor environment conditions and assess its performance in terms of power mitigation and redistribution and lithium confinement. Initial testing without Li demonstrated the efficacy of a closed VBM structure in inducing detachment via neutral gas accumulation. Apertures which enabled non-condensing gas to be effectively pumped while ensuring lithium condensed on the inner surfaces were therefore added. With a lithium capillary porous structure target used, lithium is directly vaporized by the plasma, forming a dense lithium vapour cloud that interacts with the incoming plasma. This resulted in a significant reduction of the target temperature of at least 48%, together with a temperature locking effect, a phenomenon typically observed in the VS regime. Lithium vapour confinement within the VBM was strongly correlated with the wall temperature. Relatively cold walls promoted Li re-condensation and therefore improved Li confinement, although with the expected trade-off of increased hydrogenic retention on lithium-wetted surfaces. As the wall temperature increased, the confinement efficiency decreased, consistent with reduced Li re-condensation and thermally activated Li–H chemistry and remobilization at the walls. Diagnostic measurements through embedded thermocouples and calorimetry revealed that lithium vaporization and re-condensation processes also playedsignificant roles in plasma power dissipation. The results advance the case for a closed divertor chamber with direct lithium evaporation from the strike-points as a viable method to manage divertor heat fluxes in future fusion reactors.

Romano, Fabio [Dutch Institute for Fundamental Ene

The NERVA Engine Program

The objective of the NERVA engine program is the development of a nuclear rocket engine for use in space missions. The letters N E R V A mean Nuclear Engine for Rocket Vehicle Application. NERVA is a long-range program that had its beginning in about 1955 when the Los Alamos Scientific Laboratory began preliminary studies on the feasibility of thermal reactors for rocket application. At about the same time, the Livermore Laboratory began parallel studies, but this dual effort was discontinued about a year later. In 1961 an industrial contractor team, the Aerojet-General Corporation and the Westinghouse Electric Corporation, was selected to carry out the development of the NERVA engine, and their activity began in mid-1961. Aerojet was made the prime contractor with responsibility for the complete engine development program, and Westinghouse was made a principal subcontractor with responsibility for the development of the reactor. A government field office, the Cleveland Extension of the Space Nuclear Propulsion Office, was set up to manage this development program. This office is located in Cleveland because of the availability of technical backup at the Lewis Research Center.

Lester C Corrington

International Ultraviolet Explorer (IUE) Battery History and Performance

The "International Ultraviolet Explorer (IUE) Battery History and Performance" report provides the information on the cell/battery design, battery performance during the thirty eight (38) solar eclipse seasons and the end-of-life test data. It is noteworthy that IUE spacecraft was an in-house project and that the batteries were designed, fabricated and tested (Qualification and Acceptance) at the Goddard Space Flight Center. A detailed information is given on the cell and battery design criteria and the designs, on the Qualification and the Acceptance tests, and on the cell life cycling tests. The environmental, thermal, and vibration tests were performed on the batteries at the battery level as well as with the interface on the spacecraft. The telemetry data were acquired, analyzed, and trended for various parameters over the mission life. Rigorous and diligent battery management programs were developed and implemented from time to time to extend the mission life over eighteen plus years. Prior to the termination of spacecraft operation, special tests were conducted to check the battery switching operation, battery residual capacity, third electrode performance and battery impedance.

Rao, Gopalskrishna M.

NASA Talks: Space Shuttle Columbia - Lessons Learned

On February 25, 2026, two NASA Talks were held regarding the Space Shuttle Columbia (Columbia Launch & Recovery, Columbia Reconstruction, Investigation, Causes & Key Takeaways). Crew & Thermal System Division (EC) partnered with Kennedy Space Center (KSC) and Engineering Directorate (EA) to bring these talks to Johnson Space Center (JSC) centering on what led up to and transpired after the Space Shuttle Columbia accident. Some recovered debris was on exhibit during the talks. NASA Mishap Program Specialist David Erickson and retired NASA Columbia Vehicle Manager Scott Thurston presented these talks. Mr. Erickson supports NASA mishap investigations and assists with the development of NASA's new Columbia Learning Center at KSC. Mr. Thurston brought a wealth of knowledge from his mission experience. These talks were timely and a solemn reminder of the critical importance of diligence, safety, and excellence in our work. EA Director Julie Kramer White welcomed the 400+ center-wide in-person audience, and EC Division Chief Rubik Sheth introduced the speakers. This event was held in the JSC Teague Auditorium, recorded, and executed by the EC in-house STAR Productions team.

Space Shuttle Columbia

Practical Battery Thermal Modeling Techniques

Lithium-ion batteries are thermo-electrochemical devices, whereby nearly every facet of their functionality and performance are thermally driven. As a result, it is important to have thermal modeling techniques that effectively capture the intricacies of both the electrochemical nature of the battery and also the complex thermal network that typically results from the design of the battery thermal management system. Here we present a thermal modeling workflow and a set of general assumptions for how to construct a thermal model of a Li-ion battery pack. We use a 14-cell bank of 18650-format Li-ion cells, loosely based on a proposed alternative battery design for Orion, as the example. Although the workflow is performed with Thermal Desktop and related utilities, the focus of this presentation is less about software specific techniques, but rather is focused on the assumptions and conditions that should be used in a model (regardless of the tool used to build the model). Example cases and results will be presented for charge, discharge, and thermal runaway.

lithium-ion battery