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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 NTRS2015

Review of Exploration Systems Development (ESD) Integrated Hazard Development Process: Volume 2 - Appendices

The Chief Engineer of the Exploration Systems Development (ESD) Office requested that the NASA Engineering and Safety Center (NESC) perform an independent assessment of the ESD's integrated hazard development process. The focus of the assessment was to review the integrated hazard analysis (IHA) process and identify any gaps/improvements in the process (e.g. missed causes, cause tree completeness, missed hazards). This document contains the outcome of the NESC assessment.

Smiles, Michael D.↗
DOE OSTI2026

Dual-loop Solvent-based CCS for Net Negative CO 2 Emissions with Lower Cost

This final technical report details the successful design, construction, and operational validation of an innovative dual-loop CO 2 capture technology designed to achieve deep decarbonization (>99%) from Natural Gas Combined Cycle (NGCC) power plants that results in the electricity with carbon intensity of approximate 42 kg CO 2 -eq/MWh, less than the electricity produced by solar PV. The integrated process couples a primary aqueous solvent (in this project, a water lean solvent – WLS) absorption loop for bulk CO 2 removal with a secondary potassium hydroxide (KOH) polishing loop featuring electrochemical regeneration. This architecture leverages the higher exergy efficiency of the primary loop while utilizing the fastest kinetic of the secondary loop to capture dilute residual CO 2 , achieving an overall capture rate of 99.9% and co-producing pure hydrogen after moisture being condensed and dehydrated. Technical feasibility was established through a comprehensive 2,000-hour experimental campaign on a bench-scale fully-integrated unit (using 4” absorber and 4” stripper) with the feeding flue gas flowrate in the range of 8-20 cfm, confirming the attainment of Technology Readiness Level (TRL) 4. The project executed extensive parametric testing followed by 1,000 hours of continuous steady-state testing, demonstrating exceptional process stability with the electrochemical regenerator exhibiting less than a 10% reduction in electrical conductivity over the duration of the campaign. Operational characterization gathering on the bench unit revealed distinct energy profiles for the hybrid system: the primary loop required approximately 280 kJ mol -1 for bulk removal, while the polishing loop required approximately 1,600 kJ mol -1 specifically when reducing dilute CO 2 concentrations from ~740 ppm down to <50 ppm. (Please note those energy values/numbers can only be viewed as relative relationship and should not be extrapolated as absolute values required for CO 2 capture). Furthermore, dynamic testing validated the system’s flexibility for utility applications, demonstrating a rapid process response time of <30 minutes to changes in flue gas flowrate. Emission monitoring confirmed that the dual-loop architecture effectively mitigates solvent losses, utilizing a water wash to remove entrained aerosols to <1 ppm. The Techno-Economic Analysis (TEA) indicates a cost of capture of $\$$59.3/tonne and a Levelized Cost of Electricity (LCOE) of 71.7 $\$$/MWh at the overall capture efficiency of 99.8% of total carbon in the flue gas stream, with sensitivity analysis identifying an economic optimum when the primary loop captures 97% of the total CO 2 . A Life Cycle Assessment (LCA) confirms the technology’s potential for net-negative emissions, determining a Global Warming Potential (GWP) of 52 kg CO 2 -eq/MWh—significantly lower than the baseline—which further decreases to 42 kg CO 2 -eq/MWh when crediting the displacement of conventional hydrogen production.

03 NATURAL GAS↗
NASA NTRS1984

Elements of computational engine-airframe integration

Computerized flow simulation methods are being developed to refine the traditional engine-airframe integration process. These analyses reduce design risk, minimize wind tunnel and flight test requirements, and provide detailed design information not available by any other means. This paper describes computational tools which have matured sufficiently to permit project applications. Several applications are combined with research studies to illustrate the prediction of high-speed nonlinear phenomena associated with engine inlet flow rate, nacelle shape and position, afterbody shape and integration, propeller slipstream interactions, airframe-induced inlet flow, and pylon integration. Both fighter and transport configurations are used to highlight current capabilities and future requirements.

Boppe, C. W.↗
NASA NTRS1994

Rapid prototype fabrication processes for high-performance thrust cells

The Thrust Cell Technologies Program (Air Force Phillips Laboratory Contract No. F04611-92-C-0050) is currently being performed by Rocketdyne to demonstrate advanced materials and fabrication technologies which can be utilized to produce low-cost, high-performance thrust cells for launch and space transportation rocket engines. Under Phase 2 of the Thrust Cell Technologies Program (TCTP), rapid prototyping and investment casting techniques are being employed to fabricate a 12,000-lbf thrust class combustion chamber for delivery and hot-fire testing at Phillips Lab. The integrated process of investment casting directly from rapid prototype patterns dramatically reduces design-to-delivery cycle time, and greatly enhances design flexibility over conventionally processed cast or machined parts.

Hunt, K.↗
DOE OSTI2015

Process Design and Economics for the Conversion of Lignocellulosic Biomass to Hydrocarbon Fuels. Thermochemical Research Pathways with In Situ and Ex Situ Upgrading of Fast Pyrolysis Vapors

This report was developed as part of the U.S. Department of Energy’s Bioenergy Technologies Office’s efforts to enable the development of technologies for the production of infrastructurecompatible, cost-competitive liquid hydrocarbon fuels from biomass. Specifically, this report details two conceptual designs based on projected product yields and quality improvements via catalyst development and process integration. It is expected that these research improvements will be made within the 2022 timeframe. The two conversion pathways detailed are (1) in situ and (2) ex situ upgrading of vapors produced from the fast pyrolysis of biomass. While the base case conceptual designs and underlying assumptions outline performance metrics for feasibility, it should be noted that these are only two of many other possibilities in this area of research. Other promising process design options emerging from the research will be considered for future techno-economic analysis.

09 BIOMASS FUELS↗
DOE OSTI2015

Process Design and Economics for the Conversion of Lignocellulosic Biomass to Hydrocarbon Fuels: Thermochemical Research Pathways with In Situ and Ex Situ Upgrading of Fast Pyrolysis Vapors

This report was developed as part of the U.S. Department of Energy’s Bioenergy Technologies Office’s efforts to enable the development of technologies for the production of infrastructure-compatible, cost-competitive liquid hydrocarbon fuels from biomass. Specifically, this report details two conceptual designs based on projected product yields and quality improvements via catalyst development and process integration. It is expected that these research improvements will be made within the 2022 timeframe. The two conversion pathways detailed are (1) in situ and (2) ex situ upgrading of vapors produced from the fast pyrolysis of biomass. While the base case conceptual designs and underlying assumptions outline performance metrics for feasibility, it should be noted that these are only two of many other possibilities in this area of research. Other promising process design options emerging from the research will be considered for future techno-economic analysis. Both the in situ and ex situ conceptual designs, using the underlying assumptions, project MFSPs of approximately $3.5/gallon gasoline equivalent (GGE). The performance assumptions for the ex situ process were more aggressive with higher distillate (diesel-range) products. This was based on an assumption that more favorable reaction chemistry (such as coupling) can be made possible in a separate reactor where, unlike in an in situ upgrading reactor, one does not have to deal with catalyst mixing with biomass char and ash, which pose challenges to catalyst performance and maintenance. Natural gas was used for hydrogen production, but only when off gases from the process was not sufficient to meet the needs; natural gas consumption is insignificant in both the in situ and ex situ base cases. Heat produced from the burning of char, coke, and off-gases allows for the production of surplus electricity which is sold to the grid allowing a reduction of approximately 5¢/GGE in the MFSP.

09 BIOMASS FUELS↗
NASA NTRS1973

Radiant source tracker independent of nonconstant irradiance

A tracker of a radiant source is disclosed. The tracker is composed of a sectored matrix of detectors whose output voltages correspond to their respective levels of irradiance. The voltages are each sampled during a variable length period and the resulting samples are shaped into triangular samples by an integration process. They are supplied to a demodulator which provides an output corresponding to the difference of the time-voltage product of appropriate combinations of the samples. This output, after filtering, represents the angle of incidence on the detectors with respect to a central axis. The triangular samples are also supplied to a demodulator whose output is an AGC voltage which is a function of the sum of the time-voltage integrals of the triangular samples.

Campbell, F. D.↗
NASA NTRS2000

Space Shuttle Payload Information Source

The Space Shuttle Payload Information Source Compact Disk (CD) is a joint NASA and USA project to introduce Space Shuttle capabilities, payload services and accommodations, and the payload integration process. The CD will be given to new payload customers or to organizations outside of NASA considering using the Space Shuttle as a launch vehicle. The information is high-level in a visually attractive format with a voice over. The format is in a presentation style plus 360 degree views, videos, and animation. Hyperlinks are provided to connect to the Internet for updates and more detailed information on how payloads are integrated into the Space Shuttle.

Griswold, Tom↗
DOE OSTI2019

Low-Carbon Energy for Industry

The industrial sector is a major energy user. In the U.S., it uses 26 quadrillion Btu (quad) annually of the total U.S. energy load of 98 quad/yr. Globally, the industrial fraction of energy use is similar - 29%. Finding and developing low carbon energy sources for industrial energy is challenging because the sector is heterogenous and primarily requires heat. Heat is less fungible than electricity because it has a variety of temperature and quantity requirements and current technologies are incapable of moving heat efficiently across long distances. Heat integration is very common within facilities but cross-facility heat integration and valorization could provide new opportunities. NREL has performed work to identify opportunities for use of geothermal, nuclear, and solar integrated process heat in industry that are presented. A key challenge is matching the requirements of a heat load with the low carbon generation options.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
NASA NTRS1998

Dark Forward Electrical Test Techniques Developed for Large-Area Photovoltaic Arrays

Spacecraft photovoltaic arrays (PVA's) must be carefully handled during ground integration processing and transportation to the launch site. Care is exercised to avoid damage that could degrade on-orbit electrical performance. Because of this damage risk, however, PVA's are typically deployed and illuminated with a light source so performance characteristics can be measured prior to launch. For large-area arrays, such as the Mir Cooperative Solar Array (2.7- by 18-m) and the International Space Station PVA blankets (4.6- by 31.7-m), this integrity check becomes resource intensive. Large test support structures are needed to offload the array during deployment in 1g, and large-aperture illumination equipment is required to uniformly illuminate array panels. Significant program time, funds, and manpower must be allocated for this kind of test program. Alternatively, launch site electrical performance tests can be bypassed with an attendant increase in risk.

Kerslake, Thomas W.↗
DOE OSTI2022

Robust silane self-assembled monolayer coatings on plasma-engineered copper surfaces promoting dropwise condensation

Dropwise condensation is well known to result in better heat transfer performance owing to efficient condensate/droplet removal, which can be harnessed in various industrial heat/mass transfer applications such as power generation and conversion, water harvesting/desalination, and electronics thermal management. The key to enhancing condensation via the dropwise mode is thin low surface energy coatings (<100 nm) with low contact angle hysteresis. Ultrathin (<5 nm) silane self-assembled monolayers (or SAMs) have been widely studied to promote dropwise condensation due to their minimal thermal resistance and scalable integration processes. Such thin coatings typically degrade within an hour during condensation of water vapor. After coating failure, water vapor condensation transitions to the inefficient filmwise mode with poor heat transfer performance. We enhance silane SAM quality and durability during water vapor condensation on copper compared to state-of-the-art silane coatings on metal surfaces. We achieve this via (i) surface polishing to sub-10 nm levels, (ii) pure oxygen plasma surface treatment, and (iii) silane coating integration with the copper substrate in an anhydrous/moisture-free environment. The resulting silane SAM has low contact angle hysteresis (≈20°) and promotes efficient dropwise condensation of water for >360 hours without any visible sign of coating failure/degradation in the absence of non-condensable gases. We further demonstrate enhanced heat transfer performance (≈5-7× increase over filmwise condensation) over an extended period of time. Surface characterization data post-condensation leads us to propose that in the absence of non-condensable gases in the vapor environment, the silane SAM degrades due to reduction and subsequent dissolution of copper oxide at the oligomer-substrate interface. The experiments also indicate that the magnitude of surface subcooling (or condensation rate) affects the rate of coating degradation. Finally, this work identifies a pathway to durable dropwise promoter coatings that will enable efficient heat transfer in industrial applications.

42 ENGINEERING↗
NASA NTRS2025

Private Astronaut Post-Mission Debrief Interviews Study

BACKGROUND The commercialization of space will increasingly include individuals that are not rigorously-selected, highly-trained professional astronauts. Private astronaut missions (PAMs), such as Axiom-1 in 2022, will continue to travel to the International Space Station in the coming years, but the risk of integrating private astronauts with NASA astronauts has not been clearly quantified nor mitigated. An earlier internal NASA operations assessment, which consisted of a comprehensive literature review and interviews of current NASA experts, found that PAMs are likely to increase the risk to NASA astronauts during integrated missions (Landon, Whiting, Russell, Schorn, Passmore, & Roma, 2022). There are ongoing efforts at NASA to mitigate concerns from a medical, psychological, and technical perspective. NASA experts are working closely with PAM providers to offer recommendations and best practices beyond the limits of requirements to ensure crew health and safety. However, efforts are siloed between groups to some extent, and with the rate of PAMs likely to increase, a more comprehensive and integrated process is needed to reduce the burden on NASA resources. AIMS The purpose of this project is to understand private astronauts’ motivations for journeying to space, their pre-mission preparation period, and their experiences in space. Data will be collected via private astronaut post-mission debrief interviews. This data will inform training needs and in-mission support needed for missions that include private astronauts; the preparation NASA astronauts and mission support personnel will need to work with these integrated crews; and gaps in knowledge to guide research and countermeasure development. Our study aims to (1) Characterize risks posed by commercialization and private astronaut crew integration in spaceflight operations, as it relates to Team, Human Systems Integration Architecture (HSIA), and Behavioral Medicine (BMed) Risks, (2) Recommend potential countermeasures and identify gaps in current research. Countermeasures may be related to crew selection and composition, training, crew support systems (e.g., medical/psychological support, support from Mission Control, on-board resources), and habitability and human factors design. METHOD The BHP Lab will conduct 30-minute interviews with up to eight (8) private astronaut mission (PAM) astronauts (e.g., Axiom) and spaceflight participants (e.g., SFPs or “free flyers” on Polaris Dawn) per year from 2024-2030 to discuss knowledge gaps and needs related to selection and assessment, crew composition, training, crew support systems (e.g., medical/psychological support, support from Mission Control, onboard resources), and habitability and human factors design, which may influence the risk to NASA astronauts. Interviews will then be coded using thematic analysis and interpreted with the assistance of lexical analysis software (e.g., LIWC). As of the end of 2024, we have collected data from one PAM crew. At the conclusion of data collection in 2030, a final report will be prepared integrating all data collected by 2031. SUMMARY Post-return interviews of private astronauts are being conducted to understand their experiences and inform training and countermeasures to ensure the safety of all who journey to the ISS.

Private Astronaut Missions↗
DOE OSTI2026

A Quinoidal Two‐Dimensional Metal–Organic Framework for High‐Performance Micro‐Supercapacitors and Solid‐State Lithium Batteries

Two-dimensional (2D) metal-organic frameworks (MOFs) integrating redox-active linkers enable dense charge sites and open ion pathways for microscale energy storage. We report a quinoidal dicarboxylate ligand, AQM-H2L, derived from p-azaquinodimethane, forming crystalline frameworks with Cu2+ and Zn2+ nodes. The Cu-based MOF (AQM-AQM-H2L-Cu) exhibits layered sheets (>14 Å spacing) constructed from dinuclear Cu-carboxylate units and conjugated AQM linkers, which narrow the bandgap and introduce Cu2+/Cu+ pseudocapacitance. Exfoliated nanosheets (∼5 nm) retain crystallinity and excellent processability. Integrated into graphene films, they deliver areal and volumetric capacitances of 29.6 mF cm-2 and 18.1 F cm-3, achieving 2.6 mWh cm-3 energy density at 160 mW cm-3. As ionic fillers (1 wt%) in PEO solid polymer electrolytes, the nanosheets markedly enhance LiFePO4 cell performance, affording 169.8 mAh g-1 at 0.2 C and 93% retention after 400 cycles. This work establishes quinoidal linkers as a compact and robust design motif for ionically active 2D frameworks toward high-performance miniature and solid-state energy devices.

Chen, Ziman↗
DOE OSTI2018

Verification of an Algorithm for Processing Data from Multifrequency Lidar Sensing of Aerosols

We consider an algorithm for processing lidar signals, which for a lidar path with constant qualitative aerosol characteristics (particle size distribution in each aerosol mode, complex refractive index of the particles) lets us obtain a concentration profile for the fine aerosol component without using additional a priori information. The algorithm was verified based on lidar data from the Institute of Physics (National Academy of Sciences of Belarus). The vertical volume concentration profile for fine particles obtained by our algorithm is quite consistent with the results of its independent retrieval, based on integrated processing of lidar and sun photometer data.

42 ENGINEERING↗
DOE OSTI2019

Bioalcohol production from acidogenic products via a two-step process: A case study of butyric acid to butanol

This article presents the full study (lab-scale experimental study and large-scale techno-economic analysis) results of a two-step catalytic process for the conversion of organic waste–derived butyric acid to butanol. Butanol from biomass resources like organic waste promise to become an attractive and sustainable fuel and industrial precursor due to an increase in greenhouse gas content in the atmosphere. Therefore, research in this field is important for energy applications and reduction in greenhouse gas emissions. In this regard, a two-step process was applied in this study to produce butanol from butyric acid that can potentially be derived from organic waste. The two-step process consists of the (1) esterification of butyric acid to methyl butyrate and (2) hydrogenolysis of this methyl butyrate to butanol. The first reaction, esterification of butyric acid, was optimized using carbon-based catalysts. The production of butanol from methyl butyrate via hydrogenolysis was investigated using bimetallic Pt–Co catalysts. The hydrogenolysis of methyl butyrate on these catalysts under optimal conditions of 250 °C, 5 MPa H 2 , and a feed/catalyst weight ratio of 11.2 led to 54.1% selectivity toward 1-butanol. Based on the experimental results, an integrated process simulation model was developed to determine the economic potential of the two-step production of butanol from butyric acid. Using this model, the techno-economic feasibility of the two-step process was analyzed. Here, the minimum selling price (MSP) of 1-butanol produced from butyric acid using this process was US dollars 3.388 per gallon of gasoline equivalent (GGE). This MSP is in the range of recent biofuel market prices of US dollars 2.03/GGE to US dollars 3.83/GGE.

09 BIOMASS FUELS↗
DOE OSTI2025

A phase-field fracture formulation for generalized standard materials: The interplay between thermomechanics and damage

Accurately modeling fracture of ductile materials poses open challenges in the field of computational mechanics due to the multiphysics nature of their failure processes. Integrating the interplay between thermodynamics and damage into ductile fracture models is vital for predicting critical failure modes. Here, in this paper, we develop a versatile phase-field (PF) framework for modeling ductile fracture, taking into account finite-strain elasto-plasticity. The framework stems from a variational formulation of constitutive relations for generalized standard materials (GSMs), whose response is described by a Helmholtz free energy and a dissipation pseudo-potential. Its variational structure is based on a minimum principle for a functional that expresses the sum of power densities for reversible and irreversible processes. By minimizing this functional with a constraint on a von Mises yield function, we derive the evolution equation for the equivalent plastic strain and an associative flow rule. This constrained optimization problem is analytically solved for a wide class of thermo-viscoplasticity models. The key innovations of the current work include (i) a cubic plastic degradation function that accounts for a non-vanishing damage-dependent yield stress, (ii) closed-form expressions of the Helmholtz free energy and dissipation pseudo-potential for three thermo-viscoplasticity models, (iii) an extended Johnson–Cook plasticity model with a nonlinear hardening law, and (iv) a plastic work heat source that depends on the plastic degradation function and a variable Taylor–Quinney (TQ) coefficient. The capabilities of the proposed framework are tested with the aid of four ductile fracture problems, including the Sandia Fracture Challenge. In each of these problems, we examine the evolution of relevant field variables such as the PF order parameter, the equivalent plastic strain, the temperature, and the internal power dissipation density, in addition to the overall structural response quantified by the force–displacement curve. These numerical studies demonstrate that the proposed framework effectively represents ductile fracture, yielding computational results that exhibit good agreement with experimental data.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Reducing Coke and Increasing Bio-Oil Yield during Catalytic Fast Pyrolysis of Biomass Using Phosphorus-Modified Zeolite Catalysts

Catalytic fast pyrolysis (CFP) is a promising strategy for producing hydrocarbon transportation fuels from biomass feedstocks. However, catalyst development is needed to increase bio-oil yields and enhance process economics. In this work, we demonstrate how post synthetic modification of formed ZSM-5 with phosphorus shifts CFP selectivity from coke and light gases toward the desired bio-oil product. Microscale experiments demonstrated reduced coke production relative to unmodified ZSM-5 and identified an optimal P loading. Extensive catalyst characterization revealed that P interacted with Al sites to reduce the acid site density, with preferential binding to the strongest acid sites. Insights from the microscale experiments were leveraged to produce kilogram quantities of formed P-ZSM-5 for evaluation in a larger semi-integrated process. These experiments generated liters of bio-oil that was hydrotreated and fractionated into gasoline, diesel, and jet cuts. The phosphorus-modified ZSM-5 improved CFP bio-oil yield, resulting in an 11% relative increase in the carbon yield from biomass to aviation fuel and a 14% decrease in the minimum fuel selling price. These results highlight the impact targeted changes in catalyst acidity, achieved by adding 2.5 wt % P, can have on the carbon efficiency and feasibility of fuel production from biomass feedstocks.

09 BIOMASS FUELS↗