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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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DOE OSTI2024

Highly Ordered Eutectic Mesostructures via Template‐Directed Solidification within Thermally Engineered Templates

Template-directed self-assembly of solidifying eutectics results in emergence of unique microstructures due to diffusion constraints and thermal gradients imposed by the template. Here, the importance of selecting the template material based on its conductivity to control heat transfer between the template and the solidifying eutectic, and thus the thermal gradients near the solidification front, is demonstrated. Simulations elucidate the relationship between the thermal properties of the eutectic and template and the resultant microstructure. The overarching finding is that templates with low thermal conductivities are generally advantageous for forming highly organized microstructures. When electrochemically porosified silicon pillars (thermal conductivity < 0.3 Wm −1 K −1 ) are used as the template into which an AgCl-KCl eutectic is solidified, 99% of the unit cells in the solidified structure exhibit the same pattern. In contrast, when higher thermal conductivity crystalline silicon pillars (≈100 Wm −1 K −1 ) are utilized, the expected pattern is only present in 50% of the unit cells. The thermally engineered template results in mesostructures with tunable optical properties and reflectances nearly identical to the simulated reflectances of perfect structures, indicating highly ordered patterns are formed over large areas. This work highlights the importance of controlling heat flows in template-directed self-assembly of eutectics.

36 MATERIALS SCIENCE↗

NASA NTRS2016

Global Precipitation Measurement (GPM) Spacecraft Lithium Ion Battery Micro-Cycling Investigation

The Global Precipitation Measurement (GPM) spacecraft was jointly developed by NASA and JAXA. It is a Low Earth Orbit (LEO) spacecraft launched on February 27, 2014. The power system is a Direct Energy Transfer (DET) system designed to support 1950 watts orbit average power. The batteries use SONY 18650HC cells and consist of three 8s by 84p batteries operated in parallel as a single battery. During instrument integration with the spacecraft, large current transients were observed in the battery. Investigation into the matter traced the cause to the Dual-Frequency Precipitation Radar (DPR) phased array radar which generates cyclical high rate current transients on the spacecraft power bus. The power system electronics interaction with these transients resulted in the current transients in the battery. An accelerated test program was developed to bound the effect, and to assess the impact to the mission.

Lithium Ion Battery Performance↗

NASA NTRS2015

Study of Stable Cathodes and Electrolytes for High Specific Density Lithium-Air Battery

Future NASA missions require high specific energy battery technologies, greater than 400 Wh/kg. Current NASA missions are using "state-of-the-art" (SOA) Li-ion batteries (LIB), which consist of a metal oxide cathode, a graphite anode and an organic electrolyte. NASA Glenn Research Center is currently studying the physical and electrochemical properties of the anode-electrolyte interface for ionic liquid based Li-air batteries. The voltage-time profiles for Pyr13FSI and Pyr14TFSI ionic liquids electrolytes studies on symmetric cells show low over-potentials and no dendritic lithium morphology. Cyclic voltammetry measurements indicate that these ionic liquids have a wide electrochemical window. As a continuation of this work, sp2 carbon cathode and these low flammability electrolytes were paired and the physical and electrochemical properties were studied in a Li-air battery system under an oxygen environment.

cathodes↗

NASA NTRS1999

Battery/Ultracapacitor Evaluation for X-38 Crew Return Vehicle (CRV)

This presentation reported on the evaluation of the battery/ultracapacitor for the crew return vehicle (CRV). The CRV, as part of the international space station (ISS) planning, will be available to return to earth an ill or injured crew person, or if the ISS becomes unsafe, and the shuttle is not available. The requirements of the X-38 CRV are reviewed, and in light of the power requirements, the battery's required performance is reviewed. The ultracapacitor bank, and its test method is described. The test results are reviewed. A picture of the test set up is displayed showing the ultracapacitor bank and the NiMH battery. The presentation continues by reviewing tests of 5 available trade high power cell designs: (1) Hawker lead acid, (2) Bolder lead acid, (3) Energizer NiMH, (4) Sanyo NiCd, and (5) Energizer NiCd. The test methods and results are reviewed. There is also a review of the issues concerning lead acid batteries and conclusions.

Darcy, Eric↗

DOE OSTI2025

Machine Learning for Predicting Multipactor Susceptibility in Planar RF Structures

Multipactor discharge is a persistent challenge in high-power microwave (HPM) and accelerator systems, where secondary electron avalanches can cause heating, vacuum degradation, and failure. This work presents the first supervised machine learning (ML) framework for multipactor prediction, trained on high-fidelity 3D Particle-in-Cell (PIC) simulation data in planar geometries. The model maps operational, geometric, and material-dependent secondary electron yield (SEY) parameters to the time-averaged electron growth rate, enabling rapid reconstruction of susceptibility charts. Among the models evaluated, tree-based ensemble methods such as Random Forest and Extra Trees demonstrate superior generalization to unseen materials compared to neural networks such as multilayer perceptron (MLP). Performance metrics, including Intersection over Union (IoU), Structural Similarity Index Measure (SSIM), and Pearson correlation, show close agreement with simulation benchmarks. Principal Component Analysis attributes generalization limits to material feature-space disjointedness.

43 PARTICLE ACCELERATORS↗

DOE OSTI2026

Battery Material Synthesis and Scalability using a 50L Taylor Vortex Reactor (Final CRADA Report)

Under this agreement, Laminar will loan Argonne a 50L Taylor Vortex Reactor (TVR) and provide mechanical troubleshooting guidance and consulting to ensure the successful setup of the pilot-scale synthesis process. The U.S. Department of Energy (DOE) will allocate funding for the labor and materials required for the study. To evaluate the physical and electrochemical properties of the materials produced by the 50L TVR, Argonne will perform comprehensive characterizations, including XRD, SEM, PSA, ICP, tap density, and coin half-cell testing. Throughout the collaboration, Argonne will provide feedback and recommendations for mechanical improvements to the reactor system. Furthermore, Argonne will credit Laminar as a collaborator in any presentations or publications resulting from data generated by the system. Laminar will retain no rights to experimental results or intellectual property generated through the experiments conducted with the 50L TVR at Argonne.

25 ENERGY STORAGE↗

DOE OSTI2025

Development of a high fidelity CFD model for solvent evaporation and transport in porous structure during battery electrode drying

An efficient battery manufacturing process is the key to the mass production of Electric Vehicles (EV), in which drying is one of the most energy-intensive steps significantly influencing the battery cell performance. An accurate 3D CFD model for drying is essential for predicting the drying mechanism and optimizing its parameters. By optimizing the drying process, it is possible to reduce energy consumption and cost during battery manufacturing, minimize binder loading and maximize active material loading to achieve superior electrochemical performances and facilitate wider and faster public adoption of EV. This project aims to optimize the drying process during electrode manufacturing by leveraging high-fidelity, porous electrode simulations for solvent evaporation. By optimizing this process, we seek to reduce energy consumption during battery manufacturing, while minimizing binder loading and maximizing active material loading, with the overall goal of enhancing electrical vehicle performance.

Horner, Jeffrey Scott [Sandia National Laboratorie↗

NASA NTRS1977

A nickel-cadmium battery reconditioning circuit

The circuit presented is simple and small enough to be included in a typical battery charge/power control assembly, yet provides the advantage of a complete ground-type battery reconditioning discharge. Test results on the circuit when used to recondition two 24 cell, 20 A-h nickel-cadmium batteries are given. These results show that a battery reconditioned with this circuit returns to greater than 90 percent of its original capacity (greater than nameplate capacity) and follows a typical new battery degradation curve even after over 20,000 simulated orbital cycles for a 4 year period. Applications of the circuit are considered along with recommendations relative to its use. Its application in low voltage (22 to 36 Vdc) power systems and in high voltage (100 to 150 Vdc) power systems is discussed. The implications are that the high voltage systems have a greater need for battery reconditioning than their low voltage counterparts, and that using these circuit techniques, the expected life of a battery in low Earth orbit can be up to 5 years.

Lanier, R.↗

DOE OSTI2026

Mechanistic Understanding of Interphase-driven Aging in Silicon Anodes

Conventional solid electrolyte interphases (SEIs) strongly adhere to micro-silicon (µ-Si) and crack under volume changes, causing poor cycling performance. Nano-silicon improves cycling performance but remains costly with limited calendar life. Here potentiostatic ageing tests demonstrate that both calendar and cycle ageing are governed by SEI cracking and dissolution with different relative contributions. When the system is not dominated by SEI dissolution, the relative calendar life of Si anodes could correlates positively with their cycle life. LiF-rich SEI that enables long cycle life in µ-Si is therefore expected to enhance calendar life as well. Using this framework, we screened electrolytes, SEIs and electrodes and validated them with full-cell storage. LiF-rich SEI minimizes cracking and dissolution, enabling μ-Si to achieve excellent calendar life, whereas nano-silicon suffers from SEI dissolution and needs reduced electrolyte–electrode contact for better calendar life. This work clarifies calendar-ageing behaviour and accelerates electrolytes and SEI development for long-life Si anodes.

Johnson, Christopher S.↗

NASA NTRS2002

Evaluation of Cycle Life and Characterization of YTP 45 Ah Li-Ion Battery for EMU

Li-ion batteries, with longer cycle life and higher energy density features, are now more and more attractive and applied in multiple fields. The YTP 45 Ah Li-ion battery has been evaluated here and may be employed in EMU in the future. Evaluations were on: (1) Cycle life tests - 500 cycles total (completed 40 cycles in simulated shuttle use mode and 460 cycles in an accelerated use mode, and recorded differential voltage of individual cell in battery); (2) Characterization test - discharge capacity measurement in environment temperature of -10, 25, 50 C before and after 500 cycles; and (3) Thermal testing - charge and discharge at 50 C and -10 C before and after 500 cycles. The battery showed less than a 9% drop of initial discharge capacity and energy within 500 cycles with 475 cycles 59% DOD plus 25 cycles 100% DOD. The EOD voltage ranged from 16.0 to 18.0 V, which fits the requirement for operating the EMU.

Deng, Yi↗

NASA NTRS1978

The 1977 Goddard Space Flight Center Battery Workshop

The papers presented were derived from transcripts taken at the Tenth Annual Battery Workshop held at the Goddard Space Flight Center, November 15-17, 1977. The Workshop was attended by manufacturers, users, and government representatives interested in the latest results of testing, analysis, and development of the sealed nickel cadmium cell system. The purpose of the Workshop was to share flight and test experience, stimulate discussion on problem areas, and to review the latest technology improvements.

G Halpert↗

NASA NTRS1994

Analysis of the Erosion of Cubic Centered and Face Centered Metallic Materials [Analyse de L'erosion de Matereaux Metalliques de Structures Cubiques Centree et Face Centree]

A generalized law of erosion, in nondimensional form, is proposed. The aforementioned explicitly gives an account of the nature and the microstructure of the material impacted, the angle of impact of the particles, and their hardness. The erosion behavior of various steels, pig iron, and cast iron is examined as well as the behavior of new ordered intermetallic materials, Fe-25% Al-(Zr, Cr, B). The concern of such alloys in an erosion-corrosion environment is shown. --- Une loi généralisée d'usure par érosion, sous forme non dimensionnelle, est proposée. Celle-ci rend compte explicitement de la nature et de la microstructure du matériau impacté, de l'angle d'impact des particules, de leur acuité at de leur durete. Le comportement à l'érosion de divers aciers et fontes est examiné ainsi que la tenue de nouveaux matériaux intermétalliques ordonnés Fe-25% Al - (Zr, Cr, B). L'interet de tels alliages dans des environnements agressifs du type érosion-corrosion est montré. Mots clés: usure, érosion, modèle, matériaux métalliques, intermétalliques Fe-Al.

A Magnée↗

DOE OSTI2026

STANDARD REFERENCE MATERIAL CHARPY TESTING FROM HIGH FLUENCE SURVEILLANCE CAPSULE

The Palisades Nuclear Generating Station included in its original surveillance program a surveillance capsule, designated A-60. The capsule was removed from its surveillance position in early 1995 and has been resident in the spent fuel pool since that time. It was harvested to perform characterization of surveillance specimens in this capsule in 2023. This capsule was irradiated to a fluence of 1.96x1020 n/cm2 (E> 1MeV) that is equivalent for more than 150 effective full power years for the current US reactor pressure vessel (RPV) fleet. This capsule contained several materials, including Charpy specimens of standard reference material (SRM) from Heavy-Section Steel Technology (HSST) A533-B Plate 01. To perform Charpy testing of this highly irradiated material, the new Charpy specimen transfer system was designed and implemented on Charpy impact testing machine in the hot cell to accommodate remote testing of these specimens. This new transfer system includes integrated environmental chamber to cool or heat Charpy specimens to the desired temperature. Testing of this highly irradiated material revealed very large shift of Charpy transition temperature, 188oC.

Sokolov, Mikhail [ORNL] (ORCID:0000000256373346)↗

NASA NTRS2018

International Space Station Lithium-Ion Battery Status

When originally launched, the International Space Station (ISS) primary Electric Power System (EPS) used Nickel-Hydrogen (Ni-H2) batteries to store electrical energy. The electricity for the space station is generated by its solar arrays, which charge batteries during insolation for subsequent discharge during eclipse. The Ni-H2 batteries were designed to operate for ten years at a 35 percent depth of discharge (DOD) maximum during normal operation in a Low Earth Orbit. For service beyond that period, upgraded Li-Ion Orbital Replacement Units (ORUs) were designed. These are the largest Li-Ion batteries ever utilized for a human rated spacecraft. With the oldest 12 Ni-H2 battery ORUs cycling since September 2006, the first set of six was replaced by Li-Ion batteries in December 2016; the second set of six is planned for replacement in September 2018. This paper will include an overview of the ISS Li-Ion battery system architecture, on-orbit status of the first 6 batteries, start up of the second 6 batteries, and the status of the Li-Ion cell and ORU life cycle testing.

International Space Station↗

DOE OSTI2023

TRTR NRAD NRS Beamline Abstract

The Neutron Radiography (NRAD) Reactor is a 250kW TRIGA housed under the largest hot cell in the United States, making it the foremost location to perform neutron imaging of irradiated nuclear fuels and materials, including those intended for use with advanced reactors. Currently, NRAD has two radial beamlines that are used for neutron radiography and tomography. Upgrades to the North neutron beamline include the replacement of the in-tank beam chamber, through-the-wall collimator, and neutron shutter. These beamline upgrades will not only improve image quality for current capabilities but will also condition the beam to be more suitable for advanced methods such as neutron powder diffraction. These upgrades will increase the excess reactivity of the core, reduce unnecessary activation and exposure to workers, and significantly reduce the amount of shielding required around the beam. This presentation will describe how these upgrades improve beam quality, increase utilization of the reactor, and reduce radiation exposure to personnel.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

DOE OSTI2026

Atomic- and Molecular-Scale Interphase Engineering for High-Performance Solid-State Batteries

Solid-state batteries (SSBs) promise a decisive advance beyond conventional Li-ion systems, yet their development remains constrained by persistent solid–solid interfacial instabilities that degrade performance and durability. Interfaces between solid electrolytes and both cathodes and Li metal often exhibit poor wettability, limited physical contact, and high charge–transfer resistance, leading to chemical decomposition, mechanical failure, and impedance growth. Overcoming these limitations requires interphase engineering with atomic-scale precision—capabilities that conventional coating methods cannot reliably deliver. Atomic layer deposition (ALD) and molecular layer deposition (MLD) uniquely meet this need by enabling ultrathin, conformal, and composition-tunable films that stabilize reactive surfaces, suppress parasitic reactions, and regulate Li-metal morphology. Importantly, this Perspective highlights ALD/MLD systems that have already demonstrated effectiveness in liquid-electrolyte cells and discusses how these validated strategies can be deliberately translated to solid-state architectures. By grounding future directions in experimentally proven concepts rather than speculative hypotheses, we outline how atomic- and molecular-scale design principles can accelerate the development of robust, high-performance SSB technologies.

atomic and molecular layer deposition↗

NASA NTRS1977

The standard 20 AH battery

The modular power system, which is the first intended use for the NASA standard battery, is basically a four foot by four foot by eighteen inch box which can handle a complement of three 20 ampere hour batteries or later on the intended use is for three 50 ampere hour batteries to be the full complement. The system is designed to be used as a plug on component on a multi mission modular spacecraft. It has as a design point a basically 1250 watt orbital average load. The way it breaks up in a near earth orbit it would be somewhere around 1,000 watts for everything except 10 minutes, and during any 10 minute period it may go up to a peak of 3,000 watt load. Features of the battery reviewed include criteria to store electrical energy, the battery package, the covers and cases, and electrolytes. The capacities expected are 90 percent, the average cell capacity for 24 C, 90 percent of the actual battery capacity of 19 C, and 85 percent of the actual 25 degree battery capacity at zero discharge voltage for 50 percent DOD new battery is in the vicinity expected or predicted of 26.4 volts.

Zollner, M. T.↗

NASA NTRS2003

Structural Mechanics and Dynamics Branch 2002 Annual Report

The 2002 annual report of the Structural Mechanics and Dynamics Branch reflects the majority of the work performed by the branch staff during the 2002 calendar year. Its purpose is to give a brief review of the branch s technical accomplishments. The Structural Mechanics and Dynamics Branch develops innovative computational tools, benchmark experimental data, and solutions to long-term barrier problems in the areas of propulsion aeroelasticity, active and passive damping, engine vibration control, rotor dynamics, magnetic suspension, structural mechanics, probabilistics, smart structures, engine system dynamics, and engine containment. Furthermore, the branch is developing a compact, nonpolluting, bearingless electric machine with electric power supplied by fuel cells for future "more electric" aircraft. An ultra-high-power-density machine that can generate projected power densities of 50 hp/lb or more, in comparison to conventional electric machines, which generate usually 0.2 hp/lb, is under development for application to electric drives for propulsive fans or propellers. In the future, propulsion and power systems will need to be lighter, to operate at higher temperatures, and to be more reliable in order to achieve higher performance and economic viability. The Structural Mechanics and Dynamics Branch is working to achieve these complex, challenging goals.

Stefko, George↗