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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 397 records · Page 22

CFD Modeling of Cryogenic Chilldown in a Complex Channel under Normal and Low Gravity Conditions

Future NASA architectures have baselined cryogenic propulsion systems as well as cryogenic fluid management to support lunar missions and ultimately to support future missions to Mars. These missions will require chilling hardware down prior to engine restart as well as chilling lines and tanks prior to transferring and refueling these propulsion elements in orbit. In lieu of expensive tests conducted on-orbit, accurate predictive computational models of these chilldown processes can be used to reduce system and propellant mass as well as mission risk.

CFD↗

CFD Modeling of Cryogenic Chilldown in a Complex Channel under Normal and Low Gravity Conditions

Future NASA architectures have baselined cryogenic propulsion systems as well as cryogenic fluid management to support lunar missions and ultimately to support future missions to Mars. These missions will require chilling hardware down prior to engine restart as well as chilling lines and tanks prior to transferring and refueling these propulsion elements in orbit. In lieu of expensive tests conducted on-orbit, accurate predictive computational models of these chilldown processes can be used to reduce system and propellant mass as well as mission risk. To gain confidence in these computational models, appropriate anchoring and validation to experimental data in a relevant environment needs to be performed. Recent ground and sub-orbital flight experiments conducted by the Japan Aerospace Exploration Agency (JAXA) investigated chilldown of a complex channel resembling a turbopump bearing cavity at low flow rates. This work presents Computational Fluid Dynamics (CFD) model development of the chilldown experiment employing two-phase flow boiling models available in commercial CFD software STAR-CCM+ using Volume of Fluid (VOF) and the traditional Euler-Euler multiphase flow solvers. Comparisons of the numerical and experimental results under normal and low-gravity conditions are presented. An assessment of solid wall temperatures and phase distribution yielded important insights into multiphase solver choice, dependence on gravity environment, and challenges associated with cryogenic flow boiling prediction and validation.

CFD↗

Utilization of Machine Learning Techniques for Managing the Tracking and Data Relay Satellite Constellation

National Aeronautics and Space Administration’s (NASA) Goddard Space Flight Center (GSFC) operates a constellation of ten geosynchronous Tracking and Data Relay Satellites (TDRS). The TDRS constellation consists of multiple geosynchronous communication relay satellites located around the equator so they can provide continual coverage of any mission in low earth orbit. The TDRS are located primarily in three oceanic regions around the earth. NASA’s White Sands Complex provides the ground communication support for TDRS located over the Atlantic and Pacific Oceans. Another TDRS ground station in Guam supports the TDRS over the Indian Ocean. With these satellites the TDRS network can provide continuous coverage of satellites in low-earth orbit. The NASA Space Network (SN) project office at GSFC manages the constellation of spacecraft. Major customers of the TDRS constellation include, but are not limited to, the International Space Station and the Hubble Space Telescope. The TDRS constellation has three generations of satellites and has been active for over 30 years providing reliable communication links between customer satellites and corresponding ground stations. However, one of the major concerns for TDRS, and in any space mission, is to ensure the health and safety of the spacecraft. Generally, engineers use telemetry data to monitor and analyze the performance and state of health of the spacecraft. Telemetry data contains hundreds of parameters that monitor each important component in the spacecraft, which can be utilized to recognize and characterize the behavior of the spacecraft. Each parameter contains considerable information to represent time-dependent properties of each spacecraft subsystem and component. During the entire life of a TDRS spacecraft, thousands of gigabytes of telemetry data are transmitted in real-time from the spacecraft to the ground station at the White Sands Complex in Las Cruces, New Mexico, and recorded as historical data sets for engineers to process and analyze the events that occurred on-orbit. These parameters contain the function of multiple spacecraft subsystems, such as the attitude control system (ACS), Thermal, Electrical Power Subsystem (EPS), etc. . The first and second generations have exceeded their required lifetime and NASA is keen to manage these spacecrafts carefully in order to maximize the remaining life using the spacecraft telemetry. The challenge is to know when the risk of losing a spacecraft in geosynchronous orbit exceeds the benefit of continued operations for customer support. In the TDRS fleet, the EPS is the most critical subsystem related to spacecraft operations. Failure of the EPS would strand a spacecraft in geosynchronous orbit. Since EPS provides power to the spacecraft, component failures ultimately lead to the inability to support the spacecraft loads and the communications payload. For instance, TDRS-8 has several anomalies in EPS including the Bus Voltage Limiter (BVL) shunt current, solar array loss of circuits, and failed battery cells. Any of these anomalies can cause critical issues to the spacecraft. Therefore, developing a system to analyze and perform early detection of a potential anomaly is an important issue in telemetry data analysis. In recent years, Telemetry Mining (TM) has been proposed to process telemetry data by using Data Mining (DM) techniques such as classification, clustering, regression and anomaly detection. Anomaly detection, also known as outlier detection, has been widely used in many data mining areas such as remote sensing, medical data processing and digital image processing. The goal of anomaly detection is to detect abnormal data, which contains a relatively low probability of occurrence among the entire data set. Early detection of anomalies is one of the most significant issues in managing the spacecraft configuration. If anomalies can be detected early enough, then the redundant resources can be used to extend the life of the operational spacecraft. We present an unsupervised anomaly detection method to process the EPS data extracted from TDRS-8. This is different from traditional analytical methods, which use telemetry data to illustrate behavior and physical meaning of each spacecraft component. TM connects multiple parameters as a vector and then conducts data analysis on this high dimension telemetry vector. This method is looking at the properties of a high dimensional vector that is able to consider the relationship between different parameters in the anomaly detection problem. This kind of method performs much better than the traditional limit checking method. In addition, we propose a new approach of real-time anomaly detection to process telemetry data in real-time, which can then be applied to spacecraft monitoring with high reliability, low cost and high accuracy.

Machine Learning (ML)↗

Mission operations and command assurance: Instilling quality into flight operations

Mission Operations and Command Assurance (MO&CA) is a Total Quality Management (TQM) task on JPL projects to instill quality in flight mission operations. From a system engineering view, MO&CA facilitates communication and problem-solving among flight teams and provides continuous process improvement to reduce the probability of radiating incorrect commands to a spacecraft. The MO&CA task has evolved from participating as a member of the spacecraft team to an independent team reporting directly to flight project management and providing system level assurance. JPL flight projects have benefited significantly from MO&CA's effort to contain risk and prevent rather than rework errors. MO&CA's ability to provide direct transfer of knowledge allows new projects to benefit from previous and ongoing flight experience.

Welz, Linda L.↗

Optimal Sensor Selection for Health Monitoring Systems

Sensor data are the basis for performance and health assessment of most complex systems. Careful selection and implementation of sensors is critical to enable high fidelity system health assessment. A model-based procedure that systematically selects an optimal sensor suite for overall health assessment of a designated host system is described. This procedure, termed the Systematic Sensor Selection Strategy (S4), was developed at NASA John H. Glenn Research Center in order to enhance design phase planning and preparations for in-space propulsion health management systems (HMS). Information and capabilities required to utilize the S4 approach in support of design phase development of robust health diagnostics are outlined. A merit metric that quantifies diagnostic performance and overall risk reduction potential of individual sensor suites is introduced. The conceptual foundation for this merit metric is presented and the algorithmic organization of the S4 optimization process is described. Representative results from S4 analyses of a boost stage rocket engine previously under development as part of NASA's Next Generation Launch Technology (NGLT) program are presented.

Santi, L. Michael↗

Implementation of Human System Integration Workshop at NASA for Human Spaceflight

The human is a key element in the complex system of systems underlying space exploration missions. As a critical system, its operating bands and requirements need to be characterized and integrated with other systems. Optimal integration of the human system with hardware and software elements has an impact on multiple aspects of mission execution, including human health and performance, risk mitigation, effective design and functionality, enhanced safety, and reduced lifecycle costs. The field of Human Systems Integration (HSI) represents an interdisciplinary and comprehensive cross-cutting approach encompassing technical and management processes for integrating human as a system consideration and objective within and across all other system components and multiple domains. In addition to human activities, HSI covers training, operations and support dimensions. Moreover, HSI is an essential enabler to systems engineering practice, emphasizing human system aspects toward optimizing fully integrated system of systems performance while systematically infusing the needs of all users during the earliest stages of development. Consistent with the National Space Exploration Campaign, NASA is developing the Gateway, a lunar orbiting platform that will serve as astronaut habitat, support transit to deep space, validate new technologies and systems, and function as a science laboratory and communications hub, among other uses. It is an essential element of a phase that will extend human exploration into deep space through evolvable infrastructure and advanced technology, supporting assembly and logistics of other exploration architecture elements. In an effort to explore the current status and forward plan of HSI implementation in the mission (system of systems) lifecycle, the HSI Employee Resource Group conducted an HSI workshop using the Gateway Program as a case study. It revealed how different organizations at the Johnson Space Center incorporate HSI in their processes in preparation for the development and operation of the Gateway. The workshop focused on HSI methodology for implementation of the six NASA HSI domains: Human Factors Engineering, Operations Resources, Habitability and Environment, Maintainability and Supportability, Safety, and Training. Results from the workshop are reported on this paper, as well as some historical background of HSI at NASA, and the success in using an Employee Resource Group to promote technical knowledge. The authors hope that this information can be used to disseminate best practices for translational applications to other space exploration systems.

Silva-Martinez, Jackelynne↗

Implementation of Human System Integration Workshop at NASA for Human Spaceflight

The human is a key element in the complex system of systems underlying space exploration missions. As a critical system, its operating bands and requirements need to be characterized and integrated with other systems. Optimal integration of the human system with hardware and software elements has an impact on multiple aspects of mission execution, including human health and performance, risk mitigation, effective design and functionality, enhanced safety, and reduced lifecycle costs. The field of Human Systems Integration (HSI) represents an interdisciplinary and comprehensive cross-cutting approach encompassing technical and management processes for integrating human as a system consideration and objective within and across all other system components and multiple domains. In addition to human activities, HSI covers training, operations and support dimensions. Moreover, HSI is an essential enabler to systems engineering practice, emphasizing human system aspects toward optimizing fully integrated system of systems performance while systematically infusing the needs of all users during the earliest stages of development. Consistent with the National Space Exploration Campaign, NASA is developing the Gateway, a lunar orbiting platform that will serve as astronaut habitat, support transit to deep space, validate new technologies and systems, and function as a science laboratory and communications hub, among other uses. It is an essential element of a phase that will extend human exploration into deep space through evolvable infrastructure and advanced technology, supporting assembly and logistics of other exploration architecture elements. In an effort to explore the current status and forward plan of HSI implementation in the mission (system of systems) lifecycle, the HSI Employee Resource Group conducted an HSI workshop using the Gateway Program as a case study. It revealed how different organizations at the Johnson Space Center incorporate HSI in their processes in preparation for the development and operation of the Gateway. The workshop focused on HSI methodology for implementation of the six NASA HSI domains: Human Factors Engineering, Operations Resources, Habitability and Environment, Maintainability and Supportability, Safety, and Training. Results from the workshop are reported on this paper, as well as some historical background of HSI at NASA, and the success in using an Employee Resource Group to promote technical knowledge. The authors hope that this information can be used to disseminate best practices for translational applications to other space exploration systems.

Silva-Martinez, Jackelynne↗

Contamination Sources Effects Analysis (CSEA) - A Tool to Balance Cost/Schedule While Managing Facility Availability

A CSEA is similar to a Failure Modes Effects Analysis (FMEA). A CSEA tracks risk, deterrence, and occurrence of sources of contamination and their mitigation plans. Documentation is provided spanning mechanical and electrical assembly, precision cleaning, thermal vacuum bake-out, and thermal vacuum testing. These facilities all may play a role in contamination budgeting and reduction ultimately affecting test and flight. With a CSEA, visibility can be given to availability of these facilities, test sequencing and trade-offs. A cross-functional team including specialty engineering, contamination control, electrostatic dissipation, manufacturing, testing, and material engineering participate in an exercise that identifies contaminants and minimizes the complexity of scheduling these facilities considering their volatile schedules. Care can be taken in an efficient manner to insure correct cleaning processes are employed. The result is reduction in cycle time ("schedule hits"), reduced cost due to rework, reduced risk and improved communication and quality while achieving adherence to the Contamination Control Plan.

Wilcox, Margaret↗

ARCADE (Advanced Reactor Cyber Analysis and Development Environment)

SAND2025-11780O ARCADE (Advanced Reactor Cyber Analysis and Development Environment) software performs cybersecurity experiments on Defensive Cyber Security Architectures (DCSA) for Distributed Control Systems (DCSs). The application is integrated into a cohesive environment that performs cyber risk analyses and reduces costs. ARCADE can investigate the entire cyber-attack surface of a DCS from the physics of control, down to the firmware of individual components with automated efficiency. ARCADE has five major functional components: the Data Broker system, the virtualization environment, the cyber-attack simulator, the cyber-physical analysis system, and the physics simulator. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Valme, Romuald↗

Strategy Developed for Selecting Optimal Sensors for Monitoring Engine Health

Sensor indications during rocket engine operation are the primary means of assessing engine performance and health. Effective selection and location of sensors in the operating engine environment enables accurate real-time condition monitoring and rapid engine controller response to mitigate critical fault conditions. These capabilities are crucial to ensure crew safety and mission success. Effective sensor selection also facilitates postflight condition assessment, which contributes to efficient engine maintenance and reduced operating costs. Under the Next Generation Launch Technology program, the NASA Glenn Research Center, in partnership with Rocketdyne Propulsion and Power, has developed a model-based procedure for systematically selecting an optimal sensor suite for assessing rocket engine system health. This optimization process is termed the systematic sensor selection strategy. Engine health management (EHM) systems generally employ multiple diagnostic procedures including data validation, anomaly detection, fault-isolation, and information fusion. The effectiveness of each diagnostic component is affected by the quality, availability, and compatibility of sensor data. Therefore systematic sensor selection is an enabling technology for EHM. Information in three categories is required by the systematic sensor selection strategy. The first category consists of targeted engine fault information; including the description and estimated risk-reduction factor for each identified fault. Risk-reduction factors are used to define and rank the potential merit of timely fault diagnoses. The second category is composed of candidate sensor information; including type, location, and estimated variance in normal operation. The final category includes the definition of fault scenarios characteristic of each targeted engine fault. These scenarios are defined in terms of engine model hardware parameters. Values of these parameters define engine simulations that generate expected sensor values for targeted fault scenarios. Taken together, this information provides an efficient condensation of the engineering experience and engine flow physics needed for sensor selection. The systematic sensor selection strategy is composed of three primary algorithms. The core of the selection process is a genetic algorithm that iteratively improves a defined quality measure of selected sensor suites. A merit algorithm is employed to compute the quality measure for each test sensor suite presented by the selection process. The quality measure is based on the fidelity of fault detection and the level of fault source discrimination provided by the test sensor suite. An inverse engine model, whose function is to derive hardware performance parameters from sensor data, is an integral part of the merit algorithm. The final component is a statistical evaluation algorithm that characterizes the impact of interference effects, such as control-induced sensor variation and sensor noise, on the probability of fault detection and isolation for optimal and near-optimal sensor suites.

Source record↗

Engineering Innovations for Exploration Challenges

This slide presentation reviews some of the engineering innovations requirements for the challenges of space exploration which NASA has and will be involved in. It reviews some significant successes in space transportation, exploration and science accomplished during 2009, and it reviews some of the places that are available for exploration in the near term and the specific missions that NASA has assigned to Marshall. It also reviews the project lifecycle management model, that is designed to reduce undefined, but known, risks. It also demonstrates the sustainable long-term program of block upgrades that contribute to long-term success of programs.

Dumbacher, Daniel L.↗

Cyber Threat Assessment of Uplink and Commanding System for Mission Operation

Most of today's Mission Operations Systems (MOS) rely on Ground Data System (GDS) segment to mitigate cyber security risks. Unfortunately, IT security design is done separately from the design of GDS' mission operational capabilities. This incoherent practice leaves many security vulnerabilities in the system without any notice. This paper describes a new way to system engineering MOS, to include cyber threat risk assessments throughout the MOS development cycle, without this, it is impossible to design a dependable and reliable MOS to meet today's rapid changing cyber threat environment.

ground data↗

NC Space Grant Report

During the summer of 2018 I supported the Safety & Mission Assurance Directorate (SMA) and Operations Support Division (QA-20) at Stennis Space Center. The mission of the SMA team is to prove safety, risk, reliability, independent assessments, configuration management and quality assurance guidance, and services for all NASA Stennis Space Center (SSC) programs, facilities, and supporting infrastructure. The office actively participates and contributes to the Agency-level Safety & Mission Assurance (S&MA) effort. Over the course of the Summer I participated in three projects. Two of them were focused around Fault Tree Analysis (FTA) and the third focused on relief valves for their E-1 engine test stand.

Torres, David↗

Immersive Digital Twin Laboratory for Engineering Education (CRADA Final Report)

This project aimed to create an immersive digital twin laboratory that incorporates advanced tracking and visualization capabilities. In collaboration with Fort Lewis College, NREL designed a state-of-the-art physical visualization laboratory, developed a software platform to enable interaction with tracked physical objects in the laboratory, and provided proof-of-concept curricula that included manipulating these tracked objects. The project was initiated to address the growing need for innovative educational tools in engineering education. As renewable energy systems, particularly solar installations, become more complex, there is a pressing need to bridge the gap between theoretical knowledge and practical application. Traditional methods of teaching solar engineering concepts often fall short of providing students with a comprehensive, hands-on understanding. This immersive digital twin laboratory was conceived to fill that gap by creating a safe, non-energized setting where students can interact with augmented solar installation objects, gaining valuable insights into system performance, design, and maintenance. The project utilized extended reality (XR) technologies, including head-mounted displays (HMDs) and a whole-room optical motion tracking system, to connect physical objects with their digital twins in real time. The laboratory was equipped with MagicLeap 2 HMDs, supported by a Vicon Vero 2.2 Optical Tracking System, which provided precise 6-degrees-of-freedom (6-DOF) tracking. We developed a software platform to manage the interaction between the tracked physical objects and their virtual counterparts, enabling real-time data synchronization, object recognition, and virtual overlays. We designed the system to be flexible and extendable, allowing for future integration of additional objects and curriculum. This research advances the field of engineering education by demonstrating the potential of immersive digital twin environments. The laboratory provides a dynamic learning space where students can experiment, collaborate, and learn without the risks associated with live experimentation. The ability to simulate and manipulate solar installation objects under various conditions has broad implications for workforce development, particularly in renewable energy. The project also highlights the economic feasibility of using XR technologies in educational settings, offering a cost-effective solution for institutions looking to enhance their curriculum. By fostering a deeper understanding of solar energy systems, this work contributes to the broader goal of supporting the global energy transition and preparing the next generation of engineers and technicians.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Unlocking the Future of Aircraft Manufacturing: The Environmental Benefits of Laser Patterning for Surface Enhancement of Aircraft-Certified Alloys

Surface protection and functional modification of aircraft-certified aluminum alloys are essential for corrosion resistance, durability, and long-term airworthiness. At the same time, increasingly restrictive environmental regulations motivate the development of alternatives to legacy wet-chemical surface treatments. This study presents an integrated assessment of ultrafast femtosecond laser surface texturing as a surface functionalization approach for Aluminum 6061 alloys within an aerospace manufacturing and sustainability context. Ultrashort-pulse laser processing enables controlled micro- and nano-scale surface topographical modification with limited thermal impact, allowing adjustment of wettability and surface functionality while preserving bulk material integrity. As a dry and contactless process, femtosecond laser treatment eliminates the use of hazardous chemicals, reduces consumable inputs, and generates minimal secondary waste. A streamlined cradle-to-gate life cycle assessment conducted in accordance with ISO 14040/14044 indicates a lower global-warming potential per functional unit compared with conventional surface treatments, including anodization, plasma-assisted coatings, and organic coating systems. Complementary qualitative analyses addressing environmental health and safety, supply-chain risk, and ESG alignment indicate potential advantages related to occupational safety, regulatory compliance, waste management, and end-of-life recyclability. The investigation is performed on planar Aluminum 6061 reference surfaces with a treated area of 25 mm 2 , providing a controlled laboratory-scale basis for analyzing process behavior, functional surface modification, and associated environmental metrics. Within this defined scope, the results support further evaluation of femtosecond laser surface texturing as a surface engineering option for future aerospace manufacturing.

corrosion resistance↗

Flight and Integrated Testing: Blazing the Trail for the Ares Launch Vehicles

It has been 30 years since the United States last designed and built a human-rated launch vehicle. The National Aeronautics and Space Administration (NASA) has marshaled unique resources from the government and private sectors that will carry the next generation of astronauts into space safer and more efficiently than ever and send them to the Moon to develop a permanent outpost. NASA's Flight and Integrated Test Office (FITO) located at Marshall Space Flight Center and the Ares I-X Mission Management Office have primary responsibility for developing and conducting critical ground and flight tests for the Ares I and Ares V launch vehicles. These tests will draw upon Saturn and the Space Shuttle experiences, which taught the value of using sound systems engineering practices, while also applying aerospace best practices such as "test as you fly" and other lessons learned. FITO will use a variety of methods to reduce the technical, schedule, and cost risks of flying humans safely aboard a launch vehicle.

Taylor, James L.↗

Application of Space Environmental Observations to Spacecraft Pre-Launch Engineering and Spacecraft Operations

This presentation focuses on the effects of the space environment on spacecraft systems and applying this knowledge to spacecraft pre-launch engineering and operations. Particle radiation, neutral gas particles, ultraviolet and x-rays, as well as micrometeoroids and orbital debris in the space environment have various effects on spacecraft systems, including degradation of microelectronic and optical components, physical damage, orbital decay, biasing of instrument readings, and system shutdowns. Space climate and weather must be considered during the mission life cycle (mission concept, mission planning, systems design, and launch and operations) to minimize and manage risk to both the spacecraft and its systems. A space environment model for use in the mission life cycle is presented.

Barth, Janet L.↗

Mitigation of safety and environmental challenges posed by refrigerants

The abatement of safety and environmental burden associated with low and ultra-low Global Warming Potential (GWP) refrigerants is a critical undertaking. As the industry shifts towards more environmentally friendly alternatives, mitigating the potential risks and ensuring safety standards becomes paramount. The adoption of mildly and highly flammable refrigerants contributes significantly to minimizing the greenhouse gas impact on the environment, aligning with global climate and sustainability goals. However, it is essential to address safety concerns and potential environmental implications associated with the end use of these refrigerants. A method to mitigate the safety risk in a flammable refrigerant based heating, ventilation, air-conditioning, and refrigeration (HVACR) system is the primary focus of this paper. Advent of A2L and A3 refrigerants as replacements to high GWP refrigerants requires careful handling of leak episodes to lower or eliminate the risk associated with creating flammable mixtures capable of fire/explosion hazard. Solid materials tailored to target the molecule of interest (i.e., refrigerant.) by engineering the microporous structure as well as chemically functionalizing the surface to attract and hold on to the chemical compound being removed from the gas stream was realized. Quantitative analysis reveals the adsorbent's effectiveness in reducing leak potential in the range of 40 %–100 % for various refrigerants. Strategic placement and active leak management with negative pressure offer promising avenues for capturing leaked refrigerants, enhancing overall safety.

42 ENGINEERING↗