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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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NASA NTRS1994

The Study of Dopant Segregation Behavior During the Growth of GaAs in Microgravity

An investigation into the segregation behavior of selenium doped gallium arsenide during directional solidification in the microgravity environment was conducted using the Crystal Growth Furnace (CGF) aboard the first United States Microgravity Laboratory (USML-1). The two crystals grown were 1.5 cm in diameter and 16.5 cm in length with an initial melt length of 14 cm. Two translation periods were executed, the first at 2.5 microns/s and after a specified time, which was different between the two experiments, the translation rate was doubled to 5.0 microns/s. The translation was then stopped and the remaining sample melt was solidified using a gradient freeze technique in the first sample and a rapid solidification in the second experiment. Measurement of the selenium dopant distribution, using quantitative infrared transmission imaging, indicates that the first sample initially achieved diffusion controlled growth as desired. However, after about 1 cm of growth, the segregation behavior was driven from a diffusion controlled growth regime to a complete mixing regime. Measurements in the second flight sample indicated that the growth was always in a complete mixing regime. In both experiments, voids in the center line of the crystal, indicative of bubble entrapment, were found to correlate with the position in the crystal when the translation rates were doubled.

D H Matthiesen↗

NASA NTRSDate not supplied

Physics-Guided Deep Learning for Complex System Health Management and Decision Making

The landscape of complex engineered systems is rapidly evolving, from smart manufacturing facilities to next-generation transportation vehicles. As these systems become increasingly sophisticated and interconnected, the need for advanced health management systems grows ever more critical. These systems must go beyond simple monitoring, actively predicting potential failures before they occur. This paradigm shift from fixed maintenance schedules to condition-based predictions is key to optimizing system performance, enhancing safety, and paving the way for autonomous decision-making across various industries. Whether in industrial processes, energy systems, or advanced transportation, the ability to anticipate and prevent failures is becoming a cornerstone of operational excellence. To accurately predict the future health of any complex system, knowledge of its current health state and future operational conditions is essential. Recent advancements in data-driven algorithms have generated growing interest in artificial intelligence for industrial applications. However, the limitations of pure data-driven methods, particularly in industries where data acquisition is costly and limited, have become apparent. This has led to a focus on blending physics with data-driven algorithms, mitigating the drawbacks of both approaches while emphasizing their respective advantages. This research proposes a novel framework for integrating physics-based performance models with deep learning algorithms for the prognostics of complex safety-critical systems. In this approach, physics-based models serve as a blueprint, capturing fundamental system behaviors, while deep learning algorithms, leveraging real-world sensor data, fill in gaps and identify subtle patterns indicative of potential problems. This hybrid methodology, utilizing techniques such as Physics-Informed Neural Networks (PINNs), offers a powerful solution for predicting system health. By fusing domain knowledge with data-driven insights, this approach promises more accurate, adaptable, and reliable models for health prediction. The resulting framework is versatile, applicable across various sectors including aerospace, manufacturing, and energy systems, ultimately contributing to safer, more efficient operations in our increasingly complex technological landscape.

Diagnostics↗

NASA NTRSDate not supplied

Powering the Lunar Surface: Managing Dust, Extreme Environments, and Power Needs

Power availability remains one of the primary constraints for lunar surface science. This talk reviews power requirements from previously flown instruments to help prepare future payloads for upcoming CLPS opportunities and highlights the testing and environmental simulation capabilities at NASA JSC that enable reliable lunar payload development. It also outlines the power needs, environmental challenges, and emerging technologies required to support sustained human and robotic operations on the lunar surface as part of NASA’s Moon to Mars strategy. Key challenges include variable solar illumination at polar and equatorial regions, extreme thermal environments, and dust driven degradation that limit current surface power systems. The science data needed for resource identification and landing site planning will allow for the successful preparation of crewed Artemis activities and long-term presence. Building on recent missions, current test infrastructure, and emerging power technology pathways, this presentation equips industry, academia, and government teams with the information needed to design robust lunar payloads, reduce development risk, and fully leverage the increasing cadence of CLPS missions. These developments will form a critical technical foundation for long duration lunar presence and future Mars exploration.

lunar power↗

NASA NTRSDate not supplied

Advanced Composite Structures and Materials Technologies for Launch Vehicles

The NASA's Advanced Composites Technologies (ACT) Project has the potential to develop composite materials and structures technologies for the largest composite aerospace structures ever made. The objective the ACT Project of is to develop mid-technology readiness level (TRL) composite materials and structures technologies to TRL 6 for specific heavy lift Ares V launch vehicle and Altair lunar lander applications. To accomplish this objective, the ACT Project has four major technical elements: materials and manufacturing; structural concepts development and assessment of lightweight components; testing and evaluation; and highly loaded composite struts. The Project uses capabilities from across NASA to form multi-disciplinary, cross-center teams to meet the milestones of these technical elements. This presentation will describe the activities and plans for the ACT Project. Studies from the first execution year of the project will be summarized including results from materials selection and structural concept evaluation studies. Plans for continuing activities include studies for nondestructive evaluation/structural health monitoring, damage tolerance, joints, and material and structural testing, and these studies will be described. A major emphasis this fiscal year is the start of work for a manufacturing demonstration barrel. This structure will be composed of six, 5-m-diameter, 3-m-long curved panels that when assembled, result in a 10-m-diameter barrel. Activities related to the development of this structure will also be described.

Mark J Shuart↗

NASA NTRS1962

ELECTRIC PROPULSION- A NEW TECHNOLOGY

Within the past 3 years, electric thrust devices have passed from the first exploratory feasibility experiments to the flight-engineered hardware phase. This rapid surge of development has been punctuated by equally rapid improvements in the performance figures of electrical thrust devices. The most spectacular advances were made in ion engine technology. Total energy expenditure per ion pair has gone from 35,000 ev in 1958 to about 600 ev at the present time leading to power utilization efficiencies of up to 80 per cent, depending upon the specific impulse. The percentage of the particles intercepting the accelerating and focusing electrodes has been reduced from more than 50 per cent in 1958 to less than 0.01 per cent at the present time. Great improvements in ion current per unit area have also been realized, leading to greater thrust "pressures."

ELECTRIC PROPULSION↗

NASA NTRS1978

A new battery charger/discharger converter

A new optimum topology dc-to-dc switching converter is extended to provide bidirectional current flow. The resulting two-quadrant converter can be employed to eliminate the discontinuous current mode in normal unidirectional applications, but is especially suited for spacecraft battery conditioning as a charge-discharge regulator in place of the conventional separate converters. Implementation of the control features and the battery charge current and voltage limits are discussed.

Middlebrook, R. D.↗

NASA NTRS2026

NASA Sonic Boom Wind Tunnel Testing

Explore the source record for details and available documents.

Low-Boom Technology↗

NASA NTRS2026

GVIPS Prediction of Cyclic Ratchetting Behavior and Cycles with Interrupted Relaxation Periods of TIMETAL 21S at 650 °C

The predictive performance of a multimechanism GVIPS model with saturating hardening function is assessed against a set of high temperature cyclic experiments under both strain-control and stress-control at varying rates of loading as well as several complex interrupted cyclic responses. The material specimens were composed of the titanium alloy, TIMETAL 21S, and tested at 650 °C, see Lissenden et al., 2007. The model did a very good job of predicting the variety of tests, particularly given the fact that only monotonic loading tests (tensile, creep, relaxation) and a single fully reversed cycle was used for characterization. It was particularly interesting that the model was capable of reasonably capturing the rate of accumulated strain during ratchetting under tensile mean stress. Given complex interrupted cyclic response, the model was able to both qualitatively and even quantitatively predict reasonably well both the cyclic and associated relaxation periods (in all quadrants of the stress-strain space) thus confirming the validity of the chosen functional forms for both hardening and thermal recovery. The quantitative inaccuracy is associated with the fact that the material specimens tested by Lissenden et al., 2007 was significantly “softer” than those tested by Castelli in Saleeb et al., 1994 which were used for characterization of the GVIPS model parameters.

Viscoplaticity↗

NASA NTRSDate not supplied

3D Woven Mid-Density Carbon Phenolic (3MDCP) Full-Scale Heatshield Development for Mars Sample Return (MSR) Earth Entry System (EES)

The Mars Sample Return (MSR) mission will be returning samples of Martian soil to Earth. The samples will be returned in the Earth Entry System (EES). The EES capsule is protected by a new thermal protection system; the 3-Dimensionally Woven, Mid-Density, Carbon Phenolic (3MDCP) material which is derived from the Heatshield for Extreme Entry Environment Technology (HEEET). The baseline 3MDCP design is a single piece thermal protection system that avoids the manufacturing and certification challenges associated with a tiled configuration. A 3MDCP heatshield begins as a flat woven preform that is formed to the final heatshield shape and then infused with phenolic resin. A NASA Ames lead team, in collaboration with Spirit Textiles (formerly TEAM Inc.), Fiber Materials Inc. (FMI, a Spirit AeroSystems Company), and Kratos SRE, has been developing and demonstrating the processes to fabricate the 3MDCP heatshield and characterize the resulting properties. The process of forming the flat woven preform into the final heatshield shape, a sphere-cone geometry with a 52.5° cone angle, involves local but substantial movement of the yarns in the weave. This results in continuous fibers across the single piece heatshield, albeit with property variations between different regions of the heatshield. This presentation will provide a high-level status of 3MDCP development for the MSR EES heatshield. This will include an overview of the manufacturing processes with an emphasis on the impact of forming on fiber orientation, material properties, and performance. Results comparing preliminary formed and flat materials will be shown. Additionally, the presentation will layout the broader plan for property testing and tie-in to aerothermal performance.

Peter Edward Marshall↗

NASA NTRSDate not supplied

A Prognostics Framework for Battery Health Monitoring Integrated with Thermal Modeling

Urban Air Mobility (UAM) promises to revolutionize transportation in major cities, offering passenger travel, cargo delivery, and emergency medical services through a network of electric vertical takeoff and landing (eVTOL) aircraft. However, the limited range of current eVTOLs, due to the low specific energy of lithium-ion batteries along with a possibility of thermal runaway conditions poses significant safety concerns, leading to potentially compromising operational safety. To address this critical challenge, researchers are actively evaluating the impact of flight and environmental conditions on onboard lithium-ion battery health. This involves carefully assessing the performance of battery packs under laboratory and operational conditions for developing models to estimate future health using prognostics framework. This study examines the effectiveness of evaluating battery degradation leading to catastrophic failures under varying operational conditions in laboratory. These are captured using physics based models of underlying phenomenons and integrated into the prognostics framework. A fully charged battery undergoes controlled discharge cycles at varying C-rates based on the simulated power draw profile, with current and voltage, temperature data recorded throughout the experiment. The observed data provides valuable insights into how different operating conditions and mission profiles affect battery performance. This information is crucial for developing strategies to optimize battery systems, enhance range, and ultimately ensure the safe and reliable operation of UAM vehicles.

Thermal Modeling↗

NASA NTRSDate not supplied

A Prognostics Framework for Battery Health Monitoring Integrated with Thermal Modeling

Thermal Modeling↗

NASA NTRS1986

Satellite battery testing status

Because of the large numbers of satellite cells currently being tested and anticipated at the Naval Weapons Support Center (NAVWPNSUPPCEN) Crane, Indiana, satellite cell testing is being integrated into the Battery Test Automation Project (BTAP). The BTAP, designed to meet the growing needs for battery testing at the NAVWPNSUPPCEN Crane, will consist of several Automated Test Stations (ATSs) which monitor batteries under test. Each ATS will interface with an Automation Network Controller (ANC) which will collect test data for reduction.

Haag, R.↗

NASA NTRS1968

Processing and Manufacture of Composite Propellants

This paper is a chemical engineering unit processing treatment of the steps involved in the manufacture of solid propellant motors. The author treats the major processes of raw material preparation, mixing, casting and curing by describing equipment, the processing, steps and some engineering considerations associated therewith. The three simultaneous processes occurring within the solid propellant nixing, namely, homogenization, wetting and curing, are discussed in more detail, briefly touching on control of these reactions and the engineering trade-offs among them.

J F Tormey↗

NASA NTRSDate not supplied

Cryogenic Fuel Aviation – Challenges and Opportunities

NASA aeronautics goals include pioneering new technology to increase efficiency and reduce emissions from air travel. The feasibility of using of on-board cryogenic fuels systems in combination with fuel cells, high efficiency engines, and electric motors for high efficiency commercial transport aircraft is being examined at NASA in collaborations with external partners. Growing emphasis on next generation air transportation resulted in the development of strategic investigations into cryogenic fuels aviation, including roadmaps for maturing new technologies, needs to improve testing and manufacturing capabilities, and the requirements for establishing regulatory and certification standards. A NASA cross-organizational multidisciplinary project team is exploring new aircraft architectures, enabling materials, and the engineering challenges associated with cryogenic fuels for aircraft. The engineering challenges include high performance cryogenic, thermal management, and power/propulsion components and subsystems to tackle the challenging problem of development of commercially viable aircraft that would radically transform air transportation.

liquid natural gas↗

NASA NTRS1985

Geosynchronous Performance of a Lithium-titanium Disulfide Battery

An ambient temperature rechargeable Lithium-Titanium disulfide (Li-TiS2) five cell battery has completed the first orbital year of accelerated synchronous orbit testing. A novel charge/discharge, state of charge (SOC) control scheme is utilized, together with taper current charge backup to overcome deleterious effects associated with high end of charge and low end of discharge voltages. It is indicated that 10 orbital years of simulated synchronous operation may be achieved. Preliminary findings associated with cell matching and battery performance are identified.

Otzinger, B.↗

NASA NTRS2026

QS ATMS Calibration Data Book Government Version: Pre-Launch Version

The Advanced Technology Microwave Sounder (ATMS) SN301 is an instrument onboard the QuickSounder Satellite System, QuickSounder mission (renamed QS). Throughout this document the mission may be referred to as QuickSounder or QS. The purpose of this document is to provide information needed to interpret and process QS ATMS science data. The contents of the data book incorporate results from pre-launch subsystem-level and instrument-level testing as well as post-launch testing performed during instrument commissioning. Major milestones include instrument thermal vacuum (TVAC) testing in May 2024 and observatory TVAC testing in 2026. QS launch will be no earlier than Feb. 15, 2027.

Microwave Radiometer↗

NASA NTRS1994

Combustor Technology for Future Small Gas Turbine Aircraft

To enhance fuel efficiency, future advanced small gas turbine engines will utilize engine cycles calling for overall engine pressure ratios, leading to higher combustor inlet pressures and temperatures. Further, the temperature rise through the combustor and the corresponding exit temperature are also expected to increase. This report describes future combustor technology needs for small gas turbine engines. New fuel injectors with large turndown ratios which produce uniform circumferential and radial temperature patterns will be required. Uniform burning will be of greater importance because hot gas temperatures will approach turbine material limits. The higher combustion temperatures and increased radiation at high pressures will put a greater heat load on the combustor liners. At the same time, less cooling air will be available as more of the air will be used for combustion. Thus, improved cooling concepts and/or materials requiring little or no direct cooling will be required. Although presently there are no requirements for emissions levels from small gas turbine engines, regulation is anticipated in the near future. This will require the development of low emission combustors. In particular, nitrogen oxides will increase substantially if new technologies limiting their formation are not evolved and implemented. For example, staged combustion employing lean, premixed/prevaporized, lean direct injection, or rich burn-quick quench-lean burn concepts could replace conventional single stage combustors. Due to combustor size considerations, staged combustion is more easily accommodated in large engines. The inclusion of staged combustion in small engines will pose greater combustor design challenges.

Valerie J Lyons↗

NASA NTRS2016

NASA Alternative Orion Small Cell Battery Design Support

The NASA Orion Crew Module Reference Design was produced to address large scale thermal runaway (TR) hazard with specific safety controls for the Orion Spacecraft. The design presented provides the description of a full scale battery design reference for implementation as a drop in replacement to meet all spacecraft energy requirements with compatible 120 Vdc electrical and mechanical interface using small cell technology (18650) packaging. The 32V SuperBrick incorporates unique support features and an electrical bus bar arrangement that allows cells negative can insertion into heat sink that is compressively coupled to the battery enclosure to promote good thermal management. The housing design also provides an internal flame suppression "filter tray" and positive venting path internal to the enclosure to allow hot effluent ejecta to escape in the event of single cell TR. Virtual cells (14P Banks) that are supported to provide cell spacing with interstitial materials to prevent side can failures that can produce cell to cell TR propagation. These features were successfully test in four separate TR run with the full scale DTA1 test article in February 2016. Successfully Completed Test Objectives - Four separate TR test runs with Full-Scale DTA1 housing with Two SuperBricks, Two SuperBrick Emulators All Tests resulted in "clean" gas with less than 6 C rise at Battery vent All Tests resulted in less than 2 C temperature rise on cold-plate outlet All Tests resulted in less than 6 psi pressure rise in the battery housing Test Run 1 -One neighbor cell TR, highest remaining neighbor 139 C. Ejecta shorted to bus caused prolonged additional heating, One shorted cell did experience TR after 12 minutes, remaining cells had adequate thermal margin Test Run 2 - No cell to cell propagation, highest neighbor cell 112 C; Test Run 3 - No cell to cell propagation, highest neighbor cell 96 C; Test Run 4 - No cell to cell propagation, highest neighbor cell 101 C; Primary TR testing and analysis were completed and reviewed for endorsement by NASA Engineering and Safety Center team members. All Key Test Objectives were met and the small cell design alternative was demonstrated and selected to be a feasible drop in replacement for the MPCV Orion CM Battery for EM2 mission.

Haynes, Chuck↗