Search NASASearch

SEARCH · Search NASA

Results for “Phase Change Material”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

595 records · Page 30

Manufacturing Process Development of a Carbon Fiber Reinforced Polymer Composite Shaft for Electric Motors

Electric aircraft applications require electric motors with increased specific power and efficiency. Composite structural components in motors are a potential solution for reducing motor mass, reducing magnetic losses, and limiting undesired conduction paths for fault, electromagnetic interference, or common-mode currents. In this report, manufacturing trials for a high-speed carbon fiber reinforced polymer composite motor shaft are presented. Four prototype shafts were produced using a hybrid biaxial/triaxial fabric that was circumferentially wrapped onto an additively manufactured high-temperature washout mandrel. An additional traditional overbraid approach was also evaluated and shows promise for high-rate, high-performance parts using automated manufacturing. This paper discusses the shaft design, manufacturing methods explored, material selection, the manufacturing trials, and the lessons learned. The results of this manufacturing investigation show feasibility for manufacturing composite shafts for electric motors.

Electric moto shaft

Future Aerospace Technology in the Service of the Alliance: Sustained Hypersonic Flight - Volume 3

Sustained Hypersonic Flight capability is envisioned for several future military and civilian applications, such as long range immediate reaction reconnaissance, high speed interception of air targets, long range precision strike against hardened or time critical targets, and access to space. The inherent reduction in time-to-target and low vulnerability will permit new operational tactics. The symposium outlined mission needs and operational scenarios for hypersonic vehicles. Addressed were: Technological issues and challenges in external hypersonic aerodynamics and design, propulsion and engine/airframe integration, military ramjet applications, overall system design including structures and materials development needs, and test facilities. Ground based test facilities cannot provide full simulation at Mach numbers above 5. Therefore, the use of Computational Fluid Dynamics design tools is essential. For routine use of the computational tools in analysis, design and optimization, it is necessary to reduce the time for the entire computational process by two orders of magnitude. Hypersonic boundary layer transition remains a critical design issue because of the important impact on engine drag and on heating, which can affect the choice of materials and thermal protection systems. In addition, reliable prediction of scramjet net thrust is an absolute must in resolving hypersonic air breathing vehicle design issues. Due to current facility and computational shortfalls, the development of future hypersonic flight systems requires research flight tests in the technology areas of boundary layer transition and air-breathing propulsion engine performance. For sustained hypersonic flight beyond Mach 6, the supersonic combustion ramjet (scramjet) engine is the only choice for the near future. Only this air-breathing concept offers a significant promise of large reductions in required propellant fractions, increased payload fractions, and reduced size vehicles, together with a foreseeable technological feasibility. Airframe/engine integration, combustor design and thermal management are the predominant engineering tasks. Fuels, hydrogen or hydrocarbon, must be matched to the operational needs of military or civil use. Experience in existing ramjet propelled missiles capable of speeds up to Mach 4 can support the development effort. The potential mission and cost benefits of sustained hypersonic flight to both military and civil applications are tremendous. From the budget point of view, the possibility of sharing development costs between military and civil programs offers a specific advantage.

Combustion chambers

Thermoplastic Matrix Composite Design for Cryotanks Using Multiscale Modeling and Bayesian Optimization

Designing lightweight, robust cryogenic storage tanks is critical for future launch vehicles, in-space propellant storage, and hydrogen powered aircraft. This work presents a multiscale modeling and Bayesian optimization framework for the design of thermoplastic matrix composite cryotanks. Molecular dynamics simulations are first used to determine temperature-dependent constituent properties for candidate thermoplastic matrices, which are homogenized to the lamina scale using NASA’s Multiscale Analysis Tool (NASMAT). These lamina properties, in combination with laminate family generation rules, are evaluated in HyperX structural optimization software to identify stacking sequences that meet all cryogenic load requirements. A Bayesian optimization framework is applied, with HyperX in the loop (via the HyperX API) to efficiently search across material and laminate design variables, yielding an optimized cryotank configuration with significant reductions in design cycle time compared to exhaustive search approaches.

thermoplastics

Autonomous Detection and Classification of Lunar Minerals Using a Convolutional Neural Network Based Framework for the SUCR DALI Project

NASA’s long-term goal is to deploy humans to the Moon and, from there, advance human exploration to Mars, with Artemis missions as pivotal milestones. Raman spectroscopy can uniquely identify minerals, compounds, water states, and other materials, providing distinctive fingerprints for classification. A Raman instrument has been successfully deployed and utilized on the Mars surface via the Perseverance rover, but has not yet been utilized at the lunar surface The SUCR DALI project is working towards developing a Raman spectroscopy instrument to be applied in various lunar mission concepts, including within the Artemis program. The objective of my research is to assist in the maturation of the proposed SUCR DALI lunar Raman instrument through the development of an autonomous detection and classification model capable of identifying minerals and water states on the Moon’s surface.

Convolutional Neural Networks

From Exploration Flight Test-1 to Artemis II--A NASA Langley's Orion Aerosciences Overview

The Orion Aerosciences program at NASA Langley has played a central role in advancing the aerodynamic and aeroheating prediction capabilities required for the Orion crew vehicle’s return from deep space. This presentation provides a technical overview of aerosciences contributions spanning Exploration Flight Test-1 (EFT-1), Artemis I, and the ongoing post-flight analysis of Artemis II. EFT-1 provided the first high-energy entry dataset for Orion, enabling critical validation of aerodynamic force and moment predictions, static and dynamic stability characteristics, and aeroheating environments at relevant flight Mach and Reynolds numbers. Flight-derived pressure data were used to refine the Flush Air Data System (FADS) methodology for atmospheric density reconstruction and to improve Best Estimated Trajectory (BET) solutions. The EFT-1 data also offered key insights into heat shield performance, including char layer recession, in-depth thermal response, and material retention behavior under flight conditions, informing updates to both thermal response models and uncertainty quantification practices. Building on EFT-1, Artemis I extended the database to true lunar-return conditions. Observations of heat shield performance, including localized char loss, bondline response, and recession variability, provided an unprecedented opportunity to reassess Thermal Protection System (TPS) and aeroheating modeling assumptions. Aerodynamic reconstruction efforts incorporated improved FADS calibration, enhanced atmospheric modeling, and refined force and moment databases to reduce trajectory and load uncertainties. Aeroheating comparisons between pre-flight predictions and flight data enabled targeted model updates, particularly in transitional flow environments and wake heating regions. For Artemis II, these lessons were systematically incorporated into the pre-flight prediction process. Updates included refined aerodynamic databases anchored to flight-validated corrections, improved density estimation and BET methodologies using enhanced database interpolation algorithm and FADS modeling, and revised aeroheating design environments informed by Artemis I material response observations. By the time of the workshop, Artemis II post-flight analysis will be underway, and preliminary findings will be presented where available, including early comparisons of aerodynamic reconstruction, atmospheric density estimation, and thermal protection system performance relative to updated predictions. Collectively, this body of work is a testament to the dedicated and multidisciplinary team whose sustained efforts have contributed to the program’s success and to the progressive maturation of Orion aerosciences modeling through numerical modeling, ground and flight data assimilation. The integrated advancement of aerodynamics, trajectory reconstruction, FADS-based density estimation, and aeroheating analysis has reduced predictive uncertainty and strengthened confidence for future crewed lunar and deep-space missions.

Orion

Harness Thermal Heat Loss Measurement for a Lunar Surface-Deployed LEMS Artemis III Payload

The Lunar Environment Monitoring Station (LEMS) is an autonomous, survive-the-lunar-night seismic suite to be deployed on the Lunar surface by the Artemis III crew and designed to operate continuously for two years. It will see the extremes of the Lunar south pole thermal environment where surface temperatures range from -200°C to +20°C and where nighttime duration is at least 354 hours. Given power and mass constraints, the thermal system is limited to 2.5 Watts of heat during the lunar night. The electrical harnessing named the Signal and Power Passthrough (SAPP) was designed to minimize heat loss while meeting power and signal integrity requirements. To mitigate risk due to uncertainty associated with the harnessing materials, routing, and tie-downs, a flight-like thermal conductance test was performed to measure the heat loss. The test methodology, results, and model correlation are presented.

TVAC

Harness Thermal Heat Loss Measurement for A Lunar Surface-Deployed LEMS Artemis III Payload

The Lunar Environment Monitoring Station (LEMS) is an autonomous, survive-the-lunar-night seismic suite to be deployed on the Lunar surface by the Artemis III crew and designed to operate continuously for two years. It will see the extremes of the Lunar south pole thermal environment where surface temperatures range from -200°C to +20°C and where nighttime duration is at least 354 hours. Given power and mass constraints, the thermal system is limited to 2.5 Watts of heat during the lunar night. The electrical harnessing named the Signal and Power Passthrough (SAPP) was designed to minimize heat loss while meeting power and signal integrity requirements. To mitigate risk due to uncertainty associated with the harnessing materials, routing, and tie-downs, a flight-like thermal conductance test was performed to measure the heat loss. The test methodology, results, and model correlation are presented.

Thermal

Harness Thermal Heat Loss Measurement for A Lunar Surface-Deployed LEMS Artemis III Payload

The Lunar Environment Monitoring Station (LEMS) is an autonomous, survive-the-lunar-night seismic suite to be deployed on the Lunar surface by the Artemis III crew and designed to operate continuously for two years. It will see the extremes of the Lunar south pole thermal environment where surface temperatures range from -200°C to +20°C and where nighttime duration is at least 354 hours. Given power and mass constraints, the thermal system is limited to 2.5 Watts of heat during the lunar night. The electrical harnessing named the Signal and Power Passthrough (SAPP) was designed to minimize heat loss while meeting power and signal integrity requirements. To mitigate risk due to uncertainty associated with the harnessing materials, routing, and tie-downs, a flight-like thermal conductance test was performed to measure the heat loss. The test methodology, results, and model correlation are presented.

TVAC

AC and DC Fault Management for Megawatt Electrified Aircraft Electrical Powertrains - Task 2: Power Quality Filtering Using Nanocrystalline Soft Magnetic Inductor

The NASA RTAPS program on AC and DC Fault Management for Megawatt Electrified Power Train is a multi-year joint project with Pratt & Whitney (P&W), Collins Aerospace (CA), and RTX Technology Research Center (RTRC). This research program focuses on the high-voltage distribution issues that present a significant technological obstacle in the adoption of Electrified Aviation Propulsion (EAP) systems. One challenge to the adoption of high-voltage distribution systems with power electronic converters is the need for filter elements to limit the generation and propagation of noise, protect the cable systems from premature aging and prevent against excessive heating within subcomponents due to high-frequency induced currents. While increased distribution voltages aide in reducing the cable mass for a fixed power system, the associated mass with the filtering elements for power electronic converter can grow with increasing distribution voltages – thereby mitigating any benefit associated with increasing the distribution system voltage. To enable high-voltage distribution systems with high system specific power densities, new magnetic materials must be developed. Therefore, the second task of the NASA RTAPS program is associated with the design and application of advanced soft magnetic components for Megawatt class electric propulsion systems, specifically the motor drive system. This report covers the collaborative work between NASA Glenn Research Center (GRC), RTRC, P&W and CA in the development of three types of magnetic components over the span of the three-year program. These critical magnetic components are the DC side EMI filter, which limits the propagation of harmful electromagnetic noise to the rise of the distribution system, and the AC side damping with the dv/dt filter, which limits the fast rise time of the power electronic converter output voltage to limit the degradation on the cable/motor insulation systems. Each of these components are investigated from component level design and are optimized at the system level with a combined modelling and testing effort. In the final experimental evaluation of the NASA developed soft magnetic material with a dv/dt filter, a commercial-off-the-shelf (COTS) magnetic core and the GRC magnetic core are optimized and loaded at 320Arms to evaluate their difference in performance. After a run time of 30 minutes in a MW-class motor driver at RTRC, the NASA GRC cores were found to not only offer a lower temperature rise of nearly 25°𝐶, but also a reduction in measured core loss of 25% (12.75W to 9.5W).

Elecrified Aircraft Propulsion

RTE: A Computer Code for Rocket Thermal Evaluation

The numerical model for a rocket thermal analysis code (RTE) is discussed. RTE is a comprehensive thermal analysis code for thermal analysis of regeneratively cooled rocket engines. The input to the code consists of the composition of fuel/oxidant mixture and flow rates, chamber pressure, coolant temperature and pressure. dimensions of the engine, materials and the number of nodes in different parts of the engine. The code allows for temperature variation in axial, radial and circumferential directions. By implementing an iterative scheme, it provides nodal temperature distribution, rates of heat transfer, hot gas and coolant thermal and transport properties. The fuel/oxidant mixture ratio can be varied along the thrust chamber. This feature allows the user to incorporate a non-equilibrium model or an energy release model for the hot-gas-side. The user has the option of bypassing the hot-gas-side calculations and directly inputting the gas-side fluxes. This feature is used to link RTE to a boundary layer module for the hot-gas-side heat flux calculations.

Mohammad H N Naraghi

Aerodynamic Design of Axial Flow Compressors

An overview of 'Aerodynamic systems design of axial flow compressors' is presented. Numerous chapters cover topics such as compressor design, potential and viscous flow in two dimensional cascades, compressor stall and blade vibration, and compressor flow theory. Theoretical aspects of flow are also covered. This work is based substantially on a three-volume Confidential Research Memorandum f h t issued by the National Advisory Committee for Aeronautics in 1956 and declassified in .1958 for release to the general public. The material, which was of a fundamental character, has been updated for the present edition in the light of subsequent developments in the field and has been carefully reexamined for current validity by members of the staff of the NASA Lewis Research Center, Cleveland, Ohio. It is now published for the first time in a single volume to meet continuing demand for the information and to make it readily available in convenient form to the engineering community both within and outside the National Aeronautics and Space Administration.

Axial flow compressor

Enhancing Battery Safety with Fractional Thermal Runaway Calorimetry

Effective thermal management systems, designed to handle the impacts of thermal runaway (TR) and to prevent cell-to-cell propagation, are key to safe operation of lithium-ion (Li-ion) battery assemblies. Critical factors for optimising these systems include the total energy released during a single cell TR event and the fraction of the total energy that is released through the cell casing versus through the ejecta material. A unique fractional thermal runaway calorimeter (FTRC), designed to characterise said critical factors, was utilised to examine the TR behaviour of Li-ion cells). Delegates will be provided with an in-depth discussion on what fractional thermal runaway calorimetry is and how it benefits the development of safe and optimised battery assemblies that protect against thermal runaway. Delegates will see calorimetry data associated with a variety of Li-ion cells. Data presented is relevant to any industry that utilises high-energy Li-ion cells in closed environments and has a need to focus on safety.

Walker, William

Integrated Process-Structure-Property Simulations for Additive Manufacturing Using the Open-Source Materialite Package

The microstructure and properties of additively manufactured (AM) metals are strongly dependent on process conditions. Therefore, process-structure-property (PSP) simulations are a useful tool for exploring process parameter space, studying process variations, and quantifying uncertainty in material properties. However, integrating process-structure and structure-property simulations often involves connecting multiple software packages. Each package may use unique data structures and require substantial domain knowledge. This presentation demonstrates PSP simulation capabilities of Materialite, an open-source package developed at NASA Langley Research Center. Materialite simplifies model linkages by using a common data structure and model interface, enabling straightforward simulation across a PSP model chain. Physics-based models, including kinetic Monte Carlo and crystal plasticity, are implemented within the package. The model interface is also intended to simplify implementation of new models and enable integration with external simulation tools. Example use cases include uncertainty quantification with PSP models and GPU-accelerated powder bed fusion AM process models.

additive manufacturing

A Coaxial Flow Reactor - A Gaseous Nuclear-Rocket Concept

Aspects of a new gaseous nuclear-rocket concept are considered. The principle of this type of cavity reactor is one of maintaining the separation of two coaxial streams - fuel within propellant - rather than attaining the separation of fuel propellant gases within the cavity. An acceptably low uranium consumption rate is possible if the fuel stream can be maintained at an axial velocity which is 1/100 to 1/1000 of the propellant velocity. An elementary hydrodynamic analysis for laminar incompressible flow indicates that the average uranium core velocity may only reach 2 to 11 times the initial core velocity for a typical reactor. The results of a 1-D criticality analysis for a D2O/(235)U system show that the effect of shrinking the fuel region within the reactor cavity is not serious; the effects of moderator heating and structural materials on critical mass are also shown. Overall rocket performance calculations are made for reasonable operating conditions; these results indicate that thrusts from 25,000 to 50,000 pounds and accelerations from 10(exp -1) to 3 g are possible.

Herbert Weinstein

Solvent-Free Preparation of High Energy, Binder-Free Electrodes Enabled by Dry Compressible Holey Graphene

Graphene is an atomically thick sheet consisting of a graphitic carbon network with excellent mechanical strength, electrical and thermal conductivity, and chemical stability. Holey graphene, a structural derivative of graphene, has an array of through-the-thickness holes across the lateral surface of the nanosheet. The presence of these holes has minimal detrimental effect on the graphene properties and leads to enhanced performance in applications such as electronics, sensors, and energy storage. For example, these holes allow more facile cross-plane ion and gas transport than intact graphene, making holey graphene an ideal electrode material for electrochemical energy storage. This presentation will focus on the ability of holey graphene to be compression molded into robust articles or architectures under solvent-free conditions without the need for potentially parasitic binders. The unique dry compressibility of holey graphene has enabled facile fabrication of high mass loading electrodes with both high density and high porosity, which have found use in supercapacitors and various high-energy battery systems such as lithium-oxygen, lithium-sulfur, and lithium-selenium batteries.

Yi Lin

Performance of the Satellite Test Assistant Robot in JPL's Space Simulation Facility

An innovative new telerobotic inspection system called STAR (the Satellite Test Assistant Robot) has been developed to assist engineers as they test new spacecraft designs in simulated space environments. STAR operates inside the ultra-cold, high-vacuum, test chambers and provides engineers seated at a remote Operator Control Station (OCS) with high resolution video and infrared (IR) images of the flight articles under test. STAR was successfully proof tested in JPL's 25-ft (7.6-m) Space Simulation Chamber where temperatures ranged from +85 C to -190 C and vacuum levels reached 5.1 x 10 -6 torr. STAR's IR Camera was used to thermally map the entire interior of the chamber for the first time. STAR also made several unexpected and important discoveries about the thermal processes occurring within the chamber. Using a calibrated test fixture arrayed with ten sample spacecraft materials, the IR camera was shown to produce highly accurate surface temperature data. This paper outlines STAR's design and reports on significant results from the thermal vacuum chamber test.

Douglas McAffee

Development and application of a 3-D geometry/mass model for LDEF satellite ionizing radiation assessments

A computer model of the three dimensional geometry and material distributions for the LDEF spacecraft, experiment trays, and, for selected trays, the components of experiments within a tray was developed for use in ionizing radiation assessments. The model is being applied to provide 3-D shielding distributions around radiation dosimeters to aid in data interpretation, particularly in assessing the directional properties of the radiation exposure. Also, the model has been interfaced with radiation transport codes for 3-D dosimetry response predictions and for calculations related to determining the accuracy of trapped proton and cosmic ray environment models. The methodology is described used in developing the 3-D LDEF model and the level of detail incorporated. Currently, the trays modeled in detail are F2, F8, and H12 and H3. Applications of the model which are discussed include the 3-D shielding distributions around various dosimeters, the influence of shielding on dosimetry responses, and comparisons of dose predictions based on the present 3-D model vs those from 1-D geometry model approximations used in initial estimates.

B. L. Colborn

Detailed examination of LDEF's frame and the A0178 thermal blankets by the meteoroid and debris special investigations group

A responsibility of the group is to define the hypervelocity particle environment encountered by LDEF during its stay in low Earth orbit. LDEF's 6061-T6 aluminum frame and the 'Teflon silver-inconel paint' thermal blankets represent large surface areas that were widely distributed around the spacecraft. The results are reported of high resolution scans of approx. 0.36 and approx. 0.31 sq m for the intercostals and thermal blankets, respectively. The findings are in qualitative agreement with existing model predictions that suggest high differential bombardment histories for surfaces pointing into specific directions relative to the velocity vector of a non-spinning platform in LEO. The production rate for craters greater than or = 50 microns in diameter in aluminum and penetration holes greater than or = 100 microns in diameter in thin foil materials differ by more than a factor of 10 between forward and rearward facing surfaces. These are substantial differences that must be considered during the design of future long duration space platforms in LEO.

Thomas H. See