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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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The thermal performance of 50-ampere-hour, nickel cadmium batteries for use in a modular spacecraft is examined in near-Earth orbit simulation. Battery voltage and temperature profiles for temperature extreme cycles are given and discussed.
Barometric pressure, gas composition, toxicity, and thermal exchange of spacecraft cabin atmospheres are discussed. Effects of gravitation, acceleration, weightlessness, noise, and vibration on human behavior and performance during space flight are also described.
Summary report is described of historical documentation and detailed design data for development of silver-zinc battery for use on Surveyor spacecraft. Electrical and physical characteristics of battery models are included, along with data on qualification, acceptance, solar-thermal-vacuum, mission simulation testing, and actual flight performance.
The Nancy Grace Roman Space Telescope (“Roman”) is NASA’s next flagship observatory. Launching in 2026, Roman will explore the nature of dark energy as well as expand the census of exoplanets in our galaxy via microlensing. Roman’s large field of view, agile survey capabilities, and excellent stability enable these scientific objectives, yet present unique challenges for the design, test, and verification of its optical system. Roman recently completed a comprehensive thermal vacuum test of the Spacecraft bus + Integrated Payload Assembly (SCIPA), followed by integrating the Outer Barrel Assembly (OBA), Solar Array Sunshield (SASS), and Deployable Aperture Cover (DAC) with SCIPA to complete the Observatory. This paper will present an overview of the thermal vacuum optical testing as well as a status of the optical system performance and verification.
Long-term manned space missions require the onboard production of disinfectants essential for maintaining crew health and supporting life systems. Currently, disinfection aboard the International Space Station (ISS) relies on disposable wetted wipes, which are regularly resupplied from Earth. This approach imposes a significant burden on resupply logistics, storage, and waste management. To address these challenges and support future missions, efforts are underway to develop an in-situ solution that electrochemically generates hydrogen peroxide disinfectant using onboard resources. In collaboration with NASA, Faraday Technology, Inc. has advanced this concept through a series of Small Business Innovation Research (SBIR) projects, resulting in the development of a Peroxide Generation Unit (PGU). The PGU can produce up to 3 wt.% hydrogen peroxide on-demand at a rate of 1 liter per day, providing a sustainable alternative to Earth-dependent supplies. The resulting aqueous hydrogen peroxide (H₂O₂) is an effective disinfectant, safe for crew use, compatible with spacecraft systems, and free from volatiles, off-gassing, or residues. This innovation offers a reliable, efficient solution for onboard disinfection, reducing dependence on Earth-based resupply while ensuring the health and safety of space crews. Generating hydrogen peroxide at the required rate needs high voltages and currents, exceeding 20V and 2A respectively, which leads to significant heat generation from Joule heating. This temperature rise poses a risk to sensitive system components, especially critical and expensive membranes that can degrade under thermal stress. To mitigate this risk, the thermal, fluid, and electrical flows within the system are modeled computationally using the commercial software COMSOL. The numerical simulations are validated against experimental data from both sub-scale and alpha-scale systems. Once verified, the model is employed to identify thermal hotspots, investigate their underlying causes, and explore solutions to prevent them.
The medical aspects of Gemini extravehicular activities are principally concerned with the physiological responses to high workloads, high thermal stresses, and low fatigue tolerance. Analysis of physiological instrumentation data. from extravehicular flights and training operations contributed significantly to the understanding of extra-vehicular workloads and the means of controlling these workloads.
The needs and requirements for an electrochemical energy storage for deep space exploration is well explored. It is often understood that different mission sites and environmental conditions require different battery chemistries or technologies. Additionally, various engineering solutions are deployed to overcome specific chemical challenges. One often overlooked need is the “health” monitoring of an electrochemical storage system. The term generalized health monitoring, as envisioned in this work, refers to the monitoring of various aspects such as electrode health, electrolyte health, reaction pathway health, cooling system health, sensor health, and BMS health [1]. Generalized health monitoring allows mission leads, engineers, and scientists to incorporate flexibility in mission designs, make on-the-fly mission changes, and extend the duration of science missions. Moreover, it enables automation and data-driven decision-making without compromising safety and performance. Recently, our group developed a hierarchy of thermal reduced-order models (TROM) by combining a physics-based modeling approach and data-driven model reduction techniques applied to flight data [2]. The resulting TROMs were found to be not only accurate but also identifiable from the flight data. Consequently, the coefficient of variance of the model parameters is small over the course of hundreds of flights, allowing for monitoring the parameter evolution trajectories as the battery ages and degrades. These parameters constitute the metrics of the generalized health of a battery. Monitoring their evolution allows such models to be used for anomaly detection and prognostics, improving early detection of abnormal behavior and thus enabling timely maintenance, longer battery life, and enhanced battery safety. For this presentation, the practicality of the thermal model will be validated on a pack of 14cells under various topology configurations such as 1S14P, 2P7S, 7S2P, and 1P14S. It is well known that manufacturing and non-uniform aging lead to variability in the performance of a cell, which is exacerbated by cell balancing during active load. Additionally, in extreme scenarios, the paramount objective is to complete the mission, regardless of the stresses on the battery. Topology-induced balancing issues further stress the battery. The goal of this study is to determine if the noise (identifiability) in the reduced-order thermal model parameters is sensitive to topology, cell spacing, cooling strategy, and manufacturing or age variability. The variability in cells is considered by assuming a multimodal distribution for microscopic parameters of a cell (such as porosity, tortuosity, reaction kinetics, volumetric thermal conductivity, and volumetric heat capacity). The compounded effect of manufacturing variability, topological selection, cooling strategies, and cell balancing ages each cell in a battery differently. The study aims to clarify whether the challenge in extracting maximum information depends on the minimum number of sensors or models used for data extraction.
The arrival of the Nanoracks Airlock to the International Space Station (ISS) has provided the ISS program the capability to dispose of common trash items. The concept of operations involved the crew bagging up those items into a trash bag and then utilizing the robotic arm and the airlock to jettison the trash bag. Because of the unknown thermal vacuum stability of some of the items, a molecular contamination concern was raised by the ISS program as the trash is exposed to vacuum upon the evacuation of air from the airlock and the robotic arm moving the airlock to its jettison location. In order to characterize the representative outgassing rates for ISS trash, thermal vacuum testing was performed at White Sands Test Facility. Trash was sorted into a “lower” outgassing bag and a “mixed” bag. The “mixed” trash bag contained more items that were suspected to be not vacuum stable. Load cells were chosen as the primary means for measuring mass loss. A sharp decay in the outgassing rate was observed in the first 30 minutes followed by a slower decay. As expected, the “mixed” bag lost more mass. While Quartz Crystal Microbalances (QCMs) are often utilized to measure long term outgassing rates and the sticking coefficients of contaminants at different operating temperatures for vacuum stable materials, these measurements proved difficult due to the amount and the inclusion of materials with suspect thermal vacuum stability. Because of high rates of material outgassing, the facility was unable to maintain the CQCM temperature setpoint of 80 K QCMs.. The QCMs operating at the warmer temperatures also saturated on occasion due to high levels of condensed matter. Though testing was able to confirm high risk of outgassing contamination for the program, true sticking coefficients could not be determined, available measurements are provided herein.
Electric propulsion is of interest for manned interplanetary missions, primarily because it offers the potential of delivering and returning relatively large payload fractions from the planets. This can be achieved because of the high specific impulse obtainable when the propellant is accelerated by electrical means rather than thermally, as in chemical and nuclear rockets.
The Exploration Extravehicular Mobility Unit (xEMU) uncrewed 11 foot vacuum chamber testing evaluated the capabilities of the 11 foot vacuum chamber facility to support advanced spacesuit testing. The government reference design xEMU spacesuit provided a high-fidelity test article to demonstrate 11 foot vacuum chamber capabilities which included: gas loading of the chamber at varying simulated metabolic rates and open loop suit abort operations, Intravehicular Activity (IVA) vacuum access, consumables recharge, IVA vehicle-provided thermal loop cooling, and IVA vehicle-provided power. To demonstrate the xEMU airlock operations transitioning from IVA to EVA conditions without a test subject in the suit, test support equipment was developed to remotely actuate both the Exploration, Servicing, and Cooling Umbilical (ESCU) and the vacuum access umbilical. This test also evaluated the performance of the Exploration Portable Life Support System (xPLSS) at vacuum conditions. Data was collected and analyzed for carbon dioxide (CO2) scrubbing performance of the Rapid Cycle Amine (RCA) swingbed, for thermal regulation performance of the Suit Water Membrane Evaporator (SWME), and for sensor performance across the xPLSS. This paper will detail the findings of the testing performed with these upgrades which discussed previously laid out in ICES-2025-342.
AMSOIL ® Propylene Glycol Water (PGW), is the baselined internal thermal control fluid for multiple manned spacecraft including Gateway (HALO, IHAB, and ALM modules) and Orion. The use of AMSOIL-ANT PGW was originally validated through extensive NASA/Collins materials-compatibility testing (circa 2008–2015). However, in late 2019, AMSOIL implemented an unannounced change in its PG inhibitor package. Because of this reformulation, concerns around materials compatibility arose. Therefore, NASA initiated corrosion rate and coolant stability testing in 2024. Results showed that the reformulated AMSOIL PG produced substantially elevated corrosion rates in aluminum alloys (about two times when compared to the original AMSOIL PG formula) accompanied by visible surface degradation. Coolant stability testing indicated accelerated propylene-glycol breakdown as well, with glycolate levels about nine times higher than the original formulation. Based on these findings, NASA Materials & Processes and Thermal Control Systems groups have baselined the use of the original PGW chemistry for all spacecraft use. In response, AMSOIL produced a reformulated variant, “Super Space AMSOIL” (ANT-SSA), compliant with MPCV 70156.This paper documents the reformulation testing completed, details on the formulation change, and the development of Super Space AMSOIL.
AMSOIL ® Propylene Glycol Water (PGW), is the baselined internal thermal control fluid for multiple manned spacecraft including Gateway (HALO, IHAB, and ALM modules) and Orion. The use of AMSOIL-ANT PGW was originally validated through extensive NASA/Collins materials-compatibility testing (circa 2008–2015). However, in late 2019, AMSOIL implemented an unannounced change in its PG inhibitor package. Because of this reformulation, concerns around materials compatibility arose. Therefore, NASA initiated corrosion rate and coolant stability testing in 2024. Results showed that the reformulated AMSOIL PG produced substantially elevated corrosion rates in aluminum alloys (about two times when compared to the original AMSOIL PG formula) accompanied by visible surface degradation. Coolant stability testing indicated accelerated propylene-glycol breakdown as well, with glycolate levels about nine times higher than the original formulation. Based on these findings, NASA Materials & Processes and Thermal Control Systems groups have baselined the use of the original PGW chemistry for all spacecraft use. In response, AMSOIL produced a reformulated variant, “Super Space AMSOIL” (ANT-SSA), compliant with MPCV 70156.This paper documents the reformulation testing completed, details on the formulation change, and the development of Super Space AMSOIL.
The Systems Improved Numerical Differencing Analyzer and Fluid Integrator (SINDA/FLUINT) code has often been used to determine the transient and steady-state response of various thermal and fluid flow networks. While this code is an often used design and analysis tool, the validation of this program has been limited to a few simple studies. For the current study, the SINDA/FLUINT code was compared to four different analytical solutions. The thermal analyzer portion of the code (conduction and radiative heat transfer, SINDA portion) was first compared to two separate solutions. The first comparison examined a semi-infinite slab with a periodic surface temperature boundary condition. Next, a small, uniform temperature object (lumped capacitance) was allowed to radiate to a fixed temperature sink. The fluid portion of the code (FLUINT) was also compared to two different analytical solutions. The first study examined a tank filling process by an ideal gas in which there is both control volume work and heat transfer. The final comparison considered the flow in a pipe joining two infinite reservoirs of pressure. The results of all these studies showed that for the situations examined here, the SINDA/FLUINT code was able to match the results of the analytical solutions.
The Exploration Extravehicular Mobility Unit (xEMU) uncrewed 11 foot vacuum chamber testing evaluated the capabilities of the 11 foot vacuum chamber facility to support advanced spacesuit testing. The government reference design xEMU spacesuit provided a high-fidelity test article to demonstrate 11 foot vacuum chamber capabilities which included: gas loading of the chamber at varying simulated metabolic rates and open loop suit abort operations, Intravehicular Activity (IVA) vacuum access, consumables recharge, IVA vehicle-provided thermal loop cooling, and IVA vehicle-provided power. To demonstrate the xEMU airlock operations transitioning from IVA to EVA conditions without a test subject in the suit, test support equipment was developed to remotely actuate both the Exploration, Servicing, and Cooling Umbilical (ESCU) and the vacuum access umbilical. This test also evaluated the performance of the Exploration Portable Life Support System (xPLSS) at vacuum conditions. Data was collected and analyzed for carbon dioxide (CO2) scrubbing performance of the Rapid Cycle Amine (RCA) swingbed, for thermal regulation performance of the Suit Water Membrane Evaporator (SWME), and for sensor performance across the xPLSS. This paper will detail the findings of the testing performed with these upgrades which discussed previously laid out in ICES-2025-342.
For over six decades, the NASA Ames Entry Systems and Technology Division has been a cornerstone of U.S. space exploration, delivering critical atmospheric entry solutions since Project Mercury and now increasingly supporting the commercial space sector. The Division provides reliable entry system solutions through a unique blend of expertise, national facilities, and systems integration knowledge, a combination that is difficult to replicate outside a dedicated government entity. Consistently successful, the TS Division remains central to NASA’s exploration objectives and significantly contributes to the transfer of technology to the commercial space sector, supporting more than ten commercial space companies and supplying flight heatshields to three of them in the past five years. Its strengths in Thermal Protection System (TPS) materials, aerothermodynamics, ground test facilities, and Entry, Descent, and Landing (EDL) systems engineering drive rapid development and sustained U.S. competitiveness in space. The Division's expertise in reusable and ablative thermal protection systems, as well as mechanically deployable entry systems primarily developed for NASA missions, now benefits commercial space missions. This presentation will highlight the vision and needs of these commercial space companies, how NASA-invented technologies meet mission requirements, and how these technologies enable and distinguish their efforts.
Accurate modeling of coolant airflows, which form protective films over turbine blades, is essential for designing fuel-efficient and environmentally sustainable gas turbine engines. Excessive coolant reduces thermal efficiency, while insufficient coolant leads to blade overheating and causes damage. Therefore, precise prediction of flow field interactions with cooling air is critical for optimizing turbine performance. This study numerically investigates the cooling effectiveness of purge and film cooling flows within a high-pressure turbine (HPT) rotor using Large Eddy Simulation (LES). The study utilizes NASA Glenn Research Center’s Glenn-HT solver. The simulation models ethe conditions of the Penn State University START rotating rig. A high-fidelity structured mesh comprising up to 800 million cells is employed to resolve high-Reynolds number flow (Re ≈ 350,000) and to capture intricate secondary flow structures, including tip leakage and purge-induced vortices. Film cooling effectiveness computations are highly sensitive to boundary conditions at the cooling holes and to grid resolution. Even with well-resolved grids and included plena, strong mixing challenges traditional eddy viscosity models. To address this, a simplified configuration is simulated: a truncated row of shaped holes on the suction side near the leading edge and a row on the pressure side, both fed from internal plena while the purge slot and tip clearance are also modeled. Two isothermal LES cases are conducted at two distinct wall temperatures, which yield the adiabatic wall temperature and the heat transfer coefficient. The definition and means of computation of the effectiveness is discussed in this paper. The simulations reveal detailed three-dimensional unsteady flow features, including coherent vortical structures and secondary flows originating from the purge cavity. Film cooling effectiveness and Nusselt number distributions are presented for both the blade surface and tip, highlighting regions of elevated heat transfer and complex thermal behavior. These findings underscore the importance of high-resolution LES and realistic boundary conditions in capturing the dynamics of purge and film cooling, offering valuable insights for improving turbine blade design and thermal management strategies.
Advanced electrified aircraft propulsion (EAP) concepts with integrated power, propulsion, and thermal systems require the development of equally sophisticated controllers to fly safe and efficient missions. Hybrid electric aircraft utilize electric machines mechanically coupled to the engine shafts to extract and insert power for a variety of purposes. Additionally, electric machines may drive propulsive fans pulling from a combination of on-board energy storage devices and engine extracted power. NASA’s investment in hybrid electric aircraft hardware-in-the-loop testing enables controls research on representative engine models using a novel emulation and scaling methodology. High-voltage, high-power electrical powertrain presents several technical risks at altitude. High-power requires high efficiency to minimize losses. Superconducting electric machines and power distribution research at NASA has identified key challenges with potential controls solutions. These risks necessitate the development of controllers robust to model uncertainty, disturbances, and fault conditions. System health management and fault detection schemes play an important role in a multi-layer controls approach that utilizes a supervisor which oversees inner loops for the highly coupled power, propulsion, and thermal systems. Such a supervisory controller enables coordinates energy transfer between engines, energy storage devices, electric machines, propulsors, and heat exchangers. Existing methods have shown an improvement in engine operability using the hybrid electric powertrain.
Accurate predictions of aeroheating are critical for designing thermal protection systems for planetary entry vehicles. For larger vehicles, turbulence in the boundary layer can substantially increase convective heating. This turbulence must be accurately modeled to ensure the thermal protection system is sufficient. The majority of hypersonic turbulence model development and validation focuses on boundary layers developing over flat-plates or sharp cones; these cases are substantially different than the boundary layer that develops over the heatshield of a blunt body traveling at hypersonic speeds. Planetary missions often use blunt body geometries, such as the 70-degree sphere-cone favored by Mars missions or the 45-degree sphere-cone planned for the upcoming DAVINCI mission. Due to smaller vehicle size and the lower velocities in the stagnation region, planetary entry vehicles have relatively low Reynolds numbers. Surface curvature and high enthalpy gradients create additional challenges. These difficulties must be addressed to obtain high accuracy needed for the ambitious planetary missions in the upcoming decade. This work focuses on both assessing and improving Reynolds-averaged Navier-Stokes (RANS) turbulence models for blunt-body geometries typical of planetary entry vehicles, with a focus on one-equation and two-equation formulations.