Current status and opportunities for improved high-temperature materials for advanced turbojet engines
Material development review of high temperature materials, superalloys, alloys, and refractory metals for turbojet engines
TURBOJET ENGINE↗
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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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MSFC hot air collectors
A description of the hot air collector is given that includes a history of development, a history of the materials development, and a program summary. The major portion of the solar energy system cost is the collector. Since the collector is the heart of the system and the most costly subsystem, reducing the cost of producing collectors in large quantities is a major goal. This solar collector is designed to heat air and/or water cheaply and efficiently through the use of solar energy.
Anthony, K.↗
NIST Efforts to Quality-Assure Gunpowder Measurements
In the past few years, the National Institute for Standards and Technology (NIST) has been promoting the idea of quantitatively determining the additives in smokeless gunpowder using micellar capillary electrophoresis as a means of investigating the criminal use of hand guns and pipe bombs. As a part of this effort, we have evaluated both supercritical fluid and ultrasonic solvent extractions for the quantitative recovery of nitroglycerin (NG), diphenylamine (DPA), N-nitrosodiphenylamine (NnDPA), and ethyl centralite (EC) from gunpowder. Recoveries were evaluated by repeat extraction and matrix spiking experiments. The final extraction protocol provides greater than 95 percent recoveries. To help other researches validate their own analytical method for additive determinations, NIST is exploring the development of a standard reference material, Additives in Smokeless Gunpowder. The evaluated method is being applied to two double-base (NG-containing) powders, one stabilized with diphenylamine and the other with ethyl centralite. As part of this reference material development effort, we are conducting an interlaboratory comparison exercise among the forensic and military gunpowder measurement community.
MacCrehan, William A.↗
NASA 2018 Green Propulsion Roadmap
The Green Propulsion Working Group (GPWG) is a technical guidance working group formed April 2017 under the Agency's Capability Leadership Team The GPWG was tasked with recommending an agency road map and providing guidance to NASA on green propulsion technology development and infusion The GPWG's efforts focus on ionic liquid propellants and related technologies The GPWG was chartered with three representatives from NASA Centers currently exploring green propulsion technologies As other Centers may explore programs that utilize green propulsion, membership of the working group can be expanded to include more interested parties Working group also solicits and coordinates with other government agencies (e.g. AFRL, MDA) In 2015, JANNAF hosted a Technical Interchange Meeting (TIM) on Green Monopropellant Alternatives to Hydrazine (GMAH) Included both Government and non-Government contributions on the State-of-the-Art in Green Propulsion Technology Following the TIM, a Government-only session (USAF/AFRL/NASA/MDA/DLA) reviewed and identified remaining technical gaps in Green Propulsion In 2016, an inter-agency team (AFRL/NASA/MDA) worked together to develop an informal inter-agency "roadmap" based on the outcome of the TIM Approach consisted of near-term, mid-term, and long-term technology advancement areas, approaching incrementally larger thrust classes The NASA Green Propulsion Working Group reviewed the work of the 2016 Inter-Agency Working Group, and concurs that the identified technical gaps and technology development areas are still relevant and necessary to see green propulsion technology advanced The GPWG recommends the 2016 roadmap be adopted as baseline for NASA needs, with some additions The focus of the 2016 inter-agency roadmap was primarily on the thruster technology. The Agency must also invest in understanding the broader propulsion system-level technology gaps in parallel. Timeframes are considered suggested from a priority standpoint, but are also flexible as some efforts will need to occur in the nearer term or concurrently in order to meet specific mission requirements The GPWG developed 2018 roadmap breaks down the technology development goals into Technology Development Areas (TDA's), and identifies the near-, mid, and long-term sub-goals within those areas. Those TDA's are: Thruster Hardware Development Modeling & Tools Development Materials Properties and Compatibility Propellant Development.
Cavender, Dan↗
Affordable Development Strategy for NEP Nuclear Systems
One nuclear electric propulsion (NEP) reactor systems under consideration is a hydride moderated thermal spectrum reactor fueled by high assay low enriched uranium (HALEU). While such a reactor is expected to yield the lightest HALEU reactor design, its development challenges grow exponentially with increasing mission demands, most notably power output, specific weight of the overall system (which may require operation at temperatures exceeding 1200 K), service lifetime, and human-rated reliability. Two of the greatest cost drivers are full-powered nuclear demonstrations and extensive material development campaigns, so it is important to consider options that can minimize the need for or complexity of such tasks. This paper discusses a structured framework being developed for assessing how NEP design choices, such as materials selection, neutronic features, and heat-removal technologies, can translate into project risk and how project performance goals can be traded with development cost.Reactors operating at high temperatures often require cutting-edge heat transfer technologies and creep-resistant materials. Use of new materials in high temperature reactors brings additional complication beyond those common to any new space materials development campaign. For example, such materials may not possess necessary neutronic cross-sectional or neutronic irradiation data. Similarly, use of new materials may significantly influence core neutronics; in some extreme cases, neutronic reactivity feed-back of certain new materials can vary during their service life as radiation damage impacts the scattering cross-section. In an affordable development approach, high fidelity modeling and simulation tools are used to identify and characterize potential ‘knees-in-the-curves’ in the relationship that exists between the mission characteristics and the project risk. Of particular significance is use of modern uncertainty management and variance reduction methods to perform gap analyses that feed into phenomena identification and ranking tables (PIRT) commonly used to communicate nuclear readiness levels. Model-based measurements techniques are used to design sub-scale experiments as a substitute to minimize orcompletely eliminate the need for nuclear demonstrations.This paper will describe the approach and present preliminary results. It will lay the groundwork for developing a set of metrics that can be broadly characterized as system nuclear readiness levels and advancement degree of difficulty for nuclear systems. Equally importantly, a goal of this paper is to initiate a dialogue among stakeholders on what is the sufficient level of maturity that is required for launching a demonstration unit.
Dasari V Rao↗
Design Tool for Estimating Adsorbent Hydrogen Storage System Characteristics for Light-Duty Fuel Cell Vehicles
This work combines materials development with hydrogen storage technology advancements to address onboard hydrogen storage challenges in light-duty vehicle applications. These systems are comprised of the vehicle requirements design space, balance of plant requirements, storage system components, and materials engineering culminating in the development of an Adsorbent System Design Tool that serves as a preprocessor to the storage system and vehicle-level models created within the Hydrogen Storage Engineering Center of Excellence. Computational and experimental efforts were integrated to evaluate, design, analyze, and scale potential hydrogen storage systems and their supporting components against the Department of Energy 2020 and Ultimate Technical Targets for Hydrogen Storage Systems for Light Duty Vehicles. Ultimately, the Adsorbent System Design Tool was created to assist material developers in assessing initial design parameters that would be required to estimate the performance of the hydrogen storage system once integrated with the full fuel cell system.
08 HYDROGEN↗
Composite material characterization for large space structures.
A program phase to characterize advanced composite materials for a large reflector support truss on the ATS F & G spacecraft is described. The selection of a Hercules Incorporated, 2002M graphite fiber reinforced epoxy material was based on criteria of spacecraft system requirements and the potential of this material to meet these requirements. The objective of this phase was to develop materials data required for development, design, fabrication, test, and flight of a graphite-fiber, reinforced-plastic spacecraft structure. Testing within a temperature range from -300 F to +200 F covered the generation of data for physical, mechanical, thermophysical, and space environmental properties for the selected material. Additional testing covered adhesive bonded joint materials within the temperature ranges of the spacecraft environment. Descriptions of the spacecraft, reflector support truss, design, requirements, materials, tests, and developed data are presented.
Macneill, C. E.↗
Advanced Electrical Materials and Component Development
The primary means to develop advanced electrical components is to develop new and improved materials for magnetic components (transformers, inductors, etc.), capacitors, and semiconductor switches and diodes. This paper will give a description and status of the internal and external research sponsored by NASA Glenn Research Center on soft magnetic materials, dielectric materials and capacitors, and high quality silicon carbide (SiC) atomically smooth substrates. The rationale for and the benefits of developing advanced electrical materials and components for the PMAD subsystem and also for the total power system will be briefly discussed.
Schwarze, Gene E.↗
Developing Novel Electrode Materials for Aqueous Battery
Aqueous rechargeable batteries (ARBs) are particularly interesting for large-scale energy storage due to their inherent safety, superior rate capability and environmental friendliness. However, ARBs are not widely explored as yet, so we proposed designing, preparing, and testing new intercalation materials for ARBs. Development of these electrodes will enrich the electrode chemistry of existing ARBs, open up new avenues for high-performance electrode and system design, offer opportunities to improve energy efficiency of water purification, and inform future development of controls strategies and management systems for stationary aqueous energy storage. Researchers from Bosch and LBNL collaborated on relevant materials to pursue and the general design of experiments to implement. Bosch researchers prepared and fabricated the electrodes and used various characterization facilities at LBNL to evaluate electrode performance in-device. The research collaboration resulted in identifying electrode materials capable of Na + and Ca 2+ intercalation in aqueous systems, and their application for desalination was explored using testing platform available at LBNL. Besides the specific materials and their performance, the data collected during the study was also used to inform a broader techno-economic analysis to compare intercalation-desalination technique to commercially available capacitive desalination approach. Outcomes of this research effort will be published in peer-reviewed journals.
25 ENERGY STORAGE↗
Sustainable Electric Vehicle Batteries for a Sustainable World: Perspectives on Battery Cathodes, Environment, Supply Chain, Manufacturing, Life Cycle, and Policy
Abstract Li‐ion batteries (LIBs) can reduce carbon emissions by powering electric vehicles (EVs) and promoting renewable energy development with grid‐scale energy storage. However, LIB production and electricity generation still heavily rely on fossil fuels at present, resulting in major environmental concerns. Are LIBs as environmentally friendly and sustainable as expected at the current stage? In the past 5 years, a skyrocketing growth of the EV market has been witnessed. LIBs have garnered huge attention from academia, industry, government, non‐governmental organizations, investors, and the general public. Tremendous volumes of LIBs are already implemented in EVs today, with a continuing, exponential growth expected for the years to come. When LIBs reach their end‐of‐life in the next decades, what technologies can be in place to enable second‐life or recycling of batteries? Herein, life cycle assessment studies are examined to evaluate the environmental impact of LIBs, and EVs are compared with internal combustion engine vehicles regarding environmental sustainability. To provide a holistic view of the LIB development, this Perspective provides insights into materials development, manufacturing, recycling, legislation and policy, and beyond. Last but not least, the future development of LIBs and charging infrastructures in light of emerging technologies are envisioned.
36 MATERIALS SCIENCE↗
Protonic Ceramic Electrochemical Cells for Synthesizing Sustainable Chemicals and Fuels
Abstract Protonic ceramic electrochemical cells (PCECs) have been intensively studied as the technology that can be employed for power generation, energy storage, and sustainable chemical synthesis. Recently, there have been substantial advances in electrolyte and electrode materials for improving the performance of protonic ceramic fuel cells and protonic ceramic electrolyzers. However, the electrocatalytic materials development for synthesizing chemicals in PCECs has gained less attention, and there is a lack of systematic and fundamental understanding of the PCEC reactor design, reaction mechanisms, and electrode materials. This review comprehensively summarizes and critically evaluates the most up‐to‐date progress in employing PCECs to synthesize a wide range of chemicals, including ammonia, carbon monoxide, methane, light olefins, and aromatics. Factors that impact the conversion, selectivity, product yield, and energy efficiencies are discussed to provide new insights into designing electrochemical cells, developing electrode materials, and achieving economically viable chemical synthesis. The primary challenges associated with producing chemicals in PCECs are highlighted. Approaches to tackle these challenges are then offered, with a particular focus on deliberately designing electrode materials, aiming to achieve practically valuable product yield and energy efficiency. Finally, perspectives on the future development of PCECs for synthesizing sustainable chemicals are provided.
03 NATURAL GAS↗
Microgravity Outreach and Education
The NASA Microgravity Research Program has been actively developing classroom activities and educator's guides since the flight of the First United States Microgravity Laboratory. In addition, various brochures, posters, and exhibit materials have been produced for outreach efforts to the general public and to researchers outside of the program. These efforts are led by the Microgravity Research Outreach/Education team at Marshall Space Flight Center, with classroom material support from the K-12 Educational Program of The National Center for Microgravity Research on Fluids and Combustion (NCMR), general outreach material development by the Microgravity Outreach office at Hampton University, and electronic/media access coordinated by Marshall. The broad concept of the NCMR program is to develop a unique set of microgravity-related educational products that enable effective outreach to the pre-college community by supplementing existing mathematics, science, and technology curricula. The current thrusts of the program include summer teacher and high school internships during which participants help develop educational materials and perform research with NCMR and NASA scientists; a teacher sabbatical program which allows a teacher to concentrate on a major educational product during a full school year; frequent educator workshops held at NASA and at regional and national teachers conferences; a nascent student drop tower experiment competition; presentations and demonstrations at events that also reach the general public; and the development of elementary science and middle school mathematics classroom products. An overview of existing classroom products will be provided, along with a list of pertinent World Wide Web URLs. Demonstrations of some hands on activities will show the audience how simple it can be to bring microgravity into the classroom.
Rogers, Melissa J. B.↗
Advanced Electrical Materials and Components Development: An Update
The primary means to develop advanced electrical components is to develop new and improved materials for magnetic components (transformers, inductors, etc.), capacitors, and semiconductor switches and diodes. This paper will give an update of the Advanced Power Electronics and Components Technology being developed by the NASA Glenn Research Center for use in future Power Management and Distribution subsystems used in space power systems for spacecraft and lunar and planetary surface power. The initial description and status of this technology program was presented two years ago at the First International Energy Conversion Engineering Conference held at Portsmouth, Virginia, August 2003. The present paper will give a brief background of the previous work reported and a summary of research performed the past several years on soft magnetic materials characterization, dielectric materials and capacitor developments, high quality silicon carbide atomically smooth substrates, and SiC static and dynamic device characterization under elevated temperature conditions. The rationale for and the benefits of developing advanced electrical materials and components for the PMAD subsystem and also for the total power system will also be briefly discussed.
Schwarze, Gene E.↗
Summary Report for the Technical Interchange Meeting on Development of Baseline Material Properties and Design Guidelines for In-Space Manufacturing Activities
NASA Marshall Space Flight Center (MSFC) and the Agency as a whole are currently engaged in a number of in-space manufacturing (ISM) activities that have the potential to reduce launch costs, enhance crew safety, and provide the capabilities needed to undertake long-duration spaceflight. The recent 3D Printing in Zero-G experiment conducted on board the International Space Station (ISS) demonstrated that parts of acrylonitrile butadiene styrene (ABS) plastic can be manufactured in microgravity using fused deposition modeling (FDM). This project represents the beginning of the development of a capability that is critical to future NASA missions. Current and future ISM activities will require the development of baseline material properties to facilitate design, analysis, and certification of materials manufactured using in-space techniques. The purpose of this technical interchange meeting (TIM) was to bring together MSFC practitioners and experts in materials characterization and development of baseline material properties for emerging technologies to advise the ISM team as we progress toward the development of material design values, standards, and acceptance criteria for materials manufactured in space. The overall objective of the TIM was to leverage MSFC's shared experiences and collective knowledge in advanced manufacturing and materials development to construct a path forward for the establishment of baseline material properties, standards development, and certification activities related to ISM. Participants were asked to help identify research and development activities that will (1) accelerate acceptance and adoption of ISM techniques among the aerospace design community; (2) benefit future NASA programs, commercial technology developments, and national needs; and (3) provide opportunities and avenues for further collaboration.
Prater, T. J.↗
Toughening materials: enhancing resistance to fracture
It has been said that ‘God invented plasticity, but the Devil invented fracture!’ Both mechanisms represent the two prime modes of structural failure, respectively, plastic collapse and the rupture/breaking of a component, but the concept of developing materials with enhanced resistance to fracture can be difficult. This is because fracture resistance invariably involves a compromise—between strength and ductility, between strength and toughness—fundamentally leading to a ‘conflict’ between nano-/micro-structural damage and the mechanisms of toughening. Here, we examine the two major classes of such toughening: (i) intrinsic toughening, which occurs ahead of a crack tip and is motivated by plasticity—this is the principal mode of fracture resistance in ductile materials, and (ii) extrinsic toughening, which occurs at, or in the wake of, a crack tip and is associated with crack-tip shielding—this is generally the sole mode of fracture resistance in brittle materials. We briefly examine how these distinct mechanistic processes have been used to toughen synthetic materials—intrinsically in gradient materials and in multiple principal-element metallic alloys with the example of metallic glasses and high-entropy alloys, and extrinsically in ceramics with the example of ceramic-matrix composites—in comparison to Nature which has been especially adept in creating biological/natural materials which are toughened by one or both mechanistic classes, despite often consisting of constituents with meagre mechanical properties. The success of Nature has been driven by its ability to cultivate the development of materials with multiple length-scale hierarchical structures that display ingenious gradients and structural adaptability, a philosophy which we need to emulate and more importantly learn to synthesize to make structural materials of the future with unprecedented combinations of mechanical properties.
36 MATERIALS SCIENCE↗
Disassembly of Capsules after Irradiation of Prototype Metal and Nanocomposite Specimens in the High Flux Isotope Reactor
This report summarizes the disassembly, thermometry (TM) analysis, and future post-irradiation examination of irradiation capsules that contain nanodispersion-strengthened materials for the improved neutron irradiation resistance of fuel cladding and reactor core materials. All six capsules were successfully disassembled, and all TM was shipped to the Low Activation Materials Development and Analysis Laboratory for further analysis. The results of this project will support the development of new radiation-resistant materials by helping researchers understand the mechanism of defect evolution at interfaces in nanodispersion-strengthened materials.
36 MATERIALS SCIENCE↗
Investigation of Lunar-Inspired Geopolymer Concrete Formulations Mixed and Cured in Microgravity on the International Space Station (ISS)
The research outlined in this presentation investigates the use of various lunar regolith simulants in geopolymer lunar concrete mixes mixed and cured on the International Space Station (ISS). The motivation for this work is to study the effects of gravity on the microstructure of alkali-activated materials cured with heat, and to develop materials for the construction of long-term infrastructure on the lunar surface with in-situ resource utilization (ISRU). ISRU for construction materials reduces the cost and mass of payloads related to lunar construction. The advantage of geopolymer concrete as opposed to traditional portland cement concrete is that water acts as a medium for the polymerization reaction and leaves the system throughout the process, reducing its demand. Twelve samples of lunar regolith simulant and a solution composed of sodium hydroxide and sodium silicate were sent to the ISS. The three simulants were OPRH2N, OPRL2N, and JSC-1AF, using only particles less than 53 µm in diameter to increase reactivity of the simulant. Simulant to solution ratios were determined by workability while mixing. The simulant and solution were sealed Burst Pouches® along with 2 other sealed bags to prevent material from leaking. Crew member F-14 conducted testing on the ISS by introducing the solution to the simulant in the Burst Pouch®, mixing the sample with a spatula, and then clamping the specimen in the fresh state to prevent flow inside the Burst Pouch®. These specimens were then put in a thermos heated to 80C via sealed drinking water bags to cure for 24 hours with a temperature logger. The cured specimens remained in microgravity for at least 28 days and were returned from the ISS in February 2025. The specimens were then brought to the NASA Marshall Space Flight Center (MSFC) to analyze. Material characterization consisted of conducting Micro-CT tests of entire samples in their sealed apparatus to a resolution of 25µm. 2D image slices were saved in each orthogonal direction of each specimen at a 0.03 mm step size from the 3D model to conduct analytical porosity calculations. Representative samples from each specimen were sampled to perform helium gas pycnometery and were then mounted in resin for SEM imaging, EDS, and nanoindentation. Porosity was analyzed analytically using micromechanics modelling with the assistance of the NASA Multiscale Analysis Tool (NASMAT), as well as the NASA Advanced Supercomputing (NAS) servers (V. Saseendran & N. Yamamoto, 2024). Density was measured using helium gas pycnometery and was then compared to the theoretical density for experimental porosity calculation. Due to the samples’ non-uniform shape being cured in a pouch, traditional compression and tensile strength testing could not be performed. Nanoindentation was conducted at Clarkson University to determine the microhardness and reduced modulus of elasticity. Results from flight samples can be compared to ground samples currently in DLR’s possession to determine the effect on microstructure from being mixed and cured in microgravity. This study gives further insight and understanding of geopolymer lunar concrete and its viability as a lunar construction material with ISRU.
Adam Johnson↗
Impact Testing of 410 Stainless Steel for Material Impact Model Development
A project is underway to develop a consistent set of material properties, impact test data, and failure analysis for a variety of metallic aircraft materials that can be used to develop improved impact failure and deformation models. This project is jointly funded by the NASA Glenn Research Center and the Federal Aviation Administration William J. Hughes Technical Center. Particular features of this set of data are that all material property and impact test data are obtained using traceable material, the test methods and procedures are extensively documented, and all the raw data are available. Four parallel efforts are currently underway: measurement of material deformation and failure response over a wide range of strain rates and temperatures, failure analysis of material property specimens and impact test articles, development of improved numerical modeling techniques for deformation and failure, and impact testing of flat panels and substructures for model validation. This report describes impact testing performed on 410 stainless steel sheet and plate samples of different thicknesses with two different types of projectiles, one a regular cylinder and one with a more complex geometry incorporating features representative of a jet engine fan blade. Data from this testing will be used in validating material models developed under this program. The material tests and the material models developed in this program will be published in separate reports.
410 Stainless Steel↗