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956 records · Page 19

Hubble Space Telescope On-orbit NiH2 Battery Performance

This paper summarizes the Hubble Space Telescope (HST) nickel-hydrogen (NiH2) battery performance from launch to the present time. Over the life of HST vehicle configuration, charge system degradation and failures together with thermal design limitations have had a significant effect on the capacity of the HST batteries. Changes made to the charge system configuration in order to protect against power system failures and to maintain battery thermal stability resulted in undercharging of the batteries. This undercharging resulted in decreased usable battery capacity as well as battery cell voltage/capacity divergence. This cell divergence was made evident during on-orbit battery capacity measurements by a relatively shallow slope of the discharge curve following the discharge knee. Early efforts to improve the battery performance have been successful. On-orbit capacity measurement data indicates increases in the usable battery capacity of all six batteries as well as improvements in the battery cell voltage/capacity divergence. Additional measures have been implemented to improve battery performance, however, failures within the HST Power Control Unit (PCU) have prevented verification of battery status. As this PCU fault prevents the execution of on-orbit capacity testing, the HST Project has based the battery capacity on trends, which utilizes previous on-orbit battery capacity test data, for science mission and servicing mission planning. The Servicing Mission 38 (SM-3B) in March 2002 replaced the faulty PCU. Following the servicing mission, on-orbit capacity test resumed. A summary of battery performance is reviewed since launch in this paper.

Rao, Gopalakrishna M.

Development of an Additively Manufactured Subscale Secondary Sealed Container for the NASA FROSTE Project

This presentation details the development of an additively manufactured (AM) subscale test article for the secondary sealed container (SSC) as part of the NASA FROSTE project. FROSTE is focused on the collection of regolith samples from shadowed regions of the Moon and the preservation of those samples at cryogenic temperatures for return to Earth. Our team was integrated into the FROSTE program to leverage innovative design approaches and additive manufacturing capabilities in support of a scalable development strategy, where the subscale configuration serves as the development path toward a full-scale SSC. Scalmalloy was selected as the primary material for all AM components due to its favorable strength-to-weight ratio, thermal conductivity, and demonstrated performance in aerospace applications. Its aluminum-based composition supports robust mechanical behavior at cryogenic temperatures while enabling efficient heat transfer and control of thermal gradients within the containment system. The SSC architecture consists of an outer container assembly that houses a phase change material (PCM) tank, which in turn contains primary containers holding the regolith. Thermal management relies on controlled conductive and radiative heat transfer, including a thermal connection assembly that interfaces the PCM tank to an external cryocooler via a thermal strap, and IMLI surrounding the PCM tank to inhibit radiative heat transfer. The outer container assembly incorporates sealing interfaces, thermal connection ports, and I/O feedthroughs, with PTFE spring seals used at critical interfaces to maintain containment integrity. The PCM tank is manufactured as a single monolithic Scalmalloy component and incorporates an integral lattice structure to minimize thermal gradients, internal channels for thermocouple routing, and interface features for thermal connection assembly integration. The tank is centrally suspended within the outer container using support rings, with G10 insulating components employed to inhibit thermal leaks. This work describes the design methodology, AM approach, and key considerations used to inform the design.

regolith

Revisiting the Soyuz-1 Parachute Failure in the Context of Safety in the Modern Era

The Soyuz‑1 accident remains one of the most consequential parachute related failures in human spaceflight history and provides enduring lessons for modern Entry, Descent, and Landing (EDL) system design. Occurring during the height of the Cold War and the Space Race, the mission unfolded under extraordinary political and schedule pressure as the Soviet Union sought to maintain its early leadership in space achievements following the death of chief designer Sergei Korolev. Despite unresolved propulsion, electrical, and parachute system deficiencies, Soyuz‑1 proceeded to launch and immediately encountered critical inflight anomalies, including a failed solar panel deployment, attitude control issues, and communication dropouts. Upon reentry, a malfunction in the parachute system, driven by a primary main canopy that failed to deploy, and subsequent entanglement of the reserve main canopy with the primary drogue parachute, resulted in insufficient deceleration and the fatal crash of cosmonaut Vladimir Komarov. Subsequent investigations revealed deep rooted cultural and organizational issues within the Soviet space program, including inadequate testing, suppression of dissent, undocumented last minute design changes, and the absence of integrated parachute system verification. More than 200 design flaws were identified after the accident, and firsthand accounts, including those from Yuri Gagarin, highlighted widespread concern prior to launch. Over time, the Soviet program implemented substantial reforms: systematic design corrections, rigorous process documentation, and an extensive series of drop tests that ultimately transformed the Soyuz system into one of the world’s most reliable human-rated return vehicles. This paper examines the technical architecture of the Soyuz‑1 parachute system, reconstructs the likely deployment sequence and failure mechanism, and analyzes the cultural contributors that shaped the accident. The study draws parallels to modern spacecraft parachute development, emphasizing the critical importance of integrated system testing, transparent engineering culture, and continuous hardware surveillance. These lessons remain directly relevant to today’s NASA and Commercial Crew Programs (CCP), where the Government continues to refine its understanding of aggregate risk and strengthen overall astronaut safety in the face of increasingly complex parachute systems.

Aaron L Morris

Artificial Intelligence for Multi-Mission Planetary Operations

A brief introduction is given to an automated system called the Spacecraft Health Automated Reasoning Prototype (SHARP). SHARP is designed to demonstrate automated health and status analysis for multi-mission spacecraft and ground data systems operations. The SHARP system combines conventional computer science methodologies with artificial intelligence techniques to produce an effective method for detecting and analyzing potential spacecraft and ground systems problems. The system performs real-time analysis of spacecraft and other related telemetry, and is also capable of examining data in historical context. Telecommunications link analysis of the Voyager II spacecraft is the initial focus for evaluation of the prototype in a real-time operations setting during the Voyager spacecraft encounter with Neptune in August, 1989. The preliminary results of the SHARP project and plans for future application of the technology are discussed.

David J Atkinson

Development of global/chemistry model for jet-fuel thermal stability based on observations from static and flowing experiments

Two global-chemistry models for oxidative deposition of jet fuels are evaluated by integrating them into a Computational Fluid Dynamics with Chemistry (CFDC) code. A previously developed two-step global-chemistry model was found to be insufficient to describe the thermal-oxidation and -deposition rates associated with a Jet-A fuel. A new global-chemistry model has been developed systematically based on observations from flowing and static experiments. The global-autoxidation reaction is modified such that the reaction rate becomes zeroth-order with respect to the dissolved oxygen concentration. The generation of deposit-forming precursor is coupled with the autoxidation reaction by introducing a radical species ROO. A formulation for the sticking probability has also been developed. Deposition profiles are well represented by this new model under a variety of temperature and flow conditions. The model correctly predicts the changes in magnitude and spatial location of the deposition peak due to changes in flow. The CFDC model, which is designed for flowing systems, has been extended to static experiments. The model incorporates a non-depleting species F(sub s) representing all non-oxygen compounds responsible for deposition. Static experiments were found to provide a useful and inexpensive method for estimating the concentration of F(sub s) in the fuel.

V. R. Katta

The Significance of Water Vapor Isotopes in Improving Weather Prediction

Water vapor isotopes carry the integrated history of evaporation, condensation, mixing, and transport. Although previous studies have shown potential to improve forecasts under controlled conditions, real-world applications have been limited by systematic biases in both models and satellite retrievals arising from sparse measurements in the free troposphere. Here we assimilate mid‑tropospheric δD retrievals (peak sensitivity ~4.2 km) from the Infrared Atmospheric Sounding Interferometer into the Isotope‑incorporated Global Spectral Model and evaluate the added value beyond co‑assimilated temperature and specific humidity with identical spatial and temporal coverage. Assimilating δD improves 0–120 h forecasts of wind, temperature, specific humidity, and geopotential height, with the largest gains in the midlatitudes; heavy‑precipitation skill also increases for thresholds >3 mm per 6 h. Demonstrated in a coarse‑resolution configuration with limited observations, the results indicate that isotopic information strengthens transport tracking and hydrological constraints, motivating evaluation in operational high‑resolution forecasting systems.

Hydrology

X-Hab 2026: LiDAR-Powered Autonomous Charging Service Capability for Surface Rovers and Systems

This document details the timeline of the LiDAR-Powered Autonomous Charging Service Capability for Surface Rovers and Systems project, initiated by the Fall 2025 semester class and completed by the Spring 2026 semester class. This project focuses on developing a fully autonomous system composed of a mobile surface rover and an induction charging station with a robotic arm, both controlled by their own NVIDIA Jetson Orin Nano. Structural improvements to the rover suspension system and body eliminated excessive camber, reduced stress and strain on the plexiglass body, and improved maneuverability and durability of the rover. The charging station robotic arm was fully redesigned to increase reach while minimizing weight and increasing misalignment tolerance during docking on uneven terrain. Electrical system improvements addressed previous torque and power limitations of both the rover and charging station arm. High-torque servo motors were selected based on updated calculations which incorporated terrain slope and Factor of Safety, enabling zero-point turning for the rover and increased payload capacity of the charging station arm. Significant progress was made in autonomy and perception. The rover now employs 3D LiDAR and SLAM mapping for localization, mapping, and path planning. The Battery Monitoring System (BMS) was created to coordinate battery management between the rover and charging station. The BMS provides continuous monitoring of battery state of charge, temperature, current, and will enable the autonomous initiation, execution, and termination of the charging cycle via Bluetooth communication. Testing of the WIBOTIC induction charging system demonstrated reliable power transfer under both aligned and misaligned conditions. This project demonstrated the ability of an autonomously navigating surface rover to independently plan a path to the charging station, dock, and the charging station to autonomously deploy a robotic charging arm and initiate charging of the rover. This work details the progress made to demonstrate the feasibility of autonomous surface rover navigation and recharging systems.

Megan Steele

Novel Polyimide Battery Separator Imbibed with Room-Temperature Ionic Liquids

The journey to Mars will require advancements in many existing technologies, including space power and energy storage systems. According to the 2015 NASA Technology Roadmaps, energy storage is a critical technology area to develop for both terrestrial as well as future long-term space missions. Currently, batteries represent one of the major areas in need of advancement, both in terms of energy density as well as safety. Recently, concerns regarding the fire safety of commercial lithium-ion batteries have prompted efforts to produce nonflammable battery components, namely the electrolyte and separator. Commercial lithium-ion batteries utilize polyolefin separators imbibed with a lithium salt dissolved in cyclic carbonates. This separator/electrolyte combination imparts good ionic conductivities in the range of 10(exp -2) to 10(exp -3) S/cm. However, the cyclic carbonates and polyolefin separator are inherently flammable. Room-temperature ionic liquids (RTILs) appear to be a safer alternative to cyclic carbonates. They offer good ionic conductivities, similar to those observed in cyclic carbonates, but are inherently nonvolatile and nonflammable giving them a safety advantage. Many promising RTILs for battery electrolytes are not compatible with commercial polyolefin separator materials. Polyimide aerogels possess an open-porous, fibrillar network architecture which offers a high degree of porosity (typically greater than 85 porous), required for lithium ion conduction, as well as good mechanical properties. Furthermore, these materials are compatible with all tested RTILs. By creating a polyimide gel and imbibing the gel with a RTIL containing a lithium salt instead of super critically drying them to form aerogels, a nonflammable separator/electrolyte system with conductivities in the range of 1x10(exp -3) S/cm has been demonstrated.

Polyimide

Performance of the Satellite Test Assistant Robot in JPL's Space Simulation Facility

An innovative new telerobotic inspection system called STAR (the Satellite Test Assistant Robot) has been developed to assist engineers as they test new spacecraft designs in simulated space environments. STAR operates inside the ultra-cold, high-vacuum, test chambers and provides engineers seated at a remote Operator Control Station (OCS) with high resolution video and infrared (IR) images of the flight articles under test. STAR was successfully proof tested in JPL's 25-ft (7.6-m) Space Simulation Chamber where temperatures ranged from +85 C to -190 C and vacuum levels reached 5.1 x 10 -6 torr. STAR's IR Camera was used to thermally map the entire interior of the chamber for the first time. STAR also made several unexpected and important discoveries about the thermal processes occurring within the chamber. Using a calibrated test fixture arrayed with ten sample spacecraft materials, the IR camera was shown to produce highly accurate surface temperature data. This paper outlines STAR's design and reports on significant results from the thermal vacuum chamber test.

Douglas McAffee

LDEF experiment M0003 meteoroid and debris survey

A survey of the meteoroid and space debris impacts on LDEF experiment M0003 was performed. The purpose was to document impact phenomenology and to obtain impact crater data for comparison to current debris and micrometeoroid models. The survey consists of photomicrographs of significant impacts in a variety of material types, accurate measurements of impact crater coordinates and dimensions for selected experiment surfaces and data basing of the crater data for reduction, manipulation, and comparison models. Large area surfaces which were studied include the experiment power and data system sunshields, environment exposure control canister sunshields, and the M0003 signal conditioning unit covers. Crater diameters down to 25 microns were measured and catalogued. Both leading and trailing edge surfaces were studied and compared. The results shows the different response of materials to hypervelocity impacts. Comparison of the data to curves derived from the Kessler debris model and the Cour-Palais micrometeoroid model indicates a marked tendency for overprediction of small impacts and underprediction of large impacts with there being better agreement for the medium sized impacts. Representative impact data is presented.

M. J. Meshishnek

Spacecraft thermal balance testing using infrared sources

A thermal balance test (controlled flux intensity) on a simple black dummy spacecraft using IR lamps was performed and evaluated, the latter being aimed specifically at thermal mathematical model (TMM) verification. For reference purposes the model was also subjected to a solar simulation test (SST). The results show that the temperature distributions measured during IR testing for two different model attitudes under steady state conditions are reproducible with a TMM. The TMM test data correlation is not as accurate for IRT as for SST. Using the standard deviation of the temperature difference distribution (analysis minus test) the SST data correlation is better by a factor of 1.8 to 2.5. The lower figure applies to the measured and the higher to the computer-generated IR flux intensity distribution. Techniques of lamp power control are presented. A continuing work program is described which is aimed at quantifying the differences between solar simulation and infrared techniques for a model representing the thermal radiating surfaces of a large communications spacecraft.

G. B. T. Tan

Ruled and holographic experiment (AO 138-5)

The AO 138-5 experiment has been designed, via the French Cooperative Payload (FRECOPA) experiment with the aim to study the optical behavior of different diffraction gratings submitted to space vacuum long exposure and solar radiation. Samples were rules and holographic gratings, masters or replica, and some additional control mirrors with various coatings. The experiment was located on the B3, trailing edge of the Long Duration Exposure Facility (LDEF) and has been protected against atomic oxygen flux. The experienced thermal cycling has been evaluated from -23 C to 66 C during the flight, 34,000 orbits. The analysis has been focused on the triple point characterization including light efficiency, wavefront flatness quality and stray light level. Tests were conducted on control mirrors and gratings loaded but not exposed to cosmic dust or solar irradiations. They did not show any significant variations. Solar exposure has damaged the coating reflectivity in the ultraviolet region, the degradation is higher with the gratings, in terms of efficiency. However, wavefront flatness quality and stray light level tests revealed no additional changes.

Francis Bonnemason

Pocket nickel cadmium cell and battery evaluation

The Nickel Cadmium 129-ampere hour cell was tested in order to characterize the cell under controlled conditions. Results of charge characterization and discharge characterization are reported. Ampere hour efficiency, open circuit stand, and cycle life operation results are included. The battery is briefly described.

Lear, J. W.

Engineering the Interface: Advanced Surface Technologies for Lunar Dust Management and Equipment Longevity

Through the Artemis program, NASA intends to develop a sustainable human foothold on the Moon, ultimately paving the way for crewed exploration of Mars. The Moon's hostile environment poses numerous obstacles, including exposure to radiation, temperature extremes, micrometeoroid threats, and particularly the persistent problem of lunar dust. Lunar dust impacts nearly every aspect of surface operations through adhesion and abrasion mechanisms, with contamination from anthropogenic activities (landing, rovers) far outweighing natural phenomena. Multiple adhesion pathways contribute to surface contamination in the lunar environment, including van der Waals forces, electrostatic forces, chemical reaction, and magnetic forces from elemental iron deposits. Sharp asperities from micrometeoroid bombardment and atmospheric absence increase interaction potential and enable mechanical interlocking. Low cohesion between dust particles exacerbates these challenges, as minimal interaction potential between dust and nearby surfaces overcomes particle cohesion, causing contamination. Lunar dust adhesion mitigation technologies can be categorized as either active, requiring external energy, or passive, relying on intrinsic material properties. Ultrasonic and electrodynamic technologies have been developed to the highest technology readiness level for active approaches. Passive strategies primarily focus on surface chemistry and topography modifications. At NASA Langley Research Center, approaches include surface migration agents to reduce surface energy, topographical modification using laser ablation patterning, and tailored surface conductivity to reduce intrinsic adhesion force. Performance has been evaluated using custom-built ultrasonic and centrifuge instruments. Plume-surface interactions from lunar landers can propel micrometer-sized particles at velocities up to 1000 m s-1.8 These particles pose risks to landers, habitats and infrastructure, leading to erosion, degradation, and reduced component lifespan. A panel recovered from Surveyor III was determined to have been severely abraded because of lunar dust displaced from the Apollo 12 lunar module that landed 160 m away. The performance of metallic surfaces has been evaluated via high velocity single particle impact using the laser-induced project impact test (LIPIT) facility at the University of Utah. Peridynamics modeling, a form of continuum mechanics that uses a nonlocal approach enabling greater simulation capabilities of crack initiation and fracture, has also been utilized to gain greater insight into material response during impact events. Lunar dust contamination challenges extend to power generation systems and moving equipment. Cables, rotation stages, and other mechanisms may experience limited range of motion and reduced lifetime due to dust infiltration. NASA Langley Research Center has evaluated traditional aerospace alloys, softgoods, wear resistant ceramics, and several polymer and polymer composite materials. Test methods have included traditional techniques like Taber abrasion testing, as well as designed test configurations developed in the DUSTE (dust, ultraviolet radiation, and space thermal environmental) chamber that reproduce mechanism functions in operational environment. Beyond laboratory experiments, several flight experiments have been conducted. Materials were exposed to the low Earth orbit environment on the Materials International Space Station Experiment (MISSE) and to the lunar surface environment through the Aegis Aerospace Regolith Adherence Characterization (RAC) payload and the Honeybee Robotics PlanetVac payload. Determining lunar dust's impact on surface exploration and habitation requires comprehensive experimental and computational capabilities combined with lessons learned from initial lunar activities. Identifying the greatest environmental challenges and developing mitigation technologies provides the clearest path toward successfully, expeditiously, and efficaciously completing NASA's mission. This presentation will discuss ongoing efforts at NASA Langley Research Center and collaborator contributions to these critical objectives.

Surface Engineering

Design and Analysis of Battery Thermal Management Systems

Thermal management of battery cell packs is a critically needed technology. The purpose of this work is to design new and improved Battery Thermal Management Systems (BTMS) for use in electric airplanes. The BTMS should be 3D printable and hold twelve to sixteen 18650 batteries. To minimize aircraft’s weight, an actively air-cooled battery pack was chosen to avoid the excess weight of water-cooled and phase change material (PCM) cooled packs. As a result, significant changes were made to remove all metal in the pack and replace it with lower density polymer matrix composites (PMCs) which can be additively manufactured. Two air cooled battery pack configurations (traditional propeller fans & bladeless fans) were designed, modeled, and compared. These packs were first modeled in SolidWorks 2021 3D CAD, then imported into COMSOL MultiPhysics to be studied using the “Heat Transfer in Solids and Fluids” module. The design with the bladeless fans eliminated the need to use high conductivity heavy metal to remove unwanted thermal energy. These bladeless fans were designed entirely out of PMCs. This thermal pack design weighs 0.04 kg less than that of the traditional propeller fans design and has increased the battery pack energy density by 8.25 Wh/kg.

Thermal Management System for Battery Packs