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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
DOE OSTI2024

Use of a Lignin-Based Admixture for Tailoring the Rheological Properties of Mortars for 3D Printing: Preprint

Efforts toward decarbonizing construction materials and industrial processes related to cement and concrete can be aided via multifaceted approaches that target alternative admixtures as well as precision control of fabrication. Chemical admixtures for water reduction have played a crucial role in the development of advanced concrete mixtures. Newer biomass processing techniques developed for aviation fuel production from corn stover biomass produce a more reactive lignin byproduct that is suitable for chemical modifications to mimic the properties of polycarboxylate ether admixtures with a smaller carbon footprint. The present study examines the use of lignin-based water-reducing admixture in cement pastes and mortar mixtures for 3D printing. The experimental program explores the use of different dosages of lignin-based admixture to produce 3D-printed samples with appropriate extrudability and buildability. The rheological characterization was performed to determine the flow curve of various mixtures. Finally, the heat of hydration of cement pastes was monitored via isothermal calorimetry to assess the impact of lignin-based admixtures on the hydration process of cement. The results of this study indicate that the use of biomass by-products, such as lignin-based admixtures have great potential to effectively control the fresh-state properties of cement-based materials.

bio-based admixtures↗
NASA NTRS1991

NASA Space Engineering Research Center for Utilization of Local Planetary Resources

In the processing of propellants, volatiles, and metals subject area, the following topics are discussed: reduction of lunar regolith; reduction of carbon dioxide; and reduction of carbonaceous materials. Other areas addressed include: (1) production of structural and refractory materials; (2) resource discovery and characterization; (3) system automation and optimization; and (4) database development. The majority of these topics are discussed with respect to the development of lunar and mars bases. Some main topics of interest include: asteroid resources, lunar resources, mars resources, materials processing, construction materials, propellant production, oxygen production, and space-based oxygen production plants.

Ramohalli, Kumar↗
NASA NTRS1993

Rockets: Physical science teacher's guide with activities

This guide begins with background information sections on the history of rocketry, scientific principles, and practical rocketry. The sections on scientific principles and practical rocketry are based on Isaac Newton's three laws of motion. These laws explain why rockets work and how to make them more efficient. The background sections are followed with a series of physical science activities that demonstrate the basic science of rocketry. Each activity is designed to be simple and take advantage of inexpensive materials. Construction diagrams, materials and tools lists, and instructions are included. A brief discussion elaborates on the concepts covered in the activities and is followed with teaching notes and discussion questions. The guide concludes with a glossary of terms, suggested reading list, NASA educational resources, and an evaluation questionnaire with a mailer.

Vogt, Gregory L.↗
NASA NTRS1993

Production of Lunar Concrete Using Molten Sulfur

The United States has made a commitment to go back to the moon to stay in the early part of the next century. In order to achieve this objective it became evident to NASA that a Lunar Outpost will be needed to house scientists and astronauts who will be living on the moon for extended periods of time. A study has been undertaken by the authors and supported by NASA to study the feasibility of using lunar regolith with different binders such as molten sulfur, epoxy or hydraulic cement as a construction material for different lunar structures. The basic premise of this study is that it will be more logical and cost effective to manufacture lunar construction materials utilizing indigenous resources rather than transporting needed materials from earth. Lunar concrete (made from Hydraulic Cement and lunar soil) has been studied and suggested as the construction material of choice for some of the lunar projects. Unfortunately, its hydration requires water which is going to be a precious commodity on the moon. Therefore this study explores the feasibility of using binders other than hydraulic cement such as sulfur or epoxy with lunar regolith as a construction material. This report describes findings of this study which deals specifically with using molten sulfur as a binder for Lunar concrete. It describes laboratory experiments in which the sulfur to lunar soil simulant ratios by weight were varied to study the minimum amount of sulfur required to produce a particular strength. The compressive and tensile strengths of these mixes were evaluated. Metal and fiber glass fibers were added to some of the mixes to study their effects on the compressive and tensile strengths. This report also describes experiments where the sulfur is melted and mixed with the lunar regolith in a specially designed vacuum chamber. The properties of the produced concrete were compared to those of concrete produced under normal pressure.

Omar, Husam A.↗
NASA NTRS2024

Life Cycle Assessment and Design of LignoBlock: A Lignin Bound Block on the Path Towards a Green Transition of the Construction Industry

Lignin-based biopolymer-bound soil composites (BSCs) are a new class of sustainable construction materials that utilize a bio-based biopolymer — lignin — as a binder. Prior use of lignin suggests that lignin is a promising candidate for the development of bio-based construction materials. Inspired by these applications, lignin-based BSCs were developed using lignoboost lignin, lignoforce lignin, alkali lignin, and hydrolysis lignin. Uni-axial compressive testing of lignin-based BSC shows that the compressive strength for these BSCs range from 1.6–8.1 MPa, which makes them appropriate for low compressive strength construction applications. We performed a life cycle assessment (LCA) of lignin-based BSC, with the functional unit being a CMU-sized block ( V =6423 cm -3 ). The major advantage of BSC lies in the elimination of ordinary portland cement, which is common to many construction materials, including many forms of concrete. Furthermore, the use of lignin in lignin-based BSC results in carbon sequestration (lignin ≈ 60 wt% carbon), potentially making construction materials made from lignin-based BSC carbon negative. Additionally, a design guide for estimating the life cycle carbon footprint of lignin-based BSC for a required compressive strength was developed. By utilizing the results from material tests and the LCA, designers are now able to use lignin effectively in construction applications, as they can now design lignin-based BSC for a target compressive strength with a full understanding of the life cycle carbon footprint implications.

Lignin↗
NASA NTRSDate not supplied

Investigation of Lunar-Inspired Geopolymer Concrete Formulations Mixed and Cured in Microgravity on the International Space Station (ISS)

The research outlined in this presentation investigates the use of various lunar regolith simulants in geopolymer lunar concrete mixes mixed and cured on the International Space Station (ISS). The motivation for this work is to study the effects of gravity on the microstructure of alkali-activated materials cured with heat, and to develop materials for the construction of long-term infrastructure on the lunar surface with in-situ resource utilization (ISRU). ISRU for construction materials reduces the cost and mass of payloads related to lunar construction. The advantage of geopolymer concrete as opposed to traditional portland cement concrete is that water acts as a medium for the polymerization reaction and leaves the system throughout the process, reducing its demand. Twelve samples of lunar regolith simulant and a solution composed of sodium hydroxide and sodium silicate were sent to the ISS. The three simulants were OPRH2N, OPRL2N, and JSC-1AF, using only particles less than 53 µm in diameter to increase reactivity of the simulant. Simulant to solution ratios were determined by workability while mixing. The simulant and solution were sealed Burst Pouches® along with 2 other sealed bags to prevent material from leaking. Crew member F-14 conducted testing on the ISS by introducing the solution to the simulant in the Burst Pouch®, mixing the sample with a spatula, and then clamping the specimen in the fresh state to prevent flow inside the Burst Pouch®. These specimens were then put in a thermos heated to 80C via sealed drinking water bags to cure for 24 hours with a temperature logger. The cured specimens remained in microgravity for at least 28 days and were returned from the ISS in February 2025. The specimens were then brought to the NASA Marshall Space Flight Center (MSFC) to analyze. Material characterization consisted of conducting Micro-CT tests of entire samples in their sealed apparatus to a resolution of 25µm. 2D image slices were saved in each orthogonal direction of each specimen at a 0.03 mm step size from the 3D model to conduct analytical porosity calculations. Representative samples from each specimen were sampled to perform helium gas pycnometery and were then mounted in resin for SEM imaging, EDS, and nanoindentation. Porosity was analyzed analytically using micromechanics modelling with the assistance of the NASA Multiscale Analysis Tool (NASMAT), as well as the NASA Advanced Supercomputing (NAS) servers (V. Saseendran & N. Yamamoto, 2024). Density was measured using helium gas pycnometery and was then compared to the theoretical density for experimental porosity calculation. Due to the samples’ non-uniform shape being cured in a pouch, traditional compression and tensile strength testing could not be performed. Nanoindentation was conducted at Clarkson University to determine the microhardness and reduced modulus of elasticity. Results from flight samples can be compared to ground samples currently in DLR’s possession to determine the effect on microstructure from being mixed and cured in microgravity. This study gives further insight and understanding of geopolymer lunar concrete and its viability as a lunar construction material with ISRU.

Adam Johnson↗
NASA NTRS2007

Materials-of-Construction Radiation Sensitivity for a Fission Surface Power Convertor

A fission reactor combined with a free-piston Stirling convertor is one of many credible approaches for producing electrical power in space applications. This study assumes dual-opposed free-piston Stirling engines/linear alternators that will operate nominally at 825 K hot-end and 425 K cold-end temperatures. The baseline design options, temperature profiles, and materials of construction discussed here are based on historical designs as well as modern convertors operating at lower power levels. This notional design indicates convertors primarily made of metallic components that experience minimal change in mechanical properties for fast neutron fluences less than 10(sup 20) neutrons per square centimeter. However, these radiation effects can impact the magnetic and electrical properties of metals at much lower fluences than are crucial for mechanical property integrity. Moreover, a variety of polymeric materials are also used in common free-piston Stirling designs for bonding, seals, lubrication, insulation and others. Polymers can be affected adversely by radiation doses as low as 10(sup 5) - 10(sup 10) rad. Additionally, the absorbing dose rate, radiation hardness, and the resulting effect (either hardening or softening) varies depending on the nature of the particular polymer. The classes of polymers currently used in convertor fabrication are discussed along possible substitution options. Thus, the materials of construction of prototypic Stirling convertor engines have been considered and the component materials susceptible to damage at the lowest neutron fluences have been identified.

Bowman, Cheryl L.↗
NASA NTRSDate not supplied

SIBatt-3D: In-Space/On-Surface 3D Printing of Sodium Ion Batteries from ISRU Materials

Constructed more than 20 years ago, the International Space Station’s primary power system originally used nickel-hydrogen batteries with a lifetime of 6.5 years, until NASA began the process of replacing them in 2016 with lithium-ion batteries with a lifetime of 10 years. The demanding and costly process was accomplished after four flights of the Japanese H-II Transfer Vehicle cargo spacecraft (with a cost of about $10,000 per pound of payload), and 13 different astronauts conducting 14 spacewalks. Besides utilization in the ISS, rechargeable batteries are present in many space applications: they are installed in exploration robots, life support systems and in portable communication devices, to mention some. In this context, this project is focused on the in-space manufacturing of shape-conformable batteries using in-situ resources, and aims to address the NASA’s gaps related to the development of next generation of energy storage devices (TX03), as well as in-space manufacturing and in-situ resource utilization (TX07). The proposed work also tackles the HEOMD’s objectives targeting the in-space additive manufacturing (AM) from Lunar/Martian materials (regolith as AM feedstock) to reinvigorate America’s Human Space Exploration Program (SPD-1). This project is in direct alignment with the STMD’s objectives to demonstrate in-space autonomous manufacturing and assembly of complete systems by 2030, and to enable humans to live and explore in space and on planetary surfaces by 2040 thanks to in-space habitation, infrastructure development and in-situ resource utilization (ST1 and ST5). Manufacturing of shape conformable batteries directly in-space and using in-situ resources would also contribute to reducing the payload weight and volume (TX12) for future missions, thus reducing risk for long term Mars missions where rapid resupply is logistically infeasible. Nowadays, commercial batteries consist of stacked two-dimensional (2D) sheets, which are only manufactured in restricted geometries (cylindrical and coin cell). Evolving from conventional 2D, complex 3D battery architectures have been proven to increase the electrochemical active surface area and ion diffusion path, leading to improved areal energy density and power performance. This tendency was illustrated in our recent in-depth modeling studies by simulating a classical Ragone plot exhibiting the energy-power relationship. Our team demonstrated through modeling that a complex gyroidal 3D printed battery architecture exhibits significantly improved power performances (>150% at the current density of 6C; full discharge in 10 minutes) in comparison to a traditional 3D printed planar geometry. Motivated by these results and as the fabrication of intricate 3D battery design is only possible experimentally thanks to the geometric freedom offered by additive manufacturing (AM), our team has already initiated leveraging thermoplastic material extrusion at the laboratory scale. While 3D printing of batteries is relatively recent (2013), it has witnessed a growing interest during the last recent years, as next-generation shape-conformable 3D batteries can be co-designed with the system. Consequently, dead-volume and mass brought from Earth are minimized, in addition to improved battery performance, in alignment with the aforementioned NASA’s objectives. Further, while this project is specifically dedicated to batteries, it lends itself towards the maturation of in-space manufacturing via 3D printing using in-situ resources, stated in HEOMD and STMD goals.

In-Space Manufacturing↗
DOE OSTI2024

Saltstone Paddles and Augers Materials of Construction Study

The Saltstone Production Facility (SPF) uses a 10-inch READCO continuous, co-rotating twin-screw mixer to mix the dry premix with the low-level radioactive waste (LLW) salt solution to produce fresh saltstone grout. The paddles and augers within the mixer degrade via erosion in the region where the salt solution is introduced into the mixer. After the paddles/augers erode to a point where the throughput impacts operations, the mixer is disassembled, the effected paddles/augers are replaced, and the mixer is reassembled. Saltstone Engineering indicated that this effort requires an approximately three-week outage. The objective of this task is to assess alternative materials of construction (MOCs) that will provide better erosion characteristics and decrease the frequency in which the paddles and augers need replacement. Previous Astralloy V studies looked only at Charpy Impact and Rockwell Hardness Testing. Each of these will be examined for different alloys as well as Miller Testing (abrasion to determine wear) which will provide a good assessment of an alloy’s erosion/wear characteristics. The following facts concerning the current and proposed alloys for Saltstone Paddles and Augers are provided in this report. • Current Astralloy V material and alloy E52100 had the most favorable Miller Testing Results. • Charpy Impact Testing did not correlate with Miller Testing Results. • Hardness Testing correlated with Miller Testing results meaning that higher hardness will provide more favorable wear resistance. • Further investigation of E52100 and various tool grade steels is recommended for achieving wear resistant properties.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRSDate not supplied

Lunar Base Construction Overview

Previous lunar missions and campaigns have been restricted to using robotic landers and lunar orbiting satellites as well as sortie type of operations using astronaut crews (NASA Apollo program). The next phase of lunar exploration has begun under NASA’s Artemis program and there has been an international response where other nations such as China, Russia, India, Canada, Japan and the European Union of nations, have all expressed interest in either collaborating or competing with NASA on the Moon. This next phase has an over arching goal of achieving a permanent human presence on the Moon via sustainable methods. A lunar base with human occupancy will require infrastructure to provide shelter, utilities, landing/launch pads, roads, communications, power and all the other necessities to sustain human life and protect equipment. Since human biology is not well suited for surviving in the lunar environment, there will be many forms of automated equipment, autonomy and robotic helpers that will minimize the amount of Extra-Vehicular Activity (EVA) required by the crew. This will mean that the radiation dosage received by the crew will stay within acceptable and safe career doses. The required infrastructure must be constructed, but the mass and logistics of bringing all the construction materials from Earth are prohibitive, which makes the necessary construction difficult to achieve. In-Situ Resource Utilization (ISRU) aims to solve this challenge by sourcing construction materials locally or “in-situ”. This means that their transportation can be completely eliminated, resulting in large cost savings by avoiding the launch out of Earth’s deep gravity well and subsequent trans lunar injection, lunar orbit capture and landing. This paper will give an overview of the required construction tasks and related equipment that will be required to robotically build a lunar base using in-situ resources. It will also organize these tasks into logical groupings so that technology development and implementation can be pursued within a framework that can be referenced by all involved.

Construction↗
NASA NTRSDate not supplied

Lunar Base Construction Overview

Previous lunar missions and campaigns have been restricted to using robotic landers and lunar orbiting satellites as well as sortie type of operations using astronaut crews (NASA Apollo program). Now, the next phase of lunar exploration has begun under NASA’s Artemis program and there has been an international response where other nations such as China, Russia, India, Canada, Japan and the European Union of nations, have all expressed interest in either collaborating or competing with NASA on the Moon. This next phase has an over arching goal of achieving a permanent human presence on the Moon via sustainable methods. A lunar base with human occupancy will require infrastructure to provide shelter, utilities, landing/launch pads, roads, communications, power and all the other necessities to sustain human life and protect equipment. Since human biology is not well suited for surviving in the lunar environment, there will be many forms of automated equipment, autonomy and robotic helpers that will minimize the amount of Extra-Vehicular Activity (EVA) required by the crew. This will mean that the radiation dosage received by the crew will stay within acceptable and safe career doses. Radiation shielding via the use of regolith can also mitigate radiation dangers. The required infrastructure must be constructed, but the mass and logistics of bringing all the construction materials from Earth are prohibitive, which makes the necessary construction difficult to achieve. In-Situ Resource Utilization (ISRU) aims to solve this challenge by sourcing construction materials locally or “in-situ”. This means that their transportation can be completely eliminated, resulting in large cost savings by avoiding the launch out of Earth’s deep gravity well and subsequent trans lunar injection, lunar orbit capture and landing. This paper will give an overview of the required construction tasks and related equipment that will be required to robotically build a lunar base using in-situ resources. It will also organize these tasks into logical groupings so that technology development and implementation can be pursued within a framework that can be referenced by all involved.

Lunar Base↗
NASA NTRSDate not supplied

Lunar Base Construction Planning

Previous lunar missions and campaigns have been restricted to using robotic landers and lunar orbiting satellites as well as sortie type of operations using astronaut crews(NASA Apollo program).Now, the next phase of lunar exploration has begun under NASA’s Artemis program and there has been an international response where other nations such as China, Russia, India, Canada, Japan and theEuropean Union of nations, have all expressed interest in either collaborating or competing with NASA on theMoon. This next phase has an overarching goal of achieving a permanent human presence on theMoon via sustainable methods. A lunar base with human occupancy will require infrastructure to provide shelter, utilities, landing/launch pads, roads, communications, power and all the other necessities to sustain human life and protect equipment.Since human biology is not well suited for surviving in the lunar environment, there will be many forms of automated equipment, autonomy and robotic helpers that will minimize the amount of Extra-Vehicular Activity(EVA) required by the crew. This will mean that the radiation dosage received by the crew will stay within acceptable and safe career doses. Radiation shielding via the use of regolith can also mitigate radiation dangers.The required infrastructure must be constructed, but the mass and logistics of bringing all the construction materials from Earth are prohibitive, which makes the necessary construction difficult to achieve.In-Situ Resource Utilization (ISRU) aims to solve this challenge by sourcing construction materials locally or “in-situ”. This means that their transportation can be completely eliminated, resulting in large cost savings by avoiding the launch out of Earth’s deep gravity well and subsequent trans lunar injection, lunar orbit capture and landing. This paper will give ahistorical review and current status of lunar construction planning and a high level introduction to the required infrastructure and construction equipment that will be required to robotically build a lunar base using in-situ resources.It will also organize these tasks into logical groupings so that technology development and implementation can be pursued within a framework that can be referenced by all involved.

Lunar↗
DOE OSTI2025

Light, High Performance and Scalable Coal-Derived Composites for Construction: Precast and Cast-in-Place Applications

The overall objective of this project was to produce a coal-based construction material that has up to ~95 weight percent (wt. %) coal with physical, chemical, and thermal properties exceeding those of ordinary Portland cement (OPC)-based construction materials. Additionally, the project aimed to minimize external binders by implementing novel mixing techniques, while exceeding the performance/cost ratio of OPC. Finally, the project was to demonstrate production of precast products via the design and fabrication of products via a bench scale process. Consistent with some of these objectives, the project successfully fabricated samples of coal-based composite materials with >80 wt% coal with physical, chemical and thermal properties on par with cement-based concrete. Select samples demonstrated compressive strengths with >7,000 psi and flexural strength of >420 psi. The composite materials minimized external binders and also demonstrated durability, as evidenced by resistance to acidic and basic solutions. Finally, larger slab and beam type samples were produced using a process developed by the Recipient, although, the process was not semicontinuous in nature. Taken together, the results of this project suggest that domestic coal has potential to serve as a replacement for cementitious materials utilized in incumbent construction technologies, which could significantly reduce the energy and emissions of the construction industry

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS1980

Aircraft wing weight build-up methodology with modification for materials and construction techniques

An aircraft wing weight estimating method based on a component buildup technique is described. A simplified analytically derived beam model, modified by a regression analysis, is used to estimate the wing box weight, utilizing a data base of 50 actual airplane wing weights. Factors representing materials and methods of construction were derived and incorporated into the basic wing box equations. Weight penalties to the wing box for fuel, engines, landing gear, stores and fold or pivot are also included. Methods for estimating the weight of additional items (secondary structure, control surfaces) have the option of using details available at the design stage (i.e., wing box area, flap area) or default values based on actual aircraft from the data base.

York, P.↗
NASA NTRS2006

Material Concerns: Evaluating Sulfur Concrete for use in the Lunar Environment

On Earth sulfur "concrete" is an established construction material that has good mechanical properties, generally better than Portland cement, and can be used in corrosive environments. Troilite (FeS) has been found on the moon and raises the question of using extracted sulfur as a lunar construction material, an attractive alternative to conventional concrete as it does not require water. Troilite reduction to elemental sulfur and using it to make concrete in a lunar setting has been previously discussed. However, little has been experimentally done to evaluate its performance in the extreme lunar environment. This study subjected sets of sulfur concrete samples, prepared using JSC-1 lunar simulant, to I ) extended periods of high vacuum and 2) extreme temperature cycles. Here an overview of sulfur concrete and experimentally assessed properties, put in context of the lunar environment, is presented and discussed.

Grugel, Richard N.↗
DOE OSTI2025

Thermal and mechanical performance of gypsum composites containing fly ash cenosphere encapsulated phase change materials

Utilizing phase change materials (PCMs) within construction materials improves the thermal energy storage capabilities in the built environment. Notably, integrating PCMs into drywalls presents a promising avenue to reduce building energy use. However, incorporating PCMs into drywalls poses challenges, particularly reduced mechanical properties and workability limitations as it can adversely affect the hardening and cohesiveness of gypsum composites. To address these challenges, this study explores a novel strategy to incorporate PCMs into gypsum composites through fly ash cenosphere-encapsulated PCM, namely CenoPCM, aiming to enhance the mechanical properties and thermal conductivity over existing commercial counterparts. An experimental program was conducted to study the impact of the inclusion of CenoPCM on the mechanical and thermal performance of gypsum composites, and the results were compared to those of commercially available polymerencapsulated PCM benchmark (Micronal). The findings highlighted that PCM-charged samples exhibited up to 95.90 J/g (CenoPCM) of latent heat with 70 % CenoPCM loading. The results of mechanical tests also showed that CenoPCM outperformed its polymer-encapsulated counterpart, achieving 55 % higher mechanical strength on average. Here, this improvement is attributed to the rigid shell of fly ash cenosphere (FAC) serving as a PCM carrier, providing a skeleton-like structure to gypsum composites for higher load-bearing capacity. Additionally, hotbox tests demonstrated that the CenoPCM-charged wall panels yielded a 20 % higher thermal conductivity and a 22 % increased time lag compared to Micronal PCM-charged panels, indicating its potential to shift the peak load in buildings.

Ceno PCM↗
NASA NTRS1979

Silicon Halide-alkali Metal Flames as a Source of Solar Grade Silicon

A program is presented which was aimed at determining the feasibility of using high temperature reactions of alkali metals and silicon halides to produce low cost solar-grade silicon. Experiments are being conducted to evaluate product separation and collection processes, measure heat release parameters for scaling purposes, and determine the effects of the reactants and/or products on materials of reactor construction. During the current reporting period, the results of heat release experiments were used to design and construct a new type of thick-wall graphite reactor to produce larger quantities of silicon. A reactor test facility was constructed. Material compatibility tests were performed for Na in contact with graphite and several coated graphites. All samples were rapidly degraded at T = 1200K, while samples retained structural strength at 1700K. Pyrolytic graphite coatings cracked and separated from substances in all cases.

Olson, D. B.↗