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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 253 records · Page 14

Design and Preliminary Thermal Performance of the Mars Science Laboratory Rover Heat Exchangers

The challenging range of proposed landing sites for the Mars Science Laboratory Rover requires a rover thermal management system that is capable of keeping temperatures controlled across a wide variety of environmental conditions. On the Martian surface where temperatures can be as cold as -123 degrees Centigrade and as warm as 38 degrees Centigrade, the Rover relies upon a Mechanically Pumped Fluid Loop (MPFL) and external radiators to maintain the temperature of sensitive electronics and science instruments within a -40 degrees Centigrade to 50 degrees Centigrade range. The MPFL also manages significant waste heat generated from the Rover power source, known as the Multi Mission Radioisotope Thermoelectric Generator (MMRTG). The MMRTG produces 110 Watts of electrical power while generating waste heat equivalent to approximately 2000 Watts. Two similar Heat Exchanger (HX) assemblies were designed to both acquire the heat from the MMRTG and radiate waste heat from the onboard electronics to the surrounding Martian environment. Heat acquisition is accomplished on the interior surface of each HX while heat rejection is accomplished on the exterior surface of each HX. Since these two surfaces need to be at very different temperatures in order for the MPFL to perform efficiently, they need to be thermally isolated from one another. The HXs were therefore designed for high in-plane thermal conductivity and extremely low through-thickness thermal conductivity by using aerogel as an insulator inside composite honeycomb sandwich panels. A complex assembly of hand welded and uniquely bent aluminum tubes are bonded onto the HX panels and were specifically designed to be easily mated and demated to the rest of the Rover Heat Recovery and Rejection System (RHRS) in order to ease the integration effort. During the cruise phase to Mars, the HX assemblies serve the additional function of transferring heat from the Rover MPFL to the separate Cruise Stage MPFL so that heat generated deep inside the Rover can be dissipated via the Cruise Stage radiators. Significant fabrication challenges had to be overcome in order to make the HX design a reality. The cruise phase thermal performance of the Rover HXs was verified in the cruise phase system level thermal vacuum test that was performed at JPL in January of 2009. The Rover HXs were modeled in I-DEAS TMG and predictions are compared to actual data from the test.

Heat Rejection System↗

From Chaos to Clarity: Autonomous Materials Discovery for Extreme Environments

The pursuit of advanced functional materials for energy applications demands an understanding of their behavior under the most challenging conditions. Extreme environments, characterized by intense radiation, high temperatures, and corrosive chemistries, push materials to their limits, often revealing unexpected behaviors and degradation pathways. Traditional materials research approaches, relying on trial-and-error experimentation, are often slow and resource-intensive, ill-suited to the complexities of extreme environments. This talk will explore the transformative potential of autonomous materials science in revolutionizing our understanding of materials synthesis and degradation in extreme environments. By integrating advanced microscopy techniques, artificial intelligence, and robotic experimentation, we can accelerate the discovery and design of resilient materials for a sustainable future. The presentation will highlight recent breakthroughs in autonomous microscopy, computer vision, and machine learning, showcasing their ability to unravel complex material transformations at the atomic scale. The talk will also delve into the challenges and opportunities associated with deploying autonomous systems to probe extreme environments, emphasizing the importance of robust algorithms, real-time data analysis, and adaptive experimentation. Our ultimate goal is to empower scientists with unprecedented capabilities to explore, understand, and engineer materials that can withstand the harshest conditions, paving the way for innovations in energy, aerospace, and beyond.

artificial intelligence↗

Flight Readiness of Mochii ISS-NL Portable Spectroscopic Electron Microscope

Electron microscopes (EM’s), are workhorse tools serving diverse fields such as materials science, biological science, and engineering. Scanning EM’s (SEM’s) in particular enable high magnification study and pinpoint chemical analyses of structures down to the nanoscale by providing a powerful blend of strong optical scattering, high native resolution, large depth of focus, and energy-dispersive X-ray spectroscopy (EDS). Mochii is the world’s smallest production electron microscope, scheduled to travel to the International Space Station (ISS) this spring where it will serve as an ISS National Laboratory (ISSNL) microgravity facility on successful demonstration. We previously reported on progress preparing Mochii for space flight, in particular flight integration verifications and science application testing. These included standard integration testing such as electromagnetic interference and flight vibration, and extend to unique functional testing such as magnetic susceptibility and extreme analog environment testing under the sea. Presently, Mochii payload flight hardware has completed testing and was handed over to NASA’s ISS payload processing facility in Houston. It will make its way to the the east coast for launch currently scheduled on Space-X CRS-20 for Mission increment 62 in March 2020.

Own, C. S.↗

Comparison of Extreme Value Distributions for Electrostatic Discharge Magnitudes in Spacecraft Charging Tests

Electrostatic Discharge (ESD) induced by the accumulation of charge in the space environment is known to cause spacecraft anomalies and failures. While it is critical to estimate the worst-case expected ESD, sensitive radar instruments can be impacted by high rates of occurrence of very small ESD. To estimate the correct extreme behavior, it is important to select the correct extreme value distribution for extrapolation of test results limited in time and sensitivity. Quantile-quantile (Q-Q) analysis is used to compare electron beam-induced ESD test data to several statistical distributions used in the published literature. The best-fit distribution is shown to vary from between tests on different materials; however, it is clear that power law distributions are not good approximations for low amplitude events. Q-Q analysis is a convenient graphical method for evaluating multiple theoretical extreme-value distributions simultaneously.

Kim, Wousik↗

Radiation-Conditioned Ti–hBN Coatings for Space Mechanisms: Bridging Tribology and Irradiation Effects from Laboratory to Low-Earth Orbit

The longevity of tribological components in extraterrestrial environments is challenged by abrasive regolith, extreme temperatures, and ionizing radiation. This study evaluates the performance of vacuum plasma sprayed (VPS) Ti-2vol.% hexagonal boron nitride (hBN) coatings applied to joint mechanisms such as rod and slot, ball and socket, and hinge assemblies, fabricated from Al6061 and Ti6Al4V for planetary structures. Coated and uncoated samples were tested under vacuum with lunar regolith simulant (JSC-1A), followed by environmental exposures including electron radiation and thermal cycling. Results show that coated samples consistently outperformed uncoated counterparts across all configurations. Wear depth in coated components was reduced by over 80%, as confirmed by 3D profilometry and surface imaging. SEM analysis revealed severe abrasion and localized plastic deformation in uncoated surfaces, while coated samples retained structural integrity due to synergy of hard protective phases formed during deposition and retained hBN providing solid lubrication in the sliding surface. Coated and exposed samples exhibited smoother actuation profiles and reduced friction, indicating a beneficial "conditioning" effect from environmental exposure. The coatings-maintained performance even on complex geometries with minimal delamination. These findings demonstrate the potential of VPS Ti-hBN coatings to extend the operational life of lunar mechanisms, bridging laboratory-scale tribology with flight-relevant mechanical applications.

tribology↗

Dynamical Janus Interface Design for Reversible and Fast-Charging Zinc–Iodine Battery under Extreme Operating Conditions

Aqueous zinc (Zn) iodine (I 2 ) batteries have emerged as viable alternatives to conventional metal-ion batteries. However, undesirable Zn deposition and irreversible iodine conversion during cycling have impeded their progress. Here, to overcome these concerns, we report a dynamical interface design by cation chemistry that improves the reversibility of Zn deposition and four-electron iodine conversion. Due to this design, we demonstrate an excellent Zn-plating/-stripping behavior in Zn||Cu asymmetric cells over 1000 cycles with an average Coulombic efficiency (CE) of 99.95%. Moreover, the Zn||I 2 full cells achieve a high-rate capability (217.1 mA h g –1 at 40 A g –1 ; C rate of 189.5C) at room temperature and enable stable cycling with a CE of more than 99% at -50 °C at a current density of 0.05 A g –1 . In situ spectroscopic investigations and simulations reveal that introducing tetraethylammonium cations as ion sieves can dynamically modulate the electrode–electrolyte interface environment, forming the unique water-deficient and chloride ion (Cl – )-rich interface. Such Janus interface accounts for the suppression of side reactions, the prevention of ICl decomposition, and the enrichment of reactants, enhancing the reversibility of Zn-stripping/-plating and four-electron iodine chemistry. This fundamental understanding of the intrinsic interplay between the electrode–electrolyte interface and cations offers a rational standpoint for tuning the reversibility of iodine conversion.

25 ENERGY STORAGE↗

Rapid Oxidation of Uranium Steel Alloys: Combustion Synthesis

This project explored the use of combustion synthesis as a rapid, high-temperature method for oxidizing uranium-bearing steel alloys. Traditional laboratory-scale synthesis methods often fail to replicate the thermal and kinetic conditions experienced by real-world particulates, particularly those formed under rapid quenching or high-temperature scenarios. Combustion synthesis offers a promising alternative by enabling fast, localized heating and flexible precursor selection. A series of targeted experiments were conducted using a U 2 NiCrFe 4 alloy as the precursor. The alloy was oxidized using combustion synthesis reactions fueled by uranyl nitrate and glycine, achieving peak temperatures exceeding 1,200 °C. Postreaction analysis using scanning electron microscopy (SEM), elemental mapping, and Raman spectroscopy revealed the formation of iron-based oxides, with limited but detectable evidence of uranium oxide phases such as UO 2 . The results indicate that under the rapid reaction and cooling conditions of combustion synthesis, iron oxides form preferentially, but uranium oxide formation is kinetically limited. These findings validate combustion synthesis as a viable method for simulating the oxidation behavior of uranium steels in extreme environments and lay the groundwork for future studies aimed at enhancing uranium oxide formation through higher temperatures or modified precursor compositions.

36 MATERIALS SCIENCE↗

Development of a Temperature Sensor for Jet Engine and Space Mission Applications

Electronics for Distributed Turbine Engine Control and Space Exploration Missions are expected to encounter extreme temperatures and wide thermal swings. In particular, circuits deployed in a jet engine compartment are likely to be exposed to temperatures well exceeding 150 C. To meet this requirement, efforts exist at the NASA Glenn Research Center (GRC), in support of the Fundamental Aeronautics Program/Subsonic Fixed Wing Project, to develop temperature sensors geared for use in high temperature environments. The sensor and associated circuitry need to be located in the engine compartment under distributed control architecture to simplify system design, improve reliability, and ease signal multiplexing. Several circuits were designed using commercial-off-the-shelf as well as newly-developed components to perform temperature sensing at high temperatures. The temperature-sensing circuits will be described along with the results pertaining to their performance under extreme temperature.

Patterson, Richard L.↗

Transmission electron microscopy with in-situ ion irradiation: Facilities and community

Whilst there is a clear scientific and technological need for the technical capabilities of transmission electron microscopes with in-situ ion irradiation, it also requires a collaborative community of international researchers to support such facilities in successfully meeting this demand. Instruments of this type serve to provide fundamental understanding of the mechanisms which drive changes in materials important to nuclear fission and fusion energy, the semiconductor industry, quantum information systems, space travel, astronomy, geology and many more applications. As these areas continue to evolve and the instrumentation possibilities expand, the capacity of in-situ ion irradiation facilities must also develop hand-in-hand with the user community to deliver an ever-greater diversity of high-fidelity extreme-environment experimentation. Future directions for the field, such as miniaturization from MEMS/microfluidic devices and advanced controls with ML-based analysis, continuously emerge to advance both the hardware and software which support the coupling of TEMs with ion beams. This review sets out to provide up-to-date insights into the community and advancement of current, and development of future, facilities which have the potential to further unlock access to the nanoscale exploration of coupled extreme environments crucial to many of the important science and engineering challenges we face today.

In-situ irradiation↗

Revolutionizing Our Understanding of Particle Energization in Space Plasmas Using on-Board Wave-Particle Correlator Instrumentation

A leap forward in our understanding of particle energization in plasmas throughout the heliosphere is essential to answer longstanding questions in heliophysics, including the heating of the solar corona, acceleration of the solar wind, and energization of particles that lead to observable phenomena, such as the Earth’s aurora. The low densities and high temperatures of typical heliospheric environments lead to weakly collisional plasma conditions. Under these conditions, the energization of particles occurs primarily through collisionless interactions between the electromagnetic fields and the individual plasma particles with energies characteristic of a particular interaction. To understand how the plasma heating and particle acceleration impacts the macroscopic evolution of the heliosphere, impacting phenomena such as extreme space weather, it is critical to understand these collisionless wave-particle interactions on the characteristic ion and electron kinetic timescales. Such understanding requires high-cadence measurements of both the electromagnetic fields and the three-dimensional particle velocity distributions. Although existing instrument technology enables these measurements, a major challenge to maximize the scientific return from these measurements is the limited amount of data that can be transmitted to the ground due to telemetry constraints. A valuable, but underutilized, approach to overcome this limitation is to compute on-board correlations of the maximum-cadence field and particle measurements to improve the sampling time by several orders of magnitude. Here we review the fundamentals of the innovative field-particle correlation technique, present a formulation of the technique that can be implemented as an on-board wave-particle correlator, and estimate results that can be achieved with existing instrumental capabilities for particle velocity distribution measurements.

plasma heating↗

Viruses in Antarctic lakes

Water samples collected from four perennially ice-covered Antarctic lakes during the austral summer of 1996-1997 contained high densities of extracellular viruses. Many of these viruses were found to be morphologically similar to double-stranded DNA viruses that are known to infect algae and protozoa. These constitute the first observations of viruses in perennially ice-covered polar lakes. The abundance of planktonic viruses and data suggesting substantial production potential (relative to bacteria] secondary and photosynthetic primary production) indicate that viral lysis may be a major factor in the regulation of microbial populations in these extreme environments. Furthermore, we suggest that Antarctic lakes may be a reservoir of previously undescribed viruses that possess novel biological and biochemical characteristics.

Non-NASA Center↗

Multi-Mission Radioisotope Thermoelectric Generator Heat Exchangers for the Mars Science Laboratory Rover

The addition of the Multi-Mission Radioisotope Thermoelectric Generator (MMRTG) to the Mars Science Laboratory (MSL) Rover requires an advanced thermal control system that is able to both recover and reject the waste heat from the MMRTG as needed in order to maintain the onboard electronics at benign temperatures despite the extreme and widely varying environmental conditions experienced both on the way to Mars and on the Martian surface. Based on the previously successful Mars landed mission thermal control schemes, a mechanically pumped fluid loop (MPFL) architecture was selected as the most robust and efficient means for meeting the MSL thermal requirements. The MSL heat recovery and rejection system (HRS) is comprised of two Freon (CFC-11) MPFLs that interact closely with one another to provide comprehensive thermal management throughout all mission phases. The first loop, called the Rover HRS (RHRS), consists of a set of pumps, thermal control valves, and heat exchangers (HXs) that enables the transport of heat from the MMRTG to the rover electronics during cold conditions or from the electronics straight to the environment for immediate heat rejection during warm conditions. The second loop, called the Cruise HRS (CHRS), is thermally coupled to the RHRS during the cruise to Mars, and provides a means for dissipating the waste heat more directly from the MMRTG as well as from both the cruise stage and rover avionics by promoting circulation to the cruise stage radiators. A multifunctional structure was developed that is capable of both collecting waste heat from the MMRTG and rejecting the waste heat to the surrounding environment. It consists of a pair of honeycomb core sandwich panels with HRS tubes bonded to both sides. Two similar HX assemblies were designed to surround the MMRTG on the aft end of the rover. Heat acquisition is accomplished on the interior (MMRTG facing) surface of each HX while heat rejection is accomplished on the exterior surface of each HX. Since these two surfaces need to be at very different temperatures in order for the fluid loops to perform efficiently, they need to be thermally isolated from one another. The HXs were therefore designed for high in-plane thermal conductivity and extremely low through-thickness thermal conductivity by using aluminum facesheets and aerogel as insulation inside a composite honeycomb core. Complex assemblies of hand-welded and uniquely bent aluminum tubes are bonded onto each side of the HX panels, and are specifically designed to be easily mated and demated to the rest of the RHRS in order to ease the integration effort.

Mastropietro, A. J.↗

'Direct' Gas-Phase Metallicities, Stellar Properties, and Local Environments of Emission-Line Galaxies at Redshifts Below 0.90

Using deep narrow-band (NB) imaging and optical spectroscopy from the Keck telescope and the Multi Mirror Telescope (MMT), we identify a sample of 20 emission-line galaxies (ELGs) at z = 0.065-0.90 where the weak auroral emission line, [O iii] lambda4363, is detected at >=3sigma. These detections allow us to determine the gas-phase metallicity using the "direct" method. With electron temperature measurements, and dust attenuation corrections from Balmer decrements, we find that 4 of these low-mass galaxies are extremely metal-poor with 12+log(O/H) <= 7.65 or one-tenth solar. Our most metal-deficient galaxy has 12+log(O/H)= 7.24(+0.45 / −0.30) (95% confidence), similar to some of the lowest metallicity galaxies identified in the local universe. We find that our galaxies are all undergoing significant star formation with average specific star formation rate (SFR) of (100 Myra)(exp −1), and that they have high central SFR surface densities (average of 0.5 Solar M / yr/ sq. kpc). In addition, more than two-thirds of our galaxies have between one and four nearby companions within a projected radius of 100 kpc, which we find is an excess among star-forming galaxies at z =0.4 -- 0.85. We also find that the gas-phase metallicities for a given stellar mass and SFR lie systematically lower than the local stellar M-Z-(SFR) relation by approx. = 0.2 dex (2 sigma significance). These results are partly due to selection effects, since galaxies with strong star formation and low metallicity are more likely to yield [O iii] lambda4363 detections. Finally, the observed higher ionization parameter and high electron density suggest that they are lower redshift analogs to typical z approx. > 1 galaxies.

Direct↗

From Chaos to Clarity: Autonomous Materials Discovery for Extreme Environments [Slides]

The pursuit of advanced functional materials for energy applications demands an understanding of their behavior under the most challenging conditions. Extreme environments, characterized by intense radiation, high temperatures, and corrosive chemistries, push materials to their limits, often revealing unexpected behaviors and degradation pathways. Traditional materials research approaches, relying on trial-and-error experimentation, are often slow and resource-intensive, ill-suited to the complexities of extreme environments. This talk will explore the transformative potential of autonomous materials science in revolutionizing our understanding of materials synthesis and degradation in extreme environments. By integrating advanced microscopy techniques, artificial intelligence, and robotic experimentation, we can accelerate the discovery and design of resilient materials for a sustainable future. The presentation will highlight recent breakthroughs in autonomous microscopy, computer vision, and machine learning, showcasing their ability to unravel complex material transformations at the atomic scale. The talk will also delve into the challenges and opportunities associated with deploying autonomous systems to probe extreme environments, emphasizing the importance of robust algorithms, real-time data analysis, and adaptive experimentation. The ultimate goal is to empower scientists with unprecedented capabilities to explore, understand, and engineer materials that can withstand the harshest conditions, paving the way for innovations in energy, aerospace, and beyond.

14 SOLAR ENERGY↗

Venus High Temperature Atmospheric Dropsonde and Extreme-Environment Seismometer (HADES)

The atmospheric composition and geologic structure of Venus have been identified by the US National Research Council's Decadal Survey for Planetary Science as priority targets for scientific exploration, however the high temperature and pressure at the surface, along with the highly corrosive chemistry of the Venus atmosphere, present significant obstacles to spacecraft design that have severely limited past and proposed landed missions. Following the methodology of the NASA Innovative Advanced Concepts (NIAC) proposal regime and the Collaborative Modeling and Parametric Assessment of Space Systems (COMPASS) design protocol, this paper presents a conceptual study and initial feasibility analysis for a Discovery-class Venus lander capable of an extended-duration mission at ambient temperature and pressure, incorporating emerging technologies within the field of high temperature electronics in combination with novel configurations of proven, high Technology Readiness Level (TRL) systems. Radioisotope Thermal Power (RTG) systems and silicon carbide (SiC) communications and data handling are examined in detail, and various high-temperature instruments are proposed, including a seismometer and an advanced photodiode imager. The study combines this technological analysis with proposals for a descent instrument package and a relay orbiter to demonstrate the viability of an integrated atmospheric and in-situ geologic exploratory mission that differs from previous proposals by greatly reducing the mass, power requirements, and cost, while achieving important scientific goals.

HADES↗

Analytical and experimental investigation of the feasibility of accelerated lifetime testing of materials exposed to an atomic oxygen beam

The interaction of atomic particles with surfaces is of both scientific and technological interest. Past work emphasizes the measurement of high-energy sputtering yields. Very little work utilized low-energy beams for which chemical and electronic effects can be important. Even less work has been carried out using well-defined low-energy projectiles. The use of low-energy, reactive projectiles permits one to investigate surface processes that have not been well characterized. As the energy of the projectile decreases, the collisional cascades and spikes, that are common for high-energy projectiles, become less important, and chemical and electronic effects can play a significant role. Aspects of particle-surface interactions are of concern in several areas of technology. For example, the erosion, desorption, and glow of surfaces of spacecraft in orbit are important in the arena of space technology. The materials studied under this contract are of possible use on the exterior portions of the power generation system of Space Station Freedom. Under the original designs, Space Station Freedom's power generation system would generate potential differences on the surface as high as 200 volts. Ions in the plasma that often surround orbiting vehicles would be accelerated by these potentials leading to bombardment and erosion of the exposed surfaces. The major constituent of the atmosphere, approximately 90 percent, in the low earth orbit region is atomic oxygen. Since atomic oxygen is extremely reactive with most materials, chemical effects can arise in addition to the physical sputtering caused by the acceleration of the oxygen ions. Furthermore, the incident oxygen ions can remain embedded in the exposed surfaces, altering the chemical composition of the surfaces. Since the effective binding energy of a chemically altered surface can be quite different from that of the pure substrate, the sputtering yield of a chemically altered surface is usually different also. The low-energy O+ sputtering yield measurements, reported here, will help quantify the erosion rates for materials exposed to the low-earth orbit environment. These measurements are of technological importance in another respect. In most surface analysis techniques, a surface is bombarded with ions, electrons or photons. Information concerning the structure of the surface and near-surface bulk, abundance of impurities and defects, as well as other surface properties are obtained either from the desorbed species or from the scattered projectiles. Because of their low penetration depth, low-energy ions provide an advantage over other techniques because they provide information that is more indicative of conditions on the surface rather than integrated effects arising from deeper in the bulk. A better understanding of the microscopic processes involved in these interactions is not only of basic scientific interest, but will also aid the scientific community by increasing the accuracy and usefulness of these surface analysis techniques.

Albridge, Royal↗

Stoichiometric effects on grain growth in zirconium carbide coatings for high-temperature nuclear fuel

Interest in coated particle fuel for space nuclear propulsion (SNP) has expanded in recent years due to successful demonstrations of the resiliency of the coatings to extreme environments. For SNP applications, the coating layer for the particle design needs to be able to withstand exposure to high temperature hydrogen during operating conditions. ZrC has been proposed as a protective layer, however, it is important to understand the high temperature behavior to ensure adequate protection to this fuel. In this study, surrogate ZrC coated particles were heat treated at 1900 °C up to 300 min, to examine how the microstructure evolves when exposed to high temperature. Scanning electron microscopy and electron backscatter diffraction (EBSD) were conducted to determine grain size and grain boundary character and orientation to determine the degree of change in the ZrC layer post heat treatment. Raman spectroscopy provided insight to understand how the as-fabricated stoichiometry of each sample contributed to the differences in grain growth behavior. Despite the as-fabricated samples showing a similar initial grain size and grain boundary character, the samples with a higher amount of excess carbon exhibited smaller grain areas and slower growth rates when exposed to 1900 °C. In conclusion, this investigation details the as-fabricated microstructure of the ZrC layer, specifically grain size, evolved under high temperature as this can impact the performance of the fuel under operating conditions.

EBSD↗

Electronic assembly thermal testing - Dwell/duration/cycling

Testing of electronic assemblies varies throughout industry, NASA, and the military. Differences include test levels, atmospheric versus vacuum testing of assemblies, dwell durations at temperature extremes (especially high temperature), and thermal cycling versus dwell testing. Of particular interest are the different philosophies of thermal cycling versus single-cycle thermal dwell. An examination of the various failure physics for electronic assemblies has been initiated at JPL. The intent is to determine which failure modes are best revealed by thermal cycling testing and which are susceptible to high-temperature dwell physics. Preliminary results of this study are presented, along with discussions of testing goals, flight environments, reliability models, and the differences between industry and JPL design/test approaches.

Gibbel, Mark↗