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NASA NTRS2015

Preliminary Flight Deck Observations During Flight in High Ice Water Content Conditions

In 2006, Mason et al. identified common observations that occurred in engine power-loss events attributed to flight in high concentrations of ice crystals. Observations included light to moderate turbulence, precipitation on the windscreen (often reported as rain), aircraft total temperature anomalies, lack of significant airframe icing, and no flight radar echoes at the location and altitude of the engine event. Since 2006, Mason et al. and others have collected information from pilots who experienced engine power-loss events via interviews and questionnaires to substantiate earlier observations and support event analyses. In 2011, Mason and Grzych reported that vertical acceleration data showed increases in turbulence prior to engine events, although the turbulence was usually light to moderate and not unique to high ice water content (HIWC) clouds. Mason concluded that the observation of rain on the windscreen was due to melting of ice high concentrations of ice crystals on the windscreen, coalescing into drops. Mason also reported that these pilot observations of rain on the windscreen were varied. Many pilots indicated no rain was observed, while others observed moderate rain with unique impact sounds. Mason concluded that the variation in the reports may be due to variation in the ice concentration, particle size, and temperature.

Wind Tunnel Tests↗

DOE OSTI2025

The effect of copper additives on hybrid Zr-based chemical conversion coating morphology and chemical compositions

In the realm of corrosion protection, Zr-based conversion coatings offer an environmentally friendly, chromate-free alternative to conventional coating. This study uses advanced X-ray, electron microscopy and electrochemical testing techniques to better understand the impact of varying Cu²⁺ ion concentrations on the characteristics of Zr-based coatings on Fe substrates. Our findings demonstrate that within the tested conditions, higher Cu²⁺ additive concentrations at 40 ppm enhance surface characteristics, increasing stability towards anti-corrosion capability, particularly under NaCl treatment. Conversely, at a lower Cu²⁺ concentration of 20 ppm, coatings exhibited more significant dissolution of Cu clusters and increased vulnerability to chloride-induced degradation. X-ray photoelectron spectroscopy and synchrotron X-ray fluorescence (XRF) and X-ray absorption near edge structure (XANES) spectroscopy analyses revealed Cu²⁺ formation in Cu20, while Cu40 retained its metallic state (Cu⁰) with a slower reaction rate. Cu20 offers some protection but lacks durability, whereas in Cu40, lower I corr , and enhance corrosion resistance, making it ideal for protective coatings in salt-water environments. This study underscores the importance of balancing Cu²⁺ ions concentration in the coating solution to optimize performance, highlighting the role of Cu in enhancing both surface properties and long-term stability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRSDate not supplied

Improving Ocean Reanalyses and ENSO Forecasts By Assimilation of Rain Corrected Satellite Sea Surface Salinity Using the GMAO S2S Forecast System

During the past years, we have seen that the La Nina to El Nino transition has had a significant global socio-economic impact and so has been the key focus for improving coupled ocean-atmosphere forecasts. Assimilation of satellite altimetry and subsurface temperature and salinity from (mostly) Argo help to improve the initialization of the thermocline, while satellite Sea Surface Temperature (SST) aids in constraining surface heat-fluxes, leading to improved subseasonal to seasonal forecasts of the coupled system. However, few studies have focused on improving the fresh-water flux and near-surface density and mixing through assimilation of satellite sea surface salinity (SSS). For expediency, the few ocean models that do assimilate SSS bias-correct the satellite SSS data to normalize towards the near-surface Argo data. However, in rainy regions, where buoyant water sits as a fresh lens at the surface, this assumption is likely inadequate. In previous work, we have shown that adjusting SSS data to bulk salinity (Sb) using the Rain Impact Model (RIM) of Santos-Garcia et al., 2014 has improved the near-surface density and mixed layer depth, leading to deeper thermocline and improved the NINO3.4 SST forecasts. Now we utilize the Soil Moisture/Ocean Salinity, Rain Corrected (SMOS_RC) SSS product provided by the Centre Aval de Traitement des données SMOS (CATDS CPDC) to represent the Sb more accurately at first model layer (in our case 5 m). Rather than using a diffusivity model as with RIM, SMOS_RC relies on an observed relationship between the spatial heterogeneity of SMOS SSS and instantaneous rain rate (RR) (Supply et al., 2020). In order to test the impact of SMOS_RC versus SMOS, we compare two reanalyses over the period 2014 to 2021. For both reanalysis experiments, all available along-track absolute dynamic topography and in situ observations are assimilated using the LETKF scheme (Penny et al., 2013). One reanalysis additionally assimilates SMOS SSS data as is (i.e., with the fresh bias), and a separate reanalysis is performed assimilating the SMOS_RC data. We assess the impact for near-surface and subsurface dynamics within ocean reanalyses by validating against observations and explore how SSS assimilation (SMOS versus SMOS_RC) impacts dynamical ENSO forecasts using the NASA GMAO Sub-seasonal to Seasonal coupled forecast system (GEOS S2S-3, Molod et al., 2020, Hackert et al., 2023). We will show that improved SSS estimates and near-surface density and mixing led to more accurate coupled air/sea interaction and better ENSO forecasts.

Eric Hackert↗

NASA NTRS2020

Snow and Water Imaging Spectrometer: Final Instrument Characterization

The Snow and Water Imaging Spectrometer (SWIS) is a science-grade imaging spectrometer and telescope system suitable for CubeSat applications, spanning a 350-1700 nm spectral range with 5.7 nm sampling, a 10 degree field of view and 0.3 mrad spatial resolution. The system operates at F/1.8, providing high throughput for low-reflectivity water surfaces, while avoiding saturation over bright snow or clouds. The SWIS design utilizes heritage from previously demonstrated instruments on airborne platforms, while advancing the state of the art in compact sensors of this kind in terms of size and spectral coverage. Through frequent repeat observations from space at a moderate spatial resolution, SWIS can address key science questions concerning aquatic and terrestrial ecosystem changes, cryosphere warming and melt behavior, cloud and atmospheric science, and potential impacts of climate change and human activities on the environment. We review the optical design and innovations and key technologies developed for this instrument, as well as its measured optical performance. We discuss the radiometric calibration characterization, including detector linearity, flat field correction, and SNR. Finally, we discuss stray light modeling and the development of a focused ghost removal algorithm, which is tested and supported by laboratory results.

Bellardo, John↗

DOE OSTI2026

Impact of Porous Transport Layer Morphology on the Performance of Proton Exchange Membrane Water Electrolyzers with Ultra-Low Iridium Loadings

Reducing Ir loadings in proton exchange membrane water electrolyzer anodes is critical for lowering capital expenses. Loading reduction could be achieved by improving the Ir activity via doping/alloying and/or the development of advanced microstructures. However, the anode porous transport layer (PTL) is a comparatively simple component whose properties also impact Ir utilization. Therefore, well-designed PTLs may also enable reduced Ir loadings. In this work, we survey eight PTLs from various manufacturers to observe their impact on cell performance at low (0.4 mg Ir cm -2 ) and ultralow (0.1 mg Ir cm -2 ) Ir loadings. The PTLs were characterized by their microstructural properties, including porosity, particle size distribution, and pore size distribution. Electrochemical cell performance was correlated to PTL morphology, and it was found that PTLs with lower porosities and smaller particle and pore radii enabled good performance even at ultralow Ir loadings. 1000-h durability testing indicated that using lower porosity PTLs can significantly improve durability behavior. A runaway voltage phenomenon was observed during durability testing of cells with ultralow Ir loadings, which was caused by increases in both anode and cathode overpotentials. Furthermore, we observed that the beginning of test performance of 0.1 mg Ir cm -2 cells correlates to the 1000-h degradation rates of 0.4 mg Ir cm -2 cells, suggesting that for the Ir catalyst used in this work, short-term testing at ultralow loadings can be used as an indicator of long-term degradation at higher loadings.

08 HYDROGEN↗

NASA NTRS1999

Characterization of the Heat Extraction Capability of a Compliant, Sliding, Thermal Interface for Use in a High Temperature, Vacuum Microgravity Furnace

Much of the material science gained in microgravity research requires processing a sample in a high performance furnace. One such furnace currently being designed is the Quench Module Insert (QMI). The Principle Investigators, for whom the furnace is proposed, require high temperature gradients in their cylindrical samples to achieve the science objectives. One of the components critical to achieving high sample axial temperature gradients in the Quench Module Insert is a high performance cold zone to extract the heat from the sample. This cold zone employs a compliant, sliding thermal interface based on a Vel-Therm felt. This felt provides a conductive path between the Sample Cartridge Assembly (SCA) exterior surface and the interior surface of the water cooled chill block while allowing movement of the sample relative to the chill block. The Vel-Therm felt is composed of long polymer-based fibers affixed to a thin flexible substrate layer. The fibers are oriented perpendicular to this substrate giving the felt the appearance of a velvet fabric. The Vel-Therm felt heat extraction capability was quantified in earlier tests performed in an inert gas environment. The current activity, described in this paper, is intended to characterize the extraction capability of Vel-Therm felt in a vacuum environment similar to the QMI environment. This testing is necessary to quantify the thermal performance of the Vel-Therm felt and the sensitivity of that performance to key variables. The data derived from these tests will be incorporated into the current thermal models to improve the quality of the models and reduce uncertainty of the analytical results. In addition, the data will be used to help select the appropriate Vel-Therm felt and set proper operating limits as well as assess the performance range of the furnace. The objective of this test is to measure the heat extraction rate of the Vel-Therm felt as specified by the effective heat transfer coefficient. Therefore, the test setup was designed to force the bulk of the heat transfer through the area where the Vel-Therm felt was applied. A heat source, consisting of a ceramic heating element encased in a Copper (Cu) housing is mounted on four isolated support rods. A 6-layer molybdenum radiation shield is used to insulate against heat loss from the heater and prevent heat exchange between the hot and cold sides of the test apparatus. The Vel-Therm felt is affixed to the surface of the cold sink, a water-cooled Cu chill block. An adjustable plate supports and isolates the cold sink from above and is used to control the amount of the deflection of the Vel- Therm when in contact with the Cu heating element housing. The primary means of establishing the power being conducted through the felt is to measure the energy being transferred to the water passing through the chill block. Analysis was performed to support the assumption that the source and sink surfaces were approximately isothermal under the specific test conditions. As a check on the amount of power passing through the felt, the power supplied to the heater was also measured. Thermocouples were strategically located throughout the test apparatus for measurement purposes. A bell jar was lowered over the assembly to impose vacuum conditions. Currently, variables tested have been fiber compression and fiber type and surface temperatures (both the hot and cold side temperatures are hypothesized to be important to the performance of the Vel-Therm.) Selected runs were repeated to ensure consistency and repeatability. Results obtained thus far reveal that Vel-Therm performance is significantly degraded by fibers being exposed to high compression. It also shows that performance is somewhat negatively impacted by previous compression, thereby, raising the question of repeatability. In addition, early results show a significant dependence on temperature. A computer aided mathematical analysis of the test setup is ongoing. The results will be correlated to actual results. The correlation will examine such details as parasitic loses, conduction down the power leads and many other concerns.

Bellomy-Ezell, Jenny↗

NASA NTRS2015

A Linearized Prognostic Cloud Scheme in NASAs Goddard Earth Observing System Data Assimilation Tools

A linearized prognostic cloud scheme has been developed to accompany the linearized convection scheme recently implemented in NASA's Goddard Earth Observing System data assimilation tools. The linearization, developed from the nonlinear cloud scheme, treats cloud variables prognostically so they are subject to linearized advection, diffusion, generation, and evaporation. Four linearized cloud variables are modeled, the ice and water phases of clouds generated by large-scale condensation and, separately, by detraining convection. For each species the scheme models their sources, sublimation, evaporation, and autoconversion. Large-scale, anvil and convective species of precipitation are modeled and evaporated. The cloud scheme exhibits linearity and realistic perturbation growth, except around the generation of clouds through large-scale condensation. Discontinuities and steep gradients are widely used here and severe problems occur in the calculation of cloud fraction. For data assimilation applications this poor behavior is controlled by replacing this part of the scheme with a perturbation model. For observation impacts, where efficiency is less of a concern, a filtering is developed that examines the Jacobian. The replacement scheme is only invoked if Jacobian elements or eigenvalues violate a series of tuned constants. The linearized prognostic cloud scheme is tested by comparing the linear and nonlinear perturbation trajectories for 6-, 12-, and 24-h forecast times. The tangent linear model performs well and perturbations of clouds are well captured for the lead times of interest.

Precipitation↗

NASA NTRSDate not supplied

An Automated Refinement Process for Particle Trajectory Methods in GlennICE

Computational methods for ice accretion can simulate the impact of water drops and ice crystals on an aircraft surface in a Lagrangian reference frame or in the Eulerian reference frame. In the Eulerian reference frame, particles are considered a continuous fluid while in the Lagrangian frame individual particle trajectories are calculated. Methods that use the Eulerian reference frame are typically easier to develop as established modules used for continuum mechanics can be leveraged. The Eulerian systems can also be faster since the user does not have to simulate millions of particles in order to achieve good results. It is imperative therefore that a Lagrangian method optimize the release points of trajectories such that accurate solutions can be obtained while minimizing as much as possible the number of trajectories computed. This paper will present a methodology for this refinement process and demonstrate its effectiveness on sample three dimensional test cases.

William B Wright↗

NASA NTRSDate not supplied

An Automated Refinement Process for Particle Trajectory Methods in GlennICE

William Wright↗

DOE OSTI2025

Representing Fine‐Scale Topographic Effects on Surface Radiation Balance in Hyper‐Resolution Land Surface Models

Land surface models are increasingly used to simulate land surface processes at hyper-spatial resolutions (e.g., ∼1 km). As model resolution increases, grid-scale topographic effects on surface radiation fluxes and their interactions between adjacent grids become more pronounced. However, current land surface models routinely neglect the fine-scale topographic effects on surface radiation balance. This study developed physically-based and computationally-efficient parameterizations (fineTOP) that explicitly resolve fine-scale topographic effects on downward shortwave and longwave radiation as well as land surface radiative properties. The newly developed parameterizations were implemented and tested in the Energy Exascale Earth System Model (E3SM) Land Model (ELM). Multi-decadal km-resolution ELM simulations over the California Sierra Nevada show that fine-scale topography significantly impacts the surface energy balance and snow processes across seasons. Slope determines the magnitude of topographic effects, while aspect controls their sign. For slopes larger than 30°, topography-induced change in annual surface temperature can be as large as 3.3 K. Regionally, the mean value and standard deviation of topography-induced changes in annual surface temperature are −0.22 ± 0.38 K and +0.25 ± 0.37 K over north-facing and south-facing slopes, respectively. Topography-induced changes in surface radiative properties account for 3.5% ± 13.8% of total topographic effects on annual net radiation. With fineTOP, ELM captures the aspect-dependence of snow cover fraction, snow water equivalent, and land surface temperature found in MODIS satellite observations and a snow reanalysis data set, while the default ELM fails to capture this phenomenon. The enhanced capability to represent fine-scale topographic effects on surface radiation balance can be used to advance understanding of the role of fine-scale topography in land surface processes and land-atmosphere interactions over mountainous regions.

Hao, Dalei [Pacific Northwest National Laboratory ↗

NASA NTRS1982

Rime ice accretion and its effect on airfoil performance

A methodology was developed to predict the growth of rime ice, and the resulting aerodynamic penalty on unprotected, subcritical, airfoil surfaces. The system of equations governing the trajectory of a water droplet in the airfoil flowfield is developed and a numerical solution is obtained to predict the mass flux of super cooled water droplets freezing on impact. A rime ice shape is predicted. The effect of time on the ice growth is modeled by a time-stepping procedure where the flowfield and droplet mass flux are updated periodically through the ice accretion process. Two similarity parameters, the trajectory similarity parameter and accumulation parameter, are found to govern the accretion of rime ice. In addition, an analytical solution is presented for Langmuir's classical modified inertia parameter. The aerodynamic evaluation of the effect of the ice accretion on airfoil performance is determined using an existing airfoil analysis code with empirical corrections. The change in maximum lift coefficient is found from an analysis of the new iced airfoil shape. The drag correction needed due to the severe surface roughness is formulated from existing iced airfoil and rough airfoil data. A small scale wind tunnel test was conducted to determine the change in airfoil performance due to a simulated rime ice shape.

Bragg, M. B.↗

NASA NTRS2002

Simulation of the Climate of South-West Asia with a Regional Model

The ability of the regional model RegCM2 to simulate the climate of South-West Asia is examined. The climate of the region displays high spatial, seasonal and interannual variability, providing a strong test of climate model capabilities. RegCM2 captures the spatial variability of temperature and precipitation despite cold biases being present in the model. RegCM2 does not capture the annual cycle of precipitation on the Black and Caspian Sea coasts where very steep topography exists, nor on the eastern Mediterranean coast where the coastal mountains are not resolvable. RegCM2 does capture the seasonal cycle in the Fertile Crescent and Zagros mountains, where it is strongly influenced by a plateau circulation above the Iranian plateau. It is shown that accurate simulation of precipitation in these regions, including the inter-annual variability, requires the correct simulation of both storm tracks and topographic interactions. Through the use of regional climate models the concentration and transport pathways of water vapor through the Middle East can be explored. The results demonstrate that short lived 'events' have little impact on monthly mean atmospheric fields yet provide a significant amount of the precipitated water which flows in the Tigris river.

Evans, J. P.↗

NASA NTRS2019

Assessing precipitation, evapotranspiration, and NDVI as controls of US Great Plains plant production

Productivity throughout the North American Great Plains grasslands is generally considered to be water limited, with the strength of this limitation increasing as precipitation decreases. We hypothesize that cumulative actual evapotranspiration water loss (AET) from April to July is the precipitation-related variable most correlated to aboveground net primary production (ANPP) in the U.S. Great Plains (GP). We tested this by evaluating the relationship of ANPP to AET, precipitation, and plant transpiration (Tr). We used multi-year ANPP data from five sites ranging from semiarid grasslands in Colorado and Wyoming to mesic grasslands in Nebraska and Kansas, mean annual NRCS ANPP, and satellite-derived normalized difference vegetation index (NDVI) data. Results from the five sites showed that cumulative April-to-July AET, precipitation, and Tr were well correlated (R2: 0.54–0.70) to annual changes in ANPP for all but the wettest site. AET and Tr were better correlated to annual changes in ANPP compared to precipitation for the drier sites, and precipitation in August and September had little impact on productivity in drier sites. April-to-July cumulative precipitation was best correlated (R2 = 0.63) with interannual variability in ANPP in the most mesic site, while AET and Tr were poorly correlated with ANPP at this site. Cumulative growing season (May-to-September) NDVI (iNDVI) was strongly correlated with annual ANPP at the five sites (R2 = 0.90). Using iNDVI as a surrogate for ANPP, we found that county-level cumulative April–July AET was more strongly correlated to ANPP than precipitation for more than 80% of the GP counties, with precipitation tending to perform better in the eastern more mesic portion of the GP. Including the ratio of AET to potential evapotranspiration (PET) improved the correlation of AET to both iNDVI and mean county-level NRCS ANPP. Accounting for how different precipitation-related variables control ANPP (AET in drier portion, precipitation in wetter portion) provides opportunity to develop spatially explicit forecasting of ANPP across the GP for enhancing decision-making by land managers and use of grassland ANPP for biofuels.

Maosi Chen↗

NASA NTRS2019

Global Response Patterns of Major Rainfed Crops to Adaptation by Maintaining Current Growing Periods and Irrigation

Increasing temperature trends are expected to impact yields of major field crops by affecting various plant processes, such as phenology, growth, and evapotranspiration. However, future projections typically do not consider the effects of agronomic adaptation in farming practices. We use an ensemble of seven Global Gridded Crop Models to quantify the impacts and adaptation potential of field crops under increasing temperature up to 6 K, accounting for model uncertainty. We find that without adaptation, the dominant effect of temperature increase is to shorten the growing period and to reduce grain yields and production. We then test the potential of two agronomic measures to combat warming-induced yield reduction: (i) use of cultivars with adjusted phenology to regain the reference growing period duration and (ii) conversion of rainfed systems to irrigated ones in order to alleviate the negative temperature effects that are mediated by crop evapotranspiration. We find that cultivar adaptation can fully compensate global production losses up to 2 K of temperature increase, with larger potentials in continental and temperate regions. Irrigation could also compensate production losses, but its potential is highest in arid regions, where irrigation expansion would be constrained by water scarcity. Moreover, we discuss that irrigation is not a true adaptation measure but rather an intensification strategy, as it equally increases production under any temperature level. In the tropics, even when introducing both adapted cultivars and irrigation, crop production declines already at moderate warming, making adaptation particularly challenging in these areas.

Minoli, Sara↗

NASA NTRS1946

Waters Loads on the XJL-1 Hull as Obtained in Langley Impact Basin, TED No. NACA 2413.3

An investigation was conducted in the Langley impact basin of the water loads on a half scale model of the XJL-1 hull whose forebody has a vee bottom with exaggerated chine flare. The impact loads, moments, and pressures were determined for a range of landing conditions. A normal full-scale landing speed of 86 miles per hour was represented with effective flight paths ranging from 0.6deg to 11.6deg. Landings were made with both fixed trim and free-to-trim mounting of the float over a trim range of -15deg to 12deg into smooth water and into waves having equivalent full-scale length. of 120 feet and heights ranging from 1 to 4 feet. All data and results presented in this report are given in terms of equivalent full-scale values. Summary tables and illustrative plots are used in presenting the material. The following maximum values of load and pressure are those which are apropos for effective flight paths less than 6.5deg which was the maximum value obtained in tests with the XJL-1 hull model representing full-scale landings with vertical velocity of 4.5 feet per second into 4-foot waves. The maximum local pressure on the flat portion of the bottom is 130 pounds per square inch which was measured on a 2-inch-diameter circular area near the step. The maximum local pressure obtained in the curved area near the chines is 200 pounds per square inch. This pressure was also measured near the step.

Steiner, Margaret F.↗

NASA NTRS2008

The Manufacturing Process for the NASA Composite Crew Module Demonstration Structure

This paper will describe the approaches and methods selected in fabrication of a carbon composite demonstration structure for the Composite Crew Module (CCM) Program. The program is managed by the NASA Safety and Engineering Center with participants from ten NASA Centers and AFRL. Multiple aerospace contractors are participating in the design development, tooling and fabrication effort as well. The goal of the program is to develop an agency wide design team for composite habitable spacecraft. The specific goals for this development project are: a).To gain hands on experience in design, building and testing a composite crew module. b) To validate key assumptions by resolving composite spacecraft design details through fabrication and testing of hardware. This abstract is based on Preliminary Design data..The final design will continue to evolve through the fall of 2007 with fabrication mostly completed by conference date. From a structures perspective, the.CCM can be viewed as a pressure module with variable pressure time histories and a series of both impact and quasi-static, high intensity point, line, and area distributed loads. The portion of the overall space vehicle being designed and. fabricated by the CCM team is just the pressure module and primary loading points. The heaviest point loads are applied and distributed to the pressure module at.an aluminum Service Module/Alternate Launch Abort System (SM/ALAS) fittings and at Main and Drogue Chute fittings. Significant line loads with metal to metal impact is applied at.the Lids ring. These major external point and line loads as well as pressure impact loads (blast and water landing) are applied to the lobed floor though the reentry shield and crushable materials. The pressure module is divided into upper and lower. shells that mate together with a bonded belly band splice joint to create the completed structural assembly. The benefits of a split CCM far outweigh the risks of a joint. These benefits include lower tooling cost and less manufacturing risk. Assembly of the top and bottom halves of the pressure shell will allow access to the interior of the shell throughout remaining fabrication sequence and can also potentially permit extensive installation of equipment and .crew facilities prior to final assembly of the two shell halves. A Pi pre-form is a woven carbon composite material which is provided in pre-impregnated form and frozen for long term storage. The cross-section shape allows the top of the pi to be bonded to a flat or curved surface with a second flat plate composite section bonded between two upstanding legs of the Pi. One of the regions relying on the merits of the Pi pre-form is the backbone. All connections among plates of the backbone structure, including the upper flanges, and to the lobe base of the pressure shell are currently joined by Pi pre-forms. The intersection of backbone composite plates is formed by application of two Pi pre-forms, top flanges and lobed surfaces are bonded with one Pi pre-form. The process of applying the pre-impregnated pi-preform will be demonstrated to include important steps like surface preparation, forming, application of pressure dams, vacuum bagging for consolidation, and curing techniques. Chopped carbon fiber tooling was selected over other traditional metallic and carbon fiber tooling. The requirement of schedule and cost economy for a moderate reuse cure tool warranted composite tooling options. Composite tooling schedule duration of 18 weeks compared favorably against other metallic tooling including invar tooling. Composite tooling also shows significant cost savings over low CTE metallic options. The composite tooling options were divided into two groups and the final decision was based on the cost, schedule, tolerance, temperature, and reuse requirements.

Pelham, Larry↗

NASA NTRS2026

Thermal Cycle and Capacitance Testing of Mezzo Industries Phase Changer Material Heat Capacitor

Effective Thermal management is essential for the safety and performance of human spacecraft, especially during long-duration missions with fluctuating heat loads. Phase Change Material (PCM) heat exchangers offer a compact, efficient solution by storing and releasing thermal energy through latent heat during phase transitions. This allows PCM systems to buffer transient thermal loads without immediate heat rejection, reducing the need for oversized radiators – particularly critical during ascent and re-entry when radiators are stowed. By maintaining stable temperatures in crew cabins and equipment bays, PCM technology enhances crew comfort, protects sensitive systems, and supports long-term mission sustainability with minimal mass and volume impact. A phase change material heat capacitor prototype, designed and built under a NASA Small Business Innovation Research grant by Mezzo Technologies, utilizes a laser welding microtube manufacturing process that promises increased reliability and performance over current manufacturing methods like brazing. This heat exchanger was tested through coolant thermal cycling within the expected flow rates and temperature range of the Orion spacecraft, the crewed spacecraft taking NASA astronauts to the moon under the Artemis Program. The useful heat storage capacitance was measured and compared to Orion spacecraft requirements.

Active Thermal Control Systems↗

NASA NTRS2010

Launch Pad Flame Trench Refractory Materials

The launch complexes at NASA's John F. Kennedy Space Center (KSC) are critical support facilities for the successful launch of space-based vehicles. These facilities include a flame trench that bisects the pad at ground level. This trench includes a flame deflector system that consists of an inverted, V-shaped steel structure covered with a high temperature concrete material five inches thick that extends across the center of the flame trench. One side of the "V11 receives and deflects the flames from the orbiter main engines; the opposite side deflects the flames from the solid rocket boosters. There are also two movable deflectors at the top of the trench to provide additional protection to shuttle hardware from the solid rocket booster flames. These facilities are over 40 years old and are experiencing constant deterioration from launch heat/blast effects and environmental exposure. The refractory material currently used in launch pad flame deflectors has become susceptible to failure, resulting in large sections of the material breaking away from the steel base structure and creating high-speed projectiles during launch. These projectiles jeopardize the safety of the launch complex, crew, and vehicle. Post launch inspections have revealed that the number and frequency of repairs, as well as the area and size of the damage, is increasing with the number of launches. The Space Shuttle Program has accepted the extensive ground processing costs for post launch repair of damaged areas and investigations of future launch related failures for the remainder of the program. There currently are no long term solutions available for Constellation Program ground operations to address the poor performance and subsequent failures of the refractory materials. Over the last three years, significant liberation of refractory material in the flame trench and fire bricks along the adjacent trench walls following Space Shuttle launches have resulted in extensive investigations of failure mechanisms, load response, ejected material impact evaluation, and repair design analysis (environmental and structural assessment, induced environment from solid rocket booster plume, loads summary, and repair integrity), assessment of risk posture for flame trench debris, and justification of flight readiness rationale. Although the configuration of the launch pad, water and exhaust direction, and location of the Mobile Launcher Platform between the flame trench and the flight hardware should protect the Space Vehicle from debris exposure, loss of material could cause damage to a major element of the ground facility (resulting in temporary usage loss); and damage to other facility elements is possible. These are all significant risks that will impact ground operations for Constellation and development of new refractory material systems is necessary to reduce the likelihood of the foreign object debris hazard during launch. KSC is developing an alternate refractory material for the launch pad flame trench protection system, including flame deflector and flame trench walls, that will withstand launch conditions without the need for repair after every launch, as is currently the case. This paper will present a summary of the results from industry surveys, trade studies, life cycle cost analysis, and preliminary testing that have been performed to support and validate the development, testing, and qualification of new refractory materials.

Calle, Luz M.↗