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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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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Characterization Testing of a 20 Kelvin Cryocooler for Space Applications

Future NASA space exploration missions will require long-duration storage and liquefaction of cryogenic liquids, enabled by active cooling provided by cryocoolers. Recent gap analyses of Lunar and Mars transportation systems have identified 20 K-class cryocoolers as a critical enabling technology for chemical and nuclear thermal propulsion architectures using liquid hydrogen propellant. To address this technology gap, NASA has undergone the development of a high-efficiency, high-capacity 20 K cryocooler via an SBIR partnership with Creare. While the January 2025 testing demonstrated functionality and compliance with contractual requirements, the objective of the NASA-led characterization effort was to generate a dataset for supporting future mission designs across a broader operating envelope, including off-nominal conditions. The cryocooler demonstrated strong performance, achieving a peak coefficient of performance of 17.68% relative to Carnot efficiency and a maximum lift capacity of 24.4 W at 21 K. Overall, the results confirm that the 20 W 20 K cryocooler provides a flexible range of capabilities to enable zero boil-off storage of liquid hydrogen for future Lunar and Mars missions. The data collected provide a strong foundation for model validation and future system design efforts.

Zero boil-off↗
NASA NTRS2014

Crewed Space Vehicle Battery Safety Requirements

This requirements document is applicable to all batteries on crewed spacecraft, including vehicle, payload, and crew equipment batteries. It defines the specific provisions required to design a battery that is safe for ground personnel and crew members to handle and/or operate during all applicable phases of crewed missions, safe for use in the enclosed environment of a crewed space vehicle, and safe for use in launch vehicles, as well as in unpressurized spaces adjacent to the habitable portion of a space vehicle. The required provisions encompass hazard controls, design evaluation, and verification. The extent of the hazard controls and verification required depends on the applicability and credibility of the hazard to the specific battery design and applicable missions under review. Evaluation of the design and verification program results shall be completed prior to certification for flight and ground operations. This requirements document is geared toward the designers of battery systems to be used in crewed vehicles, crew equipment, crew suits, or batteries to be used in crewed vehicle systems and payloads (or experiments). This requirements document also applies to ground handling and testing of flight batteries. Specific design and verification requirements for a battery are dependent upon the battery chemistry, capacity, complexity, charging, environment, and application. The variety of battery chemistries available, combined with the variety of battery-powered applications, results in each battery application having specific, unique requirements pertinent to the specific battery application. However, there are basic requirements for all battery designs and applications, which are listed in section 4. Section 5 includes a description of hazards and controls and also includes requirements.

Jeevarajan, Judith A.↗
NASA NTRSDate not supplied

NASA Interests in Superconducting and Cryogenic Technology

NASA develops and operates technology for a wide range of applications and environments across its aeronautics and space portfolios. This presentation will summarize the applications and environments where superconducting technology and associated cryogenics are contributing to NASA’s missions and areas where there is an opportunity to expand the contribution. Important characteristics of high priority space environments will be discussed. An emphasis will be placed on aircraft propulsion and NASA’s Artemis mission (a Moon to Mars initiative). The discussion of space applications will include takeaways from NASA’s recent rankings of 187 space technology “shortfalls”. The aircraft propulsion application will be described in detail and existing NASA investments will be summarized.

Electrified Aircraft Propulsion↗
DOE OSTI2024

The effect of gamma ray irradiation on few layered MoSe2: A material for nuclear and space applications

In recent years, emerging two-dimensional (2D) materials, such as molybdenum diselenide (MoSe2), have been at the center of attention for many researchers. This is due to their unique and fascinating physicochemical properties that make them attractive in space and defense applications that include shielding harsh irradiation environments. In this study, we examined the effects of gamma (γ) rays at various doses on the structural, chemical, and optical properties of MoSe2 layers. After the samples were exposed to intense gamma radiation (from a 60Co source) with various exposure times to vary the total accumulated dosage (up to 100 kGy), Raman and photoluminescence spectroscopies were used to study and probe radiation-induced changes to the samples. When compared to pristine materials, very few changes in optical properties were typically observed, indicating good robustness with little sensitivity, even at relatively high doses of gamma radiation. The imaging using scanning electron microscopy revealed a number of nano-hillocks that were connected to substrate alterations. X-ray photoelectron spectroscopies revealed that Mo’s binding energies remained the same, but Se’s binding energies blueshifted. We associated this shift with the decrease in Se vacancies that occurred after irradiation as a result of Mo atoms creating adatoms next to Se atoms. When compared to pristine materials, very few changes in optical, chemical, and structural properties were typically observed. These findings highlight the inherent resilience of MoSe2 in hostile radioactive conditions, which spurs additional research into their optical, electrical, and structural characteristics as well as exploration for potential space, energy, and defense applications.

Materials Science↗
NASA NTRSDate not supplied

Laser Forming of Sheet Metal for In-Space Manufacturing Applications

As the in-space economy matures, the migration of typically Earth-bound manufacturing methods, such as metal forming and joining, up to space will be required to meet the increasing demand for refueling and supply depots, habitats, laboratories, lunar surface structures, and sites for deep-space exploration shipbuilding. Only in this way can the magnitude of individual structures begin to exceed what can be launched, deployed, docked, or inflated and allow true economies of scale to be unlocked in space. However, typical terrestrial methods of forming and shaping sheet metal require massive machinery with the ability to deflect reaction forces to a large mass in a fixed reference frame (Earth). To both limit up-mass required for manufacture and to mitigate the issues of reaction forces in the relative reference frames of space, a non-contact, laser-based method of forming metal sheet is proposed. NASA Marshall Space Flight Center (MSFC), in cooperation with DARPA and the University of Florida (UF), have begun investigation of non-contact methods of laser forming sheet metal in thermal vacuum (TVAC) conditions to great success. To date, several grades of aluminum, stainless steel, and titanium coupons have been formed via laser-induced internal stresses in these metals at both ambient atmosphere and vacuum conditions. Temperatures in these tests ranged from -120 to 60 C, and though the total energy required to induce strain does vary with workpiece temperature and environmental pressure, the method remains predictable and controllable for the materials investigated. It is believed that this method will revolutionize manufacturing in-space as it not only continues to build upon the capabilities of the laser (sensing, marking, cutting, drilling, joining, and now forming) as an all-in-one tool, but also reduces the need to counteract forming forces as would be required in mechanical bending. In theory, all required stress to induce bending is generated through thermal gradient and strain within the workpiece, meaning that the need for reaction control and fuel expense on-orbit will be limited. Archimedes once stated, “Give me a lever long enough and a fulcrum on which to place it, and I shall move the world”. With a laser as our lever and our workpiece its own fulcrum, we can move the world’s manufacturing into space.

Laser↗
NASA NTRS1976

Apollo-Soyuz Test Project: Preliminary Science Report

This document summarizes the experimental concepts and preliminary analyses (as of December 1975) for each of the 28 scientific experiments conducted during the Apollo-Soyuz Test Project from July 15 to 24, 1975. The scientific topics are X- ray and extreme ultraviolet astronomy, solar astronomy, gamma- ray detectors, Earth studies (including the upper atmosphere, meteorological phenomena, hydrology, oceanography, geology, desert studies, and gravity field studies), microbiology, heavy cosmic particle interaction with live cells, vestibular system studies, and materials processing (including high-temperature and ambient-temperature processing of industrial materials and electrophoretic processing of biological materials) .

Microbiology↗
NASA NTRS1974

Proceedings of the Third Space Processing Symposium Skylab Results: Volume 1

This publication contains the presentations from the Third Space Processing Symposium. These papers cover the results of Materials Processing Experiments conducted on NASA's SKYLAB flights and several related research activities for Materials Processing in Space beyond SKYLAB. Contents consist of the Welcoming Address by Dr. Rocco Petrone, Director, Marshall Space Flight Center; Introduction to Space Processing by Dr. Mathias P. Siebel, Director, Process Engineering Laboratory, Marshall Space Flight Center; thirty-eight papers; and the closing presentation titled Projected Future Space Processing Activities by Dr. James H. Bredt, Office of Applications, National Aeronautics and Space Administration. The Keynote Address was presented by Mr. Charles W. Mathews, Office of Applications, National Aeronautics and Space Administration.

W K Vardaman↗
NASA NTRS1989

Overview of the Center for Advanced Space Propulsion

The mission of the Center for Advanced Space Propulsion (CASP), a Center for the Commercial Development of Space (CCDS), is to strengthen U.S. competitiveness in space technology, foster cooperative research with industry and government, assist industry in developing commercial products and services, and perform research in advanced space propulsion. Current areas of focus are (1) advanced chemical propulsion, including high area ratio nozzle performance, variable thrust engine performance, and spray combustion stability; (2) artificial intelligence propulsion applications, including health monitoring of rocket engines, fault pattern detection and diagnosis, and intelligent hypertext applications; (3) microgravity fluid management, including liquid storage and transfer, a subscale orbital fluid transfer experiment, and helical, two-phase flow; (4) electric propulsion, including magnetic annular arc thruster, ion thrustor, and electrostatic plasma accelerator; and (5) laser materials processing.

George W Garrison↗
NASA NTRS1983

The 1982 Goddard Space Flight Center Battery Workshop

Various topics concerned with advanced battery technology are addressed including lithium cell and battery safety developments, mathematical modelling, charge control of aerospace power systems, and the application of nickel hydrogen cells/batteries vis-a-vis nickel cadmium cells/batteries.

G Halpert↗
NASA NTRSDate not supplied

Evaluating Crystallinity in Thermoplastic Composites for Aerospace Applications

Polymer matrix composites (PMCs) offer many benefits for the aerospace industry due to their potential for weight reduction when compared to metal or ceramic based materials. Most PMCs currently in flight use thermoset matrices, however, thermoplastic resins are being explored as alternatives due to their ability to be remelted, which is of particular interest due to the potential for in-situ repair and faster production. Most thermoplastic resins are semicrystalline polymers. The properties of semicrystalline thermoplastics are directly influenced by their crystallinity, which can vary due to many factors including thermal treatments, environmental conditions, and mechanical deformation. Within thermoplastic PMC parts, crystallinity gradients can arise due to variations in part geometry, across part thicknesses, and along bonded joints. Monitoring the crystallinity of thermoplastic composites is key to ensuring these materials meet the high demands required for aerospace. Several different analytical techniques exist that can be used to characterize the bulk crystallinity of thermoplastic materials. However, many existing methods lack the specificity required to identify the subtle variations in crystallinity that may play a significant role in the performance and durability of PMC parts. Because of this, a significant amount of work is still required to fully characterize and understand the crystallinity profiles of thermoplastic PMCs and the resulting impact to material properties. This talk discusses the use of multiple techniques such as Differential Scanning Calorimetry, Polarized Light Optical Microscopy, and Fourier-Transform Infrared Spectroscopy to characterize the crystallinity in carbon fiber/thermoplastic composites. Samples of different crystallinity profiles were manufactured using various cooling procedures. This work aims to provide the fundamental data necessary to understand the effects of crystallinity on thermoplastic PMCs, which is key to advancing their use in aerospace applications.

Thermoplastics↗
NASA NTRS1996

Space Electrochemical Research and Technology

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

Richard M Wilson↗
NASA NTRS2006

Aerospace Battery Activities at NASA/Goddard Space Flight Center

Goddard Space Flight Center has "pioneered" rechargeable secondary battery design, test, infusion and in-orbit battery management among NASA installations. Nickel cadmium batteries of various designs and sizes have been infused for LEO, GEO and Libration Point spacecraft. Nickel-Hydrogen batteries have currently been baselined for the majority of our missions. Li-Ion batteries from ABSL, JSB, SaFT and Lithion have been designed and tested for aerospace application.

Rao, Gopalakrishna M.↗
NASA NTRSDate not supplied

Thin Film Sensors for Fission Surface Power

Physical sensors fabricated with thin films could result a significant savings in space and weight with improved reliability for monitoring the long-term operation of fission surface power systems. Thin film sensors of 1 µm or less are attractive for FSP applications because they can be incorporated onto component surfaces with minimal machining and the additional weight to a system is minimal compared to thick film-, wire-, or foil-based sensors. The thin, surface fabrication of the sensors is also expected to make them less susceptible to deep dose effects that affect thicker sensors. An overview of thin film sensors using thermocouples and resistive elements designed, fabricated, and demonstrated at GRC for aerospace applications exceeding 900°C is presented.

Physical Sensors↗
NASA NTRS2026

Advanced Materials Testing Plan for the Space Suit Portable Life Support System

The Space Suit Portable Life Support System (PLSS) has a tight mass requirement to meet while also meeting other requirements for supporting a crewmember in space, on the Moon, or on Mars. To meet these requirements, atypical materials must be considered to close the mass budget allocations. However, many of these materials and processes are relatively new and untested. Therefore, initial analysis and testing of some new and advanced processes have been conducted following a roadmap presented last year. This material testing has focused primarily on thermoplastics, both additively manufactured and machined, to assess plating and fastening operations that will be required. These processes will provide additional strength and shielding capability typically only achieved with metallics. This testing has also helped to define a forward plan to certify these materials and processes for critical spaceflight applications. This report will review testing plated thermoplastics both for strength and thermal properties. It will also review fastener and fastening options and look at insert and fastener testing. It will also review state-of-the-art methods being considered elsewhere and some additional testing being conducted. Using the testing results researched here, there will be recommendations on applications for each of these types of methods going forward.

Ryan Ogilvie↗
NASA NTRS2026

Advanced Materials Testing Plan for the Space Suit Portable Life Support System

The Space Suit Portable Life Support System (PLSS) has a tight mass requirement to meet while also meeting other requirements for supporting a crewmember in space, on the Moon, or on Mars. To meet these requirements, atypical materials must be considered to close the mass budget allocations. However, many of these materials and processes are relatively new and untested. Therefore, initial analysis and testing of some new and advanced processes have been conducted following a roadmap presented last year. This material testing has focused primarily on thermoplastics, both additively manufactured and machined, to assess plating and fastening operations that will be required. These processes will provide additional strength and shielding capability typically only achieved with metallics. This testing has also helped to define a forward plan to certify these materials and processes for critical spaceflight applications. This report will review testing plated thermoplastics both for strength and thermal properties. It will also review fastener and fastening options and look at insert and fastener testing. It will also review state-of-the-art methods being considered elsewhere and some additional testing being conducted. Using the testing results researched here, there will be recommendations on applications for each of these types of methods going forward.

Ryan Ogilvie↗
NASA NTRS1989

Advanced Space Power PEM Fuel Cell Systems

A model showing mass and heat transfer in proton exchange membrane (PEM) single cells is presented. For space applications, stack operation requiring combined water and thermal management is needed. Advanced hardware designs able to combine these two techniques are available. Test results are shown for membrane materials which can operate with sufficiently fast diffusive water transport to sustain current densities of 300 ma per square centimeter. Higher power density levels are predicted to require active water removal.

PEM↗
NASA NTRS2026

Expanding Space with Inflatable Softgoods: Roadmap for In-Space Manufacturing of Resilient Space Structures

Overview of inflatable softgoods and their emerging role in enabling large, resilient space habitats and infrastructure. It highlights the advantages of inflatable systems, such as exceptional packing efficiency and scalable habitable volume, while also addressing challenges related to outfitting, complex material behavior, structural design, manufacturing precision, and testing limitations. Core architectural elements of crewed inflatable habitats are described, along with shell layer composition, structural interfaces, and examples of conceptual habitat configurations for transit, lunar, and surface applications. The presentation concludes by outlining key technology shortfalls, including structural health monitoring, ultra‑high‑strength materials, lifetime performance, and integration strategies, emphasizing the need for continued development to support future in‑space manufacturing and exploration missions.

Habitat↗