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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
NASA NTRS2026

Mechanical Design and Operation of a Novel Lunar Environment Structural Test Rig (LESTR)

The Lunar Environment Structural Test Rig (LESTR) was developed to address a critical gap in mechanical property data for metal alloy wire materials under lunar-relevant conditions down to 40 K. Conventional aerospace material databases provide thermophysical properties for bulk metals over a wide temperature range, but validated mechanical and physical property data below 77 K, particularly for small-diameter wires, remain limited and are generally the exception rather than the rule. These conditions are essential for Artemis mission hardware such as shape memory alloy (SMA) rover tires. LESTR’s design requirements were to combine a high-stiffness electrodynamic load frame with closed- cycle cryogenic cooling, high-vacuum capability (10–6 torr), and noncontact optical strain measurement to enable tensile, four-point bend, and fatigue testing of wires or other materials and geometries at temperatures from 40 to 125 K. These considerable requirements were merged with the need to lower the barrier of testing for the end user as measured in terms of cost-per-test cycle, safety improvement, and reduction in upkeep costs associated with state-of-the-art solutions associated with cryomechanical material characterization. The system incorporates modular gripping and alignment fixtures; precision thermal management using cryocoolers and embedded heaters; and integrated instrumentation for displacement, load, temperature, and vacuum control. Calibration procedures establish correlations between tooling and specimen temperature, ensuring accurate thermal conditions across the design envelope unbound by cryofluid conditions in heritage immersion-based test systems. Initial validation tests using Inconel (Special Metals Corp.) wire demonstrated accurate ultimate strength and post-yield behavior. The load frame operation was also verified under representative service conditions, including thermal cycling and prolonged fatigue loading. By generating mechanical property data at ultralow temperatures, LESTR fills a critical gap in existing materials databases and provides a scalable platform for iterative alloy development and durability assessment for planetary hardware. This capability supports NASA’s long-term objectives for surface exploration by enabling design confidence for components operating in extreme cryogenic environments.

LESTR↗
NASA NTRS2014

Tank Applied Testing of Load-Bearing Multilayer Insulation (LB-MLI)

The development of long duration orbital cryogenic storage systems will require the reduction of heat loads into the storage tank. In the case of liquid hydrogen, complete elimination of the heat load at 20 K is currently impractical due to the limitations in lift available on flight cryocoolers. In order to reduce the heat load, without having to remove heat at 20 K, the concept of Reduced Boil-Off uses cooled shields within the insulation system at approximately 90 K. The development of Load-Bearing Multilayer Insulation (LB-MLI) allowed the 90 K shield with tubing and cryocooler attachments to be suspended within the MLI and still be structurally stable. Coupon testing, both thermal and structural was performed to verify that the LB-MLI should work at the tank applied level. Then tank applied thermal and structural (acoustic) testing was performed to demonstrate the functionality of the LB-MLI as a structural insulation system. The LB-MLI showed no degradation of thermal performance due to the acoustic testing and showed excellent thermal performance when integrated with a 90 K class cryocooler on a liquid hydrogen tank.

Thermal Insulation↗
NASA NTRS2014

Tank Applied Testing of Load-Bearing Multilayer Insulation (LB-MLI)

The development of long duration orbital cryogenic storage systems will require the reduction of heat loads into the storage tank. In the case of liquid hydrogen, complete elimination of the heat load at 20 K is currently impractical due to the limitations in lift available on flight cryocoolers. In order to reduce the heat load, without having to remove heat at 20 K, the concept of Reduced Boil-Off uses cooled shields within the insulation system at approximately 90 K. The development of Load-Bearing Multilayer Insulation (LB-MLI) allowed the 90 K shield with tubing and cryocooler attachments to be suspended within the MLI and still be structurally stable. Coupon testing both thermally and structurally were performed to verify that the LB-MLI should work at the tank applied level. Then tank applied thermal and structural (acoustic) testing was performed to demonstrate the functionality of the LB-MLI as a structural insulation system. The LB-MLI showed no degradation of thermal performance due to the acoustic testing and showed excellent thermal performance when integrated with a 90 K class cryocooler on a liquid hydrogen tank.

Space Environment Simulation↗
DOE OSTI2025

Beam combining of high-power terahertz lasers with semiconductor metasurface gratings

Spectral beam combining (SBC) of an array of single-mode lasers has the potential for realizing a chip-scale electrically tunable multispectral laser source without any moving parts and with emission at closely spaced discrete frequencies. Here, we demonstrate SBC of an array of single-mode THz quantum-cascade lasers (QCLs) with small frequency spacing. Semiconductor-based metasurface THz blazed gratings are developed for integration with QCLs in a compact cryocooler setup. Single-lobed beams of four QCLs emitting around 3.2 THz and spectrally separated by ~14 GHz are combined to achieve collinear propagation of spatially overlapped and collimated beams in the far field with ≲ 0.1° of pointing error. Peak optical power in the range 50–100 mW is detected from each of the QCLs after combining. The dense frequency spacing in our method provides a pathway to incorporate tens of QCLs on a chip to realize a high-power discretely tunable THz laser source for applications in THz spectroscopy.

Jia, Fei [Lehigh Univ., Bethlehem, PA (United Stat↗
NASA NTRS2017

Mars Propellant Liquefaction Modeling in Thermal Desktop

NASAs current Mars architectures are assuming the production and storage of 23 tons of liquid oxygen on the surface of Mars over a duration of 500+ days. In order to do this in a mass efficient manner, an energy efficient refrigeration system will be required. Based on previous analysis NASA has decided to do all liquefaction in the propulsion vehicle storage tanks. In order to allow for transient Martian environmental effects, a propellant liquefaction and storage system for a Mars Ascent Vehicle (MAV) was modeled using Thermal Desktop. The model consisted of a propellant tank containing a broad area cooling loop heat exchanger integrated with a reverse turbo Brayton cryocooler. Cryocooler sizing and performance modeling was conducted using MAV diurnal heat loads and radiator rejection temperatures predicted from a previous thermal model of the MAV. A system was also sized and modeled using an alternative heat rejection system that relies on a forced convection heat exchanger. Cryocooler mass, input power, and heat rejection for both systems were estimated and compared against sizing based on non-transient sizing estimates.

Cryogenics↗
NASA NTRS1993

Miniature Long-life Space Cryocoolers

TRW has designed, built, and tested a miniature integral Stirling cooler and a miniature pulse tube cooler intended for long-life space application. Both efficient, low-vibration coolers were developed for cooling IR sensors to temperatures as low as 50 K on lightsats. The vibrationally balanced nonwearing design Stirling cooler incorporates clearance seals maintained by flexure springs for both the compressor and the drive displacer. The design achieved its performance goal of 0.25 W at 65 K for an input power to the compressor of 12 W. The cooler recently passed launch vibration tests prior to its entry into an extended life test and its first scheduled flight in 1995. The vibrationally balanced, miniature pulse tube cooler intended for a 10-year long-life space application incorporates a flexure bearing compressor vibrationally balanced by a motor-controlled balancer and a completely passive pulse tube cold head.

Tward, E.↗
NASA NTRS2001

An Overview of NASA Efforts on Zero Boiloff Storage of Cryogenic Propellants

Future mission planning within NASA has increasingly motivated consideration of cryogenic propellant storage durations on the order of years as opposed to a few weeks or months. Furthermore, the advancement of cryocooler and passive insulation technologies in recent years has substantially improved the prospects for zero boiloff storage of cryogenics. Accordingly, a cooperative effort by NASA's Ames Research Center (ARC), Glenn Research Center (GRC), and Marshall Space Flight Center (MSFC) has been implemented to develop and demonstrate "zero boiloff" concepts for in-space storage of cryogenic propellants, particularly liquid hydrogen and oxygen. ARC is leading the development of flight-type cryocoolers, GRC the subsystem development and small scale testing, and MSFC the large scale and integrated system level testing. Thermal and fluid modeling involves a combined effort by the three Centers. Recent accomplishments include: 1) development of "zero boiloff" analytical modeling techniques for sizing the storage tankage, passive insulation, cryocooler, power source mass, and radiators; 2) an early subscale demonstration with liquid hydrogen 3) procurement of a flight-type 10 watt, 95 K pulse tube cryocooler for liquid oxygen storage and 4) assembly of a large-scale test article for an early demonstration of the integrated operation of passive insulation, destratification/pressure control, and cryocooler (commercial unit) subsystems to achieve zero boiloff storage of liquid hydrogen. Near term plans include the large-scale integrated system demonstration testing this summer, subsystem testing of the flight-type pulse-tube cryocooler with liquid nitrogen (oxygen simulant), and continued development of a flight-type liquid hydrogen pulse tube cryocooler.

Hastings, Leon J.↗
NASA NTRS2017

NASA Cryocooler Technology Developments and Goals to Achieve Zero Boil-Off and to Liquefy Cryogenic Propellants for Space Exploration

NASA's interest in human exploration of Mars has driven it to invest in 20K cryocooler technology to achieve zero boil-off of liquid hydrogen and 90K cryocooler technology to achieve zero boil-off liquid oxygen or liquid methane as well as to liquefy oxygen or methane that is produced on the surface of Mars. These investments have demonstrated efficiency progress, mass reductions, and integration insights. A history of the application of cryocooler technology to zero boil-off propellant storage is presented. A trade space on distributed cooling is shown, along with the progress of reverse turbo-Brayton cycle cryocoolers, where the specific power and specific mass have dropped, decreasing the mass and power of these cryocoolers. Additionally, the cryocooler technology advancements of recuperators and compressors are described. Finally, NASA's development ideas with respect to zero boil-off technology are discussed.

zero boil-off↗
NASA NTRS2017

NASA Cryocooler Technology Developments and Goals to Achieve Zero Boil-Off and to Liquefy Cryogenic Propellants for Space Exploration

NASAs interest in human exploration of Mars has driven it to invest in 20K cryocooler technology to achieve zero boil-off of liquid hydrogen and 90K cryocooler technology to achieve zero boil-off liquid oxygen or liquid methane as well as to liquefy oxygen or methane that is produced on the surface of Mars. These investments have demonstrated efficiency progress, mass reductions, and integration insights. A history of the application of cryocooler technology to zero boil-off propellant storage is presented. A trade space on distributed cooling is shown, along with the progress of reverse turbo-Brayton cycle cryocoolers, where the specific power and specific mass have dropped, decreasing the mass and power of these cryocoolers. Additionally, the cryocooler technology advancements of recuperators and compressors are described. Finally, NASAs development ideas with respect to zero boil-off technology are discussed.

reverse turbo-Brayton cycle cryocooler↗
NASA NTRS2001

An Overview of NASA's In-Space Cryogenic Propellant Management Technologies

Future mission planning within NASA continues to include cryogenic propellants for in space transportation, with mission durations ranging from days to years. Between 1995 and the present, NASA has pursued a diversified program of ground-based testing to prepare the various technologies associated with in-space cryogenic fluid management (CFM) for implementation. CFM technology areas being addressed include passive insulation, zero gravity pressure control, zero gravity mass gauging, capillary liquid acquisition devices, and zero boiloff storage. NASA CFM technologies are planned, coordinated, and implemented through the Cryogenic Technology Working Group which is comprised of representatives from the various NASA Centers as well as the National Institute of Standards and Technologies (NIST) and, on selected occasions, the Air Force. An overview of the NASA program and Marshall Space Flight Center (MSFC) roles, accomplishments, and near-term activities are presented herein. Basic CFM technology areas being addressed include passive insulation, zero gravity pressure control, zero gravity mass gauging, capillary liquid acquisition devices, and zero boiloff storage. Recent MSFC accomplishments include: the large scale demonstration of a high performance variable density multilayer insulation (MLI) that reduced the boiloff by about half that of standard MLI; utilization of a foam substrate under MLI to eliminate the need for a helium purge bag system; demonstrations of both spray-bar and axial-jet mixer concepts for zero gravity pressure control; and sub-scale testing that verified an optical sensor concept for measuring liquid hydrogen mass in zero gravity. In response to missions requiring cryogenic propellant storage durations on the order of years, a cooperative effort by NASA's Ames Research Center, Glenn Research Center, and MSFC has been implemented to develop and demonstrate zero boiloff concepts for in-space storage of cryogenic propellants. An MSFC contribution to this cooperative effort is a large-scale demonstration of the integrated operation of passive insulation, destratification/pressure control, and cryocooler (commercial unit) subsystems to achieve zero boiloff storage of liquid hydrogen. Testing is expected during the Summer of 2001.

Tucker, Stephen↗
NASA NTRS2000

Low-Cost Tracking Ground Terminal Designed to Use Cryogenically Cooled Electronics

A computer-controlled, tracking ground terminal will be assembled at the NASA Glenn Research Center at Lewis Field to receive signals transmitted by the Glenn's Direct Data Distribution (D3) payload planned for a shuttle flight in low Earth orbit. The terminal will enable direct data reception of up to two 622-megabits-per-second (Mbps) beams from the space-based, K-band (19.05-GHz) transmitting array at an end-user bit error rate of up to 10(exp -12). The ground terminal will include a 0.9-m-diameter receive-only Cassegrain reflector antenna with a corrugated feed horn incorporating a dual circularly polarized, K-band feed assembly mounted on a multiaxis, gimbaled tracking pedestal as well as electronics to receive the downlink signals. The tracking system will acquire and automatically track the shuttle through the sky for all elevations greater than 20 above the horizon. The receiving electronics for the ground terminal consist of a six-pole microstrip bandpass filter, a three-stage monolithic microwave integrated circuit (MMIC) amplifier, and a Stirling cycle cryocooler (1 W at 80 K). The Sterling cycle cryocooler cools the front end of the receiver, also known as the low-noise amplifier (LNA), to about 77 K. Cryocooling the LNA significantly increases receiver performance, which is necessary so that it can use the antenna, which has an aperture of only 0.9 m. The following drawing illustrates the cryoterminal.

Wald, Lawrence W.↗
NASA NTRSDate not supplied

Control System Development for A Zero Boil-Off Hydrogen Storage Demonstration With Two-Stage Active Cooling

A NASA team is designing and building a test article to demonstrate the long duration storage of liquid hydrogen via active cooling (cryocoolers) while implementing a two-stage cooling approach. This activity is one of a large portfolio of NASA’s Space Technology Mission Directorate funded activities which focuses on the technology maturation needed for long duration storage of cryogenic liquid in-space. The current state-of-the-art for liquid hydrogen storage on-orbit is on the order of hours while NASA’s planned missions require storage for months, or even years. To enable such a long duration, Zero Boil-Off conditions must be achieved which requires passive technologies to minimize environmental heat loads, but also active cooling to intercept and reject the remaining heat to deep space. The implementation of active cooling results in a significant amount of dry mass added to the vehicle. Utilizing a Two-Stage Cooling approach, analysis and testing to date indicates the Zero Boil-Off of liquid hydrogen can be achieved with less mass and electrical power relative to a single-stage cooling approach where only one cryocooler is used. This activity will demonstrate the fully integrated suite of technologies needed to enable the Two-Stage Cooling approach which includes Multi-Layer Insulation blankets, Low Conductivity Structures, a Tube-On-Tank Heat Exchanger, Tube-On-Shield Heat Exchanger and a Two-Stage Cryogenerator (both 90 Kelvin and 20 Kelvin) with each stage having an independently controlled circulation loop. The bulk of the heat load is intercepted by the 90 Kelvin loop via a thin foil heat exchanger internal to the insulation blankets (also known as a Broad Area Cooling Shield), with the remainder removed at cryofluid temperature (20 Kelvin) by tubes directly welded to the outer tank surface. In this paper, we examine the challenges of controlling the system, and describe the development of control algorithms and software for future testing with liquid hydrogen. The interactions between the cryofans which control circulation loop mass flow rates, electrical heaters which vary the cryocooler lift to simulate the operation of variable-lift flight units, tank heaters which can vary the overall heat load, and the effects of changes in circulation loop pressure as temperatures change, can be complex and must be well understood to maintain steady-state propellant conditions and achieve Zero Boil-Off. Parallel PID loops and watchdog programs implemented on the user interface system will help bring the systems to steady state operation and keep them at selected operating points within acceptable error, while avoiding runaway feedback loops.

cryogenics↗
NASA NTRS1990

Requirements for long-life mechanical cryocoolers for space applications

The growing demand for long wavelength infrared and submillimeter imaging instruments for space observational applications, together with the emergence of the multiyear life Oxford University Stirling cycle cooler, has led to a rapidly expanding near term commitment to mechanical cryocoolers throughout the subkelvin to 150 K temperature range for long-life space missions. To satisfy this growing commitment, emerging cryocoolers must successfully address not only the input power, cooling power, and mass constraints of the spacecraft and instruments, but also the broad array of complex interface requirements that critically affect successful integration to the sensitive instrument detectors. Generic requirements are presented for each of the cryocooler requirement areas, which are then contrasted with the projected capabilities of emerging space cryocoolers. The degree of match is used to highlight both the strengths of existing technologies and the areas in need of increased development.

Ross, R. G., Jr.↗
NASA NTRS2019

Integrated Refrigeration and Storage of LNG for Compositional Stability

Growing interest in liquefied natural gas (LNG) as a rocket fuel necessitates a greater technical understanding of the compositional changes due to preferential boil-off (or weathering) that occurs during long duration storage. The purity of methane in LNG can range from 90 to 98%, and is subject to preferential boil-off due to its low boiling point compared to other constituents despite the use of high-performance thermal insulation systems. Active heat extraction (i.e. refrigeration) is required to completely eliminate weathering. For future operational safety and reliability, and to better understand the quality and efficiency of the LNG as a cryofuel, a 400-liter Cryostat vessel was designed and constructed to measure the composition and temperatures of the LNG at a number of different liquid levels over long durations. The vessel is the centerpiece of a custom-designed lab-scale integrated refrigeration and storage (IRaS) system employing a pulse tube cryocooler capable of roughly 50 W of lift at 100 K. Instrumentation includes ten temperature sensors mounted on a vertical rake and five liquid sample tubes corresponding to five liquid levels. Two modes of operation are studied. The first is without refrigeration in order to determine a baseline in the change in composition, and to study stratification of the LNG. The second is performed with the cryocooler active to determine the operational parameters of the IRaS system for eliminating the weathering as well as stratification effects in the bulk liquid. The apparatus design and test method, as well as preliminary test results are presented in this paper. As a bonus in cost-saving and operational efficiency, the capability of the IRaS system to provide zero-loss capabilities such as zero boil-off (ZBO) keeping of the LNG and zero-loss filling/transfer operations are also discussed.

Rose, Laura P.↗
NASA NTRS2019

Integrated Refrigeration and Storage of LNG for Compositional Stability

Growing interest in liquefied natural gas (LNG) as a rocket fuel necessitates a greater technical understanding of the compositional changes due to preferential boil-off (or weathering) that occurs during long duration storage. The purity of methane in LNG can range from 90 to 98%, and is subject to preferential boil-off due to its low boiling point compared to other constituents despite the use of high-performance thermal insulation systems. Active heat extraction (i.e. refrigeration) is required to completely eliminate weathering. For future operational safety and reliability, and to better understand the quality and efficiency of the LNG as a cryofuel, a 400-liter Cryostat vessel was designed and constructed to measure the composition and temperatures of the LNG at a number of different liquid levels over long durations. The vessel is the centerpiece of a custom-designed lab-scale integrated refrigeration and storage (IRaS) system employing a pulse tube cryocooler capable of roughly 50 W of lift at 100 K. Instrumentation includes ten temperature sensors mounted on a vertical rake and five liquid sample tubes corresponding to five liquid levels. Two modes of operation are studied. The first is without refrigeration in order to determine a baseline in the change in composition, and to study stratification of the LNG. The second is performed with the cryocooler active to determine the operational parameters of the IRaS system for eliminating the weathering as well as stratification effects in the bulk liquid. The apparatus design and test method, as well as preliminary test results are presented in this paper. As a bonus in cost-saving and operational efficiency, the capability of the IRaS system to provide zero-loss capabilities such as zero boil-off (ZBO) keeping of the LNG and zero-loss filling/transfer operations are also discussed.

Rose, L.↗
NASA NTRS2021

ElectroChemical Hydrogen Refrigeration (ECHR)

NASA and Meta Vista have been actively working the development of a new type of cryogenic refrigeration cycle, one that uses hydrogen as the working fluid and compresses this hydrogen using an electrochemical hydrogen compressor. This new cycle has many advantages compared to current state of the art. The electrochemical compressor is more efficient than a mechanical compressor. It is a solid-state device with no moving parts, no vibration, and no lubrication requirements. The compressor is powered by direct current, so there is no Electromagnetic Interference (EMI). The power systems integration will be simpler and more efficient than typical space cryocooler power systems.

Adam M Swanger↗
NASA NTRS2005

A high performance frequency standard and distribution system for Cassini Ka-band experiment

This paper provides an overview and update of a specialized frequency reference system for the NASA Deep Space Network (DSN) to support Ka-band radio science experiments with the Cassini spacecraft, currently orbiting Saturn. Three major components, a Hydrogen Maser, Stabilized Fiber-optic Distribution Assembly (SFODA), and 10 Kelvin Cryocooled Sapphire Oscillator (10K CSO) and frequency-lock-loop, are integrated to achieve the very high performance, ground based frequency reference at a remote antenna site located 16 km from the hydrogen maser. Typical measured Allan Deviation is 1.6 -14 1 0a't 1 second and 1.7 x 10 -15 at 1000 seconds averaging intervals. Recently two 10K CSOs have been compared in situ while operating at the remote DSN site DSS-25. The CSO references were used operationally to downconvert the Ka band downlink received from the Cassini spacecraft in a series of occultation measurements performed over a 78 day period from March to June 2005.

sapphire↗