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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS1992

Thermal conductance of two interface materials and their applications in space systems

Two polymeric materials, the Cho-Therm 1671 elastomer and the CV-2946 conductive RTV silicone, have been evaluated. Tests were conducted in vacuum and in air, for many clamping pressures, power densities, and as a function of time. Results obtained show that the CV-2946 thermal conductance after 24 hour in vacuum is 0.62 W/sq cm C(4W/sq in C) when clamped with an average pressure of about 350 psi. The maximum conductance of Cho-Therm 1671 is 4.3 W/sq in C at the clamping pressure about 200 psi. After 72 h in vacuum, the conductance reaches a steady 3.4 W/sq in C, independent of clamping pressure. It is concluded that the tightly bolted, torqued fixtures do not buckle or distort and provide an optimum thermal conductance. The fixtures simulating an actual spacecraft configuration suffered severe bowing and separating, which caused considerable degradation of conductance values.

Scialdone, J. J.↗
NASA NTRS2003

Performance Testing of Thermal Interface Filler Materials in a Bolted Aluminum Interface Under Thermal/Vacuum Conditions

A thermal interface material is one of the many tools often used as part of the thermal control scheme for space-based applications. Historically, at Marshall Space Flight Center, CHO-THERM 1671 has primarily been used for applications where an interface material was deemed necessary. However, numerous alternatives have come on the market in recent years. It was decided that a number of these materials should be tested against each other to see if there were better performing alternatives. The tests were done strictly to compare the thermal performance of the materials relative to each other under repeatable conditions and do not take into consideration other design issues, such as off-gassing, electrical conduction, isolation, etc. The purpose of this Technical Memorandum is to detail the materials tested, test apparatus, procedures, and results of these tests. The results show that there are a number of better performing alternatives now available.

Glasgow, S. D.↗
NASA NTRS2003

Performance Testing of Thermal Interface Filler Materials in a Bolted Aluminum Interface Under Thermal/Vacuum Conditions

A thermal interface material is one of the many tools that are often used as part of the thermal control scheme for space-based applications. These materials are placed between, for example, an avionics box and a cold plate, in order to improve the conduction heat transfer so that proper temperatures can be maintained. Historically at Marshall Space Flight Center, CHO-THERM@ 1671 has primarily been used for applications where an interface material was deemed necessary. However, there have been numerous alternatives come on the market in recent years. It was decided that a number of these materials should be tested against each other to see if there were better performing alternatives. The tests were done strictly to compare the thermal performance of the materials relative to each other under repeatable conditions and they do not take into consideration other design issues such as off-gassing, electrical conduction or isolation, etc. This paper details the materials tested, test apparatus, procedures, and results of these tests.

Glasgow, Shaun↗
NASA NTRS2003

Conducting the Heat

Heat conduction plays an important role in the efficiency and life span of electronic components. To keep electronic components running efficiently and at a proper temperature, thermal management systems transfer heat generated from the components to thermal surfaces such as heat sinks, heat pipes, radiators, or heat spreaders. Thermal surfaces absorb the heat from the electrical components and dissipate it into the environment, preventing overheating. To ensure the best contact between electrical components and thermal surfaces, thermal interface materials are applied. In addition to having high conductivity, ideal thermal interface materials should be compliant to conform to the components, increasing the surface contact. While many different types of interface materials exist for varying purposes, Energy Science Laboratories, Inc. (ESLI), of San Diego, California, proposed using carbon velvets as thermal interface materials for general aerospace and electronics applications. NASA s Johnson Space Center granted ESLI a Small Business Innovation Research (SBIR) contract to develop thermal interface materials that are lightweight and compliant, and demonstrate high thermal conductance even for nonflat surfaces. Through Phase II SBIR work, ESLI created Vel-Therm for the commercial market. Vel-Therm is a soft, carbon fiber velvet consisting of numerous high thermal conductivity carbon fibers anchored in a thin layer of adhesive. The velvets are fabricated by precision cutting continuous carbon fiber tows and electrostatically flocking the fibers into uncured adhesive, using proprietary techniques.

Source record↗
DOE OSTI2025

Characterizing Electrode Materials and Interfaces in Solid-State Batteries

Solid-state batteries (SSBs) could offer improved energy density and safety, but the evolution and degradation of electrode materials and interfaces within SSBs are distinct from conventional batteries with liquid electrolytes and represent a barrier to performance improvement. Over the past decade, a variety of imaging, scattering, and spectroscopic characterization methods has been developed or used for characterizing the unique aspects of materials in SSBs. These characterization efforts have yielded new understanding of the behavior of lithium metal anodes, alloy anodes, composite cathodes, and the interfaces of these various electrode materials with solid-state electrolytes (SSEs). This review provides a comprehensive overview of the characterization methods and strategies applied to SSBs, and it presents the mechanistic understanding of SSB materials and interfaces that has been derived from these methods. This knowledge has been critical for advancing SSB technology and will continue to guide the engineering of materials and interfaces toward practical performance.

25 ENERGY STORAGE↗
NASA NTRSDate not supplied

Construction of an Exact Pressure-Equilibrium Scheme for the Five-Equation Two-Phase Flow Model With Thermal Relaxation

Numerical simulation of compressible multiphase flows based on the four-equation (homogeneous relaxation) model is known to suffer from two fundamental difficulties with (a) wave propagation and (b) pressure equilibrium preservation. First, the mixture sound speed exhibits non-monotonic dependency with respect to the volume fraction, which leads to robustness issues in the resolution of shocks and acoustic wave propagation across two-phase regions. This difficulty can be mitigated by solving Allaire’s five-equation model augmented with infinitely fast phasic temperature equilibrium, from which solutions of the four-equation model can be recovered. However, when temperature is non-uniform, this augmented five-equation formulation still fails to preserve pressure equilibrium across material interfaces. In this work, we propose a fully conservative numerical scheme that exactly preserves pressure equilibrium at the discrete level for the augmented five-equation model, for arbitrary initial distributions of temperature and volume fraction. Combined with the monotonic sound speed property of the five-equation formulation, the proposed pressure-equilibrium preserving scheme significantly improves robustness in the presence of strong multiphase interactions, including shock–interface interactions and advection of material interfaces.

ESG↗
NASA NTRS1989

Optimum interface properties for metal matrix composites

Due to the thermal expansion coefficient mismatch (CTE) between the fiber and the matrix, high residual sresses exist in metal matrix composite systems upon cool down from processing temperature to room temperature. An interface material can be placed between the fiber and the matrix to reduce the high tensile residual stresses in the matrix. A computer program was written to minimize the residual stress in the matrix subject to the interface material properties. The decision variables are the interface modulus, thickness and thermal expansion coefficient. The properties of the interface material are optimized such that the average distortion energy in the matrix and the interface is minimized. As a result, the only active variable is the thermal expansion coefficient. The optimum modulus of the interface is always the minimum allowable value and the interface thickness is always the maximum allowable value, independent of the fiber/matrix system. The optimum interface thermal expansion coefficient is always between the values of the fiber and the matrix. Using this analysis, a survey of materials was conducted for use as fiber coatings in some specific composite systems.

Ghosn, Louis J.↗
DOE OSTI2024

Physics-informed neural networks for heterogeneous poroelastic media

This study presents a novel physics-informed neural network (PINN) framework for modeling poroelasticity in heterogeneous media with material interfaces. The approach introduces a composite neural network (CoNN) where separate neural networks predict displacement and pressure variables for each material. While sharing identical activation functions, these networks are independently trained for all other parameters. To address challenges posed by heterogeneous material interfaces, the CoNN is integrated with the Interface-PINNs (I-PINNs) framework (Sarma et al., Comput. Methods Appl. Mech. Eng. 429: 117135, 2024), allowing different activation functions across material interfaces. Further, this ensures accurate approximation of discontinuous solution fields and gradients. Performance and accuracy of this combined architecture were evaluated against the conventional PINNs approach, a single neural network (SNN) architecture, and the eXtended PINNs (XPINNs) framework through two one-dimensional benchmark examples with discontinuous material properties. The results show that the proposed CoNN with I-PINNs architecture achieves an RMSE that is two orders of magnitude better than the conventional PINNs approach and is at least 40 times faster than the SNN framework. Compared to XPINNs, the proposed method achieves an RMSE at least one order of magnitude better and is 40% faster.

42 ENGINEERING↗
DOE OSTI2025

Hierarchical Hybrid Multifunctional Materials through Interface Engineering

This project focuses on the development of stimuli-responsive hybrid multifunctional materials. We place emphasis on the design, synthesis, structural characterization, evaluation of functional properties (electronic, thermal and optical) of several (1-x)Cu 2 Se/(x)WBGS hierarchical bulk composites between Cu 2 Se, a narrow band gap semiconductor (NBGS), with a range of wider band gap semiconductors (WBGS) such as CuMSe 2 (M = Al, Ga, In, Fe, Cr) and Cu 4 TiSe 4 . Cu2Se is a well-studied NBGS with excellent thermoelectric properties (high electrical conductivity, large thermopower, etc.) while CuMSe 2 and Cu 4 TiSe 4 are high performance solar absorber materials (large band gap, large absorption coefficient, etc.). Our primary objectives are (i) to demonstrate the ability to integrate dissimilar functional properties such as large optical absorption coefficient and high electronic conductivity, within (1-x)Cu 2 Se/(x)WBGS composite; and (ii) to establish the correlation between the hierarchical structural entanglement of Cu 2 Se with WBGS (CuMSe 2 or Cu 4 TiSe 4 ) phase, the interactions between native electronic defects within the coexisting phases in the resulting (1-x)Cu 2 Se/(x)WBGS bulk composites , and the impacts on their electronic conductivity, thermal transport and optical properties.

36 MATERIALS SCIENCE↗
NASA NTRS1980

Development of simplified process for environmentally resistant cells

This report describes a program to develop a simple, foolproof, all vacuum solar cell manufacturing process which can be completely automated and which results in medium efficiency cells which are inherently environmentally resistant. All components of the completed cells are integrated into a monolithic structure with no material interfaces. The exposed materials (SI, Al2O3, Al, Ni) are all resistant to atmospheric attack and the junction, per se, is passivated to prevent long term degradation. Such cells are intended to be incorporated into a simple module consisting basically of a press formed metallic superstructure with a separated glass cover for missile, etc., protection.

King, W. J.↗
NASA NTRS2005

Materials Control for Aerospace Applications

The distant future of mankind and the ultimate survivability of the human race, as it is known today, will depend on mans' ability to break earthly bonds and establish new territorial positions throughout the universe. Man must therefore be positioned to not only travel to, but also, to readily adapt to numerous and varying environments. For this mass migration across the galaxies nothing is as import to the human race as is NASA's future missions into Low Earth Orbit (LEO), to the moon, and/or Mars. These missions will form the building blocks to eternity for mankind. From these missions, NASA will develop the foundations for these building blocks based on sound engineering and scientific principles, both known and yet to be discovered. The integrity of the program will lead to development, tracking and control of the most basic elements of hardware production: That being development and control of applications of space flight materials. Choosing the right material for design purposes involves many considerations, such as governmental regulations associated with manufacturing operations, both safety of usage and of manufacturing, general material usage requirements, material longevity and performance requirements, material interfacing compatibility and material usage environments. Material performance is subject to environmental considerations in as much as a given material may perform exceptionally well at standard temperatures and pressures while performing poorly under non-standard conditions. These concerns may be found true for materials relative to the extreme temperatures and vacuum gradients of high altitude usage. The only way to assure that flight worthy materials are used in design is through testing. However, as with all testing, it requires both time on schedule and cost to the operation. One alternative to this high cost testing approach is to rely on a materials control system established by NASA. The NASA community relies on the MAPTIS materials control system founded at MSFC and supported by the other NASA Centers. This system is a data bank of all materials used in space flight operations. These materials are rated for several characteristics that are common concerns in high altitude or deep space usage: Odor, off gassing, material fluid compatibility, toxicity, corrosion susceptibility, stress corrosion susceptibility, etc.

Ferguson, Michael↗
NASA NTRS1992

Numerical Study of Mixing of Two Fluids Under Low Gravity

The mixing characteristics of two fluids inside a cavity due to buoyancy driven flow fields for low gravity conditions is investigated via numerical experiments. The buoyancy driven flow, depending on the parametric region, stretches and deforms the material interface into a wave morphological pattern. The morphological pattern affects the resulting stratification thickness of the mixed region. Three basic mixing regimes occur: convective, diffusive, and chaotic. In the convective regime, an overturning motion occurs which gives rise to a stable wave formation. This wave oscillates and its decay leads to a stable stratification. Whereas, in the diffusive regime, the length of the interface remains constant while mixing occurs. This limiting behavior is very important to materials processing in space, and it admits a closed form solution corresponding to vanishing convective terms which agrees with computational results. Finally, in the chaotic regime, the material interface continuously stretches and folds on itself similar to a horseshoe map. The length of stretch of the interface increases exponentially. Internal wavebreaking occurs for this case. This wavebreaking generates local turbulence, and provides an effective mechanism for mixing.

Duval, Walter M. B.↗
DOE OSTI2025

Novel Superionic Na Conductors for Solid‐State Na batteries: Materials and Interface

This project aims to advance the fundamental understanding on how the cation or anion doping influence on the crystal structure, phase stability and ion transport of novel Na superionic conductors. Specifically, we focus on the Na 3-x A x SbS 4-y X y family solid electrolytes (A: cation dopant, X: anion dopant), a class of promising materials for all-solid-state sodium batteries owing to their high ionic conductivity and compositional tunability. By integrating materials synthesis, neutron scattering, and electrochemical characterization and theoretical simulations, this project sees to elucidate 1) how does the synthesis approaches (solid-state reaction, low-temperature reaction) on the phase purity and doping process; 2) how chemical doping (A: cation dopants such as Sn; X: anion dopants such as Se, F) modulate lattice dynamics and Na+ migration as well as interface stability toward Na metal. Specifically, this project’s proposed technology involves three objectives: (1) synthesize novel Na-ion conductors (anion or cation doped Na 3 SbS 4 ) with high phase purity and examine their structural features (e.g., phase stability); (2) understand Na-ion conductive properties of new Na-ion conductors through a combination of experimental characterizations and theoretical simulations; (3) investigate the interface stability of novel Na superionic conductors with electrode materials in solid-state Na batteries. These objectives will be achieved through combined experimental synthesis/characterizations and computational approaches. The obtained knowledge will provide a comprehensive synthesis-structure-property correlation, enabling the rational design of novel solid-state conductors with excellent conductivity and stability.

25 ENERGY STORAGE↗
NASA NTRS2003

Development of Probabilistic Life Prediction Methodologies and Testing Strategies for MEMS

This effort is to investigate probabilistic life prediction methodologies for MicroElectroMechanical Systems (MEMS) and to analyze designs that determine stochastic properties of MEMS. This includes completion of a literature survey regarding Weibull size effect in MEMS and strength testing techniques. Also of interest is the design of a proper test for the Weibull size effect in tensile specimens. The Weibull size effect is a consequence of a stochastic strength response predicted from the Weibull distribution. Confirming that MEMS strength is controlled by the Weibull distribution will enable the development of a probabilistic design methodology for MEMS - similar to the GRC developed CARES/Life program for bulk ceramics. Another potential item of interest is analysis and modeling of material interfaces for strength as well as developing a strategy to handle stress singularities at sharp corners, filets, and material interfaces. The ultimate objective of this effort is to further develop and verify the ability of the Ceramics Analysis and Reliability Evaluation of Structuredlife (CARES/Life) code to predict the time-dependent reliability of MEMS structures subjected to multiple transient loads. Along these lines work may also be performed on transient fatigue life prediction methodologies.

Jadaan, Osama M.↗
NASA NTRS2003

Development of Testing Methodologies for the Mechanical Properties of MEMS

This effort is to investigate and design testing strategies to determine the mechanical properties of MicroElectroMechanical Systems (MEMS) as well as investigate the development of a MEMS Probabilistic Design Methodology (PDM). One item of potential interest is the design of a test for the Weibull size effect in pressure membranes. The Weibull size effect is a consequence of a stochastic strength response predicted from the Weibull distribution. Confirming that MEMS strength is controlled by the Weibull distribution will enable the development of a probabilistic design methodology for MEMS - similar to the GRC developed CARES/Life program for bulk ceramics. However, the primary area of investigation will most likely be analysis and modeling of material interfaces for strength as well as developing a strategy to handle stress singularities at sharp corners, filets, and material interfaces. This will be a continuation of the previous years work. The ultimate objective of this effort is to further develop and verify the ability of the Ceramics Analysis and Reliability Evaluation of Structures Life (CARES/Life) code to predict the time-dependent reliability of MEMS structures subjected to multiple transient loads.

Ekwaro-Osire, Stephen↗
NASA NTRS1993

ASRM nozzle thermal analysis

This report describes results from the nozzle thermal analysis contract which has been performed to support NASA/Marshall Space Flight Center in the development of the Advanced Solid Rocket Motor (ASRM). The emphasis of this study has been directed to four potential problem areas of the nozzle. These areas are the submerged nozzle region containing the flex seal, the nozzle entrance region, the material interface region in the nozzle exit cone, and the aft region of the exit cone. This study was limited throughout by inadequate material response models, especially for the polyisoprene flex seal and the low density carbon phenolic used in the exit cone. Thermal response and particle erosion calculations were performed for each of the potential problem areas. Results from these studies showed excessive erosion (large negative safety margins) to occur in the flex seal and nozzle entrance regions. The exit cone was found to be marginally adequate (near zero safety margins) and the material interface region was found not to be a problem.

Strobel, Forrest↗
DOE OSTI2026

A cell-centered AMR-ALE framework for 3D multi-material hydrodynamics. Part I: Lagrangian and indirect Euler AMR algorithms

Many applications of physics and engineering involve wide ranges of time and spatial scales. The numerical simulation of localized small scales such as shock waves and material interfaces requires a large number of computational cells in these regions. For these applications, Lagrangian and Arbitrary-Lagrangian-Eulerian (ALE) related methods are engaging since the moving mesh feature naturally brings mesh cells on shock discontinuities and material interfaces are carefully captured. In addition, Adaptive-Mesh-Refinement (AMR) strategies aim to optimize computational resources by concentrating finer mesh cells only in areas of interest while using coarser cells elsewhere. A key but challenging AMR requirement consists in efficiently distributing the computational effort to achieve high accuracy without the prohibitive computational costs associated with uniformly fine grids. Here, in this document, the coupling of the p4est AMR library with a cell-centered Lagrangian scheme is presented with the goal to perform reliable 3D Lagrangian-AMR and indirect Euler-AMR multi-material simulations. In particular, it is shown that starting from a 3D indirect ALE code, the memory management and load balancing requirements can be delegated to an external library (here the p4est library) to unlock ALE-AMR capabilities. First, we present a strategy to transcribe the octant-based connectivity of the 3D AMR framework with that of an unstructured mesh of polygonal cells used in Lagrangian hydrodynamics. Then, we show how refinement and coarsening operations must be adapted to the particular Lagrangian framework to ensure the conservation of volume during those steps. Finally, several numerical test cases are presented that demonstrate the capabilities of the Lagrangian-AMR and indirect Euler-AMR algorithms.

3D cell-centered Lagrangian numerical scheme↗
NASA NTRS1985

Efficient Joints for Graphite/Epoxy Structures

Bonded joints perform well through wide temperature range. Tests indicate significant improvement in joint efficients available through geometric modifications and hybrid material additions at adherent interfaces. Material modifications consisted of placing S-glass polyimide fabric in joint between adherents. Most fabric interface specimens delaminated between two fabric plies as opposed to failing in base adherents.

Skoumal, D. E.↗