Fire Containment System for Lithium-Ion Batteries
Explore the source record for details and available documents.
Batteries↗
SEARCH · Search NASA
Results for “thermal nondestructive evaluation”
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.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Research and development programs Quarterly report, Jan. - Mar. 1967
Thin film and semiconductor microelectronics, radar scattering, radome thermal stress, boundary layer phenomena, guided missile parts, turbulent mixing, antenna systems, and plasma dynamics
RADAR SCATTERING↗
Mars Sample Retrieval Lander Thermal Protection System Design
The Mars Sample Return (MSR) Sample Retrieval Lander (SRL) was slated to launch in 2031 and enter Mars’ atmosphere after a 15-month cruise. After several iterations of vehicle design and trajectories, the latest mission architecture included a 4.72-meter diameter entry capsule entering the Martian atmosphere at 8 km/s, marking a 3.5x increase in kinetic energy when entering the atmosphere in comparison to Mars 2020. Designed to be the heaviest and fastest vehicle to enter Mars’ atmosphere, SRL required slim mass margins, and as such, the thermal protection system (TPS) design methodology needed to be tailored appropriately. The entry capsule aeroshell is composed of a heatshield, backshell, parachute support cone, and parachute lid, as shown in Fig. 1.
Hannah Alpert↗
Li-ion EMU Battery Testing
A 45Ah Lithium ion (Li-Ion) battery comprised of 5 Yardney prismatic cells was evaluated to replace the silver-zinc cells in the Extra-vehicular Mobility Unit (EMU). Tests determined that the five cell battery can meet the mission objective of 500 duty cycles and maintain a minimum voltage of 16.0 V without an individual cell voltage dropping below 3.0V. Forty real time cycles were conducted to develop BOL trend data. Decision to switch to accelerated cycling for the remaining 460 cycles was made since Real Time cycling requires 1 day/cycle. Conclusions indicate that battery replacement would indeed be prudent.
Rehm, Raymond↗
Artemis II Mission Performance of the Orion Active Thermal Control System
The Orion spacecraft has recently completed Artemis II, the first crewed mission around the moon in 54 years. This test flight demonstrated vehicle capability as the foundation for all future missions under the Artemis program. As a major system of Orion, the Active Thermal Control System (ATCS) successfully managed crew and vehicle heat loads to provide adequate cooling and thermal comfort for the duration of the Artemis II mission. Thermal control on the Orion vehicle is managed through two redundant cooling loops in the Crew Module (CM) that absorb heat loads from the cabin and Air Revitalization System (ARS) heat exchangers, the Liquid Cooling Garment (LCG) heat exchanger, and the avionics cold plates, and then transfer those heat loads to the Service Module (SM) radiator loops and/or the Phase Change Material (PCM) and ammonia boilers when required through thermal configuration or mission phase. During Artemis II, Orion did not necessitate any supplemental cooling from ammonia boilers until service module separation, allowing the maximum availability of ammonia cooling prior to entry. This presentation will provide an overview of the Orion ATCS major subsystems, highlight the performance during key mission phases, and comment on the applicability of the observed thermal response to future Artemis missions.
Ellie Thurston↗
Stochastic Reconstruction of Ablating Material Properties for Uncertainty Propagation in Material Response Simulations
Explore the source record for details and available documents.
Thermal Protection Materials↗
In Situ Synchrotron Micro-CT of Microballoon-Filled RTV Silicone During Thermal Decomposition
This work investigates the thermal decomposition of microballoon-filled room-temperature-vulcanizing (RTV) silicone using time-resolved synchrotron micro-CT at the Advanced Light Source. In situ imaging of constrained and unconstrained samples captures the evolution of the internal microstructure during heating, including material expansion, microballoon and void growth, tearing, pyrolysis, shrinkage, and increasing porosity. The measurements provide new insight into the mechanisms governing RTV degradation and generate three-dimensional data for future quantitative analysis and material-response model development.
TPS↗
Fracture‐Resistant and Thermally Insulating Ultrahigh‐Temperature Carbide Foams
Dense ultrahigh‐temperature ceramics (UHTCs) carbides are recognized as potential materials for thermal protection systems (TPS) owing to properties beyond existing structural materials’ capabilities. Recent advances in UHTCs have enabled the development of multiscale porous microstructures. Herein, it is highlighted that the porosity in UHTCs are no longer treated as a defect but as a functional property specifically tailored for thermal insulation. It is a promising solution to design and fabricate bulk UHTC foams via a freeze‐drying (FD) approach followed by calibrated pressureless spark plasma sintering. Herein, monolithic TaC and HfC UHTC foams and their composite show the partial solid–solution formation of (Ta, Hf)C with porosity ≥50%. TaC–HfC foam (≈80–92 N) shows an intermediate load‐bearing capability compared to monolithic TaC (≈120–135 N) and HfC (≈28–35 N) foams, with no evident cracking on the sample surface. The thermal conductivity of partial solid‐solution TaC–HfC foam increases up to fivefold compared to parent UHTC foams. In the results, solid solutions’ efficacy and pores’ unidirectionality in providing thermal insulation to TaC–HfC while maintaining its high‐load bearing capability are illustrated. In conclusion, the developed technique establishes a new paradigm shift in UHTCs, expanding their potential for TPS in extreme environments.
36 MATERIALS SCIENCE↗
International Space Station Lithium-Ion Main Battery Thermal Runaway Propagation Test
In 2010, the ISS Program began the development of Lithium-Ion (Li-Ion) batteries to replace the aging Ni-H2 batteries on the primary Electric Power System (EPS). After the Boeing 787 Li-Ion battery fires, the NASA Engineering and Safety Center (NESC) Power Technical Discipline Team was tasked by ISS to investigate the possibility of Thermal Runaway Propagation (TRP) in all Li-Ion batteries used on the ISS. As part of that investigation, NESC funded a TRP test of an ISS EPS non-flight Li-Ion battery. The test was performed at NASA White Sands Test Facility in October 2016. This paper will discuss the work leading up to the test, the design of the test article, and the test results.
International Space Statio↗
Refueling Infrastructure Testing for Lunar Surface Operations
Explore the source record for details and available documents.
Texas Space Institute↗
Heat Capacity and Thermal Relaxation of Bulk Helium Very Near the Lambda Point
In October 1992 a low temperature experiment was flown on the Space Shuttle in low Earth orbit. The objective of the mission was to measure the heat capacity and thermal conductivity of helium very close to the lambda point with the smearing effect of gravity removed. We report preliminary results from the experiment, and compare them with related measurements performed on the ground. The sample was s sphere of helium 3.5 cm in diameter contained within a copper calorimeter of vey high thermal conductivity. The calorimeter was attached to a pair of high resolution paramagnetic salt thermometers with noise levels in the 10 -10 K range and suspended from a high stability thermal isolation system. During the mission we found that the resolution of the thermometers was degraded somewhat due to the impact of charged particles. This effect limited the useful resolution of the measurements to about two nanokelvins from the lambda point. The results reported here are limited to about ten nanokelvins from the transition.
John A Lipa↗
Developmental and Cryogenic Thermal Vacuum (TVAC) Testing Lessons Learned
Developmental thermal vacuum (TVAC) testing is a critical step in maturing hardware designs and validating performance prior to flight qualification. Unlike qualification or acceptance testing, developmental testing provides flexibility to explore design margins, uncover integration challenges, and refine test approaches before formal verification activities begin. This presentation highlights the value of developmental testing while sharing common pitfalls encountered during developmental TVAC campaigns. Lessons learned from hands-on testing experience, including extensive developmental testing at cryogenic temperatures, will be shared in this presentation. Topics include test planning and preparation, instrumentation strategies, contamination control considerations, troubleshooting unexpected anomalies, and approaches for staying on schedule while meeting test objectives. The audience will gain practical insights and best practices that can improve test efficiency, reduce risk, and enhance the overall success of future developmental TVAC efforts.
Mackenzie Byrnes↗
Mechanical, Electrochemical & Thermal Models - Training (CRADA CRD-19-00798 Final Report)
Under the proposed effort in partnership with Hyundai Motor Company (HMC), the National Renewable Energy Laboratory (NLR) will host Dr. Jaeyoung Lim from HMC for a period of one year to jointly develop mathematical models for battery cells and modules subject to mechanical crush. NLR will assist with the development of mathematical models that Dr. Lim will incorporate into his research effort on new concepts of mobility with electric vehicles.
33 ADVANCED PROPULSION SYSTEMS↗
Designing a Propylene-Glycol Coolant Servicer System for Gateway’s Internal Active Thermal Control System
A human spacecraft ATCS—especially one using single-phase coolant loops exposed to cabin atmospheric conditions—requires periodic degassing and refilling to support long-duration missions of 15 to 30 years. During initial fill operations, system maintenance, gas permeation, and quick-disconnect mating or de-mating, small amounts of gas can gradually enter the coolant system over time. This can lead to degraded heat transfer performance, pump cavitation, and potentially pump vapor lock if a significant gas volume accumulates over time. Additionally, system leaks and routine fluid sampling can gradually reduce accumulator volumes to unacceptable levels, requiring periodic refills. In more severe cases, catastrophic changes in fluid composition may necessitate emergency draining, refilling, and degassing to ensure continued system functionality. These risks were identified and mitigated on the ISS ITCS through the development of a dual-membrane degasser ORU and a Fluid Servicer System ORU for coolant refilling. These systems were developed for the fully water-based ISS ITCS Coolant[1]. The Gateway space station, the first permanent human habitat in lunar orbit, uses a propylene-glycol/water coolant mixture, which has significantly different fluid properties compared to pure water. Because microgravity degassing technologies are sensitive to fluid surface tension and viscosity, existing ISS hardware is not suitable for servicing a propylene-glycol-based TCS. Unlike the ISS, the Gateway will operate in a higher-radiation environment and must meet stricter mass constraints due to its location outside of low earth orbit. This Government Furnished Equipment (GFE) flight hardware project aims to develop a lightweight, radiation-resistant Coolant Servicer System (CSS) capable of degassing and refilling Gateway’s propylene-glycol water-based IATCS.
Propylene Glycol Water↗
Designing a Propylene-Glycol Coolant Servicer System for Gateway’s Internal Active Thermal Control System
A human spacecraft ATCS—especially one using single-phase coolant loops exposed to cabin atmospheric conditions—requires periodic degassing and refilling to support long-duration missions of 15 to 30 years. During initial fill operations, system maintenance, gas permeation, and quick-disconnect mating or de-mating, small amounts of gas can gradually enter the coolant system over time. This can lead to degraded heat transfer performance, pump cavitation, and potentially pump vapor lock if a significant gas volume accumulates over time. Additionally, system leaks and routine fluid sampling can gradually reduce accumulator volumes to unacceptable levels, requiring periodic refills. In more severe cases, catastrophic changes in fluid composition may necessitate emergency draining, refilling, and degassing to ensure continued system functionality. These risks were identified and mitigated on the ISS ITCS through the development of a dual-membrane degasser ORU and a Fluid Servicer System ORU for coolant refilling. These systems were developed for the fully water-based ISS ITCS Coolant[1]. The Gateway space station, the first permanent human habitat in lunar orbit, uses a propylene-glycol/water coolant mixture, which has significantly different fluid properties compared to pure water. Because microgravity degassing technologies are sensitive to fluid surface tension and viscosity, existing ISS hardware is not suitable for servicing a propylene-glycol-based TCS. Unlike the ISS, the Gateway will operate in a higher-radiation environment and must meet stricter mass constraints due to its location outside of low earth orbit. This Government Furnished Equipment (GFE) flight hardware project aims to develop a lightweight, radiation-resistant Coolant Servicer System (CSS) capable of degassing and refilling Gateway’s propylene-glycol water-based IATCS.
Propylene Glycol Water↗
A transport-based framework for solidification cracking in Ni-based superalloys processed by laser powder bed fusion
Solidification cracking remains a persistent barrier to laser powder bed fusion (LPBF) processing of solid-solution-strengthened (SSS) Ni-based superalloys and is commonly attributed to carbide formation, liquation-type failure, or elemental segregation. In this work, the cracking behavior of three SSS Ni-based superalloys—Inconel 625 (625), Inconel 617 (617), and Haynes 230 (230)—is examined under comparable LPBF conditions to evaluate the origins of their cracking susceptibility. Carbides were present in both 625 and 230, yet cracking behavior differed significantly. MC-type carbides in 625 remain discrete and preserve liquid connectivity, whereas Cr-rich M23C6 carbides in 230 form at cellular triple junctions that bottleneck the interdendritic liquid network, influencing cracking through liquid connectivity rather than as an independent cause. Alloy 617 exhibited anomalous segregation without resolvable secondary phases yet cracked mildly, indicating that extensive carbide formation is not a prerequisite for cracking. To rationalize these observations, a transport-limited framework is proposed in which cracking occurs when terminal-liquid feeding cannot accommodate solidification-induced strain; among the mechanisms evaluated, this framework is most consistent with the physical constraints imposed by LPBF solidification. Transport-based crack-susceptibility indexes incorporating permeability, viscosity, and solidification kinetics distinguish the alloy hierarchy; permeability ratios Krat increased from approximately 7 (625) to 11.5 (617) and 14.5 (230), with corresponding increases in the μ-weighted mushy zone risk index (CSIMZRM). These results are consistent with transport-limited liquid feeding as a rate-limiting contributor to solidification cracking in LPBF-processed SSS Ni-based superalloys, providing a physically grounded basis for alloy and process design.
Hyer, Holden [ORNL] (ORCID:0000000343915561)↗
Fuel Heating System Design and Thermal Modeling for Aviation Combustion Research
Aviation fuels offer substantial heat-sink capability that can be applied to aircraft thermal-management strategies and advanced propulsion-system concepts. Accurate control of fuel temperature is critical for understanding combustion behavior and supporting high temperature fuel experimental studies. This work describes the modeling and experimental validation of a portable, high temperature fuel-conditioning system designed for multiple NASA Glenn Research Center’s combustion facilities. The system utilizes a circulating-oil heating unit and modular tube-in-tube heat exchangers capable of conditioning Jet-A to temperatures approaching 600 K. A Thermal Desktop model was created to analyze heat exchanger configurations and predict performance across a range of operating conditions. Model predictions were compared with measurements collected in the CE-13C test facility, showing good agreement across the tested flow range except at low fuel flow rate around 2 kg/hr. Results provide guidance for sizing future fuel heating system for combustion research applications.
Jet fuel heating system↗
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↗