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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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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Advancing the Oxygen Generation Assembly Design to Increase Reliability and Reduce Costs for a Future Long Duration Mission

The state-of-the-art Oxygen Generation Assembly (OGA) has been reliably producing breathing oxygen for the crew aboard the International Space Station (ISS) for over eight years. Lessons learned from operating the ISS OGA have led to proposing incremental improvements to advance the baseline design for use in a future long duration mission. These improvements are intended to reduce system weight, crew maintenance time and resupply mass from Earth while increasing reliability. The proposed improvements include replacing the cell stack membrane material, deleting the nitrogen purge equipment, replacing the hydrogen sensors, deleting the wastewater interface, replacing the hydrogen dome and redesigning the cell stack power supply. The development work to date will be discussed and forward work will be outlined. Additionally, a redesigned system architecture will be proposed.

Kevin C Takada↗
NASA NTRSDate not supplied

STABLE Study for the Habitable Worlds Observatory

We report on progress on the STABLE study, which was awarded on the NASA 2023 ROSES D.19 opportunity. In the study, we are developing technologies for the Habitable Worlds Observatory (HWO) in four areas: Micrometeoroid Impact Mitigation, Telescope Temperature Control, Ultra-Stable Telescope Structure Materials and Modeling, and Improvement of Thermal Expansion Test Capability. This study is a collaboration between Northrop Grumman, Kratos, NeXolve, JPL, STScI, NASA’s White Sands Test Facility, and NASA Goddard’s Ultra-Stable Test Facility. We will also discuss our plans for our follow-on study as part of NASA’s 2024 ROSES D.19. In this study, we will address additional technologies as well as perform analysis of HWO architecture options.

Habitable Worlds Observatory↗
NASA NTRS2024

Ejecta Management in a Safe Lithium Ion Battery Design

As lithium-ion battery energy densities continue to rise, managing the heat and pressure generated during failure events has become increasingly critical. Safety systems must effectively relieve pressure without releasing sparks, flames, or particulate matter, requiring robust filtration solutions. The challenge is compounded by the reduced free volume available for gas expansion in high-density designs, which increases the demands on these filters. While significant progress has been made through experimental studies and modeling efforts to understand the behavior of ejecta during battery failures, there remains a pressing need for practical, rule-of-thumb sizing parameters. These parameters would help correlate high-energy waste streams with appropriate filter design, ensuring reliable containment and safety. This talk will explore recent experimental findings in this area and discuss the potential pathways for developing these essential sizing guidelines.

Ejecta Management↗
NASA NTRS2026

Manufacturing and Scale-Up of Natural Fiber Composite eVTOL Propeller Skin and C-Channel

This report presents the manufacturing and scale-up of natural fiber composites for aerospace applications, conducted within NASA’s Convergent Aeronautics Solutions portfolio to advance aircraft capabilities and efficiency. The effort focused on the development and demonstration of two proof-of-concept articles, an Electric Vertical Take-off and Landing (eVTOL) propeller skin and a C-channel, produced through an iterative design and process optimization approach. Best practices and guidance on addressing key challenges with bio-based composite materials and manufacturing is provided. Ideally suited for non-load-bearing structural components, these emerging materials offer potential for weight reduction, vibration damping, noise mitigation, interference-free communication, and cost savings, without compromising the performance of safety-critical primary structures.

Natural fibers↗
NASA NTRSDate not supplied

Boundary Layer Analysis of Shock Tube Flows

Shock tubes offer a controlled environment to reproduce kinetic and radiative phenomena characteristic of atmospheric entry flows under ground-test conditions. The boundary layer developing behind the incident shock wave determines the available test time, influences particle residence times important for similarity scaling, and can affect radiative energy transport. In this study, we couple a quasi-1D space marcher with the compressible boundary-layer equations to numerically compute the post-shock flow in a shock frame of reference for various test gas mixtures representative of different planetary atmospheres. The solvers are individually verified against CFD simulations and analytical correlations available in the literature. Coupled solutions are computed for a finite-rate chemistry in the boundary layer and a non-catalytic isothermal wall. Results yield refined estimates of the maximum separation distance, as well as insights into concentration profiles of relevant species within the boundary layer.

Andrea Fagnani↗
NASA NTRS1990

Planning for Execution Monitoring on A Planetary Rover

A planetary rover will be traversing largely unknown and often unknowable terrain. In addition to geometric obstacles such as cliffs, rocks, and holes, it may also have to deal with non-geometric hazards such as soft soil and surface breakthroughs which often cannot be detected until rover is in imminent danger. Therefore, the rover must monitor its progress throughout a traverse, making sure to stay on course and to detect and act on any previously unseen hazards. Its onboard planning system must decide what sensors to monitor, what landmarks to take position readings from, and what actions to take if something should go wrong. The planning systems being developed for the Pathfinder Planetary Rover to perform these execution monitoring tasks are discussed. This system includes a network of planners to perform path planning, expectation generation, path analysis, sensor and reaction selection, and resource allocation.

Erann Gat↗
NASA NTRS2025

Mechanics of Preloaded Bolt Tensile Loading With Focus on Load Introduction Factor

The bolt tensile and joint separation loads are directly influenced by the locations at which the external loads enter the clamped members of a preloaded bolted joint (PBJ) and the associated load-paths through the joint. This physical load introduction mechanism affecting the bolt tensile loading is typically represented in the bolt tensile load equation, in part, by a load introduction factor (LIF), which was shown by H.M. Lee of Marshall Spaceflight Center to be a natural product of the bolt tensile load equation using a linear spring stiffness model. This LIF, being a function of load-path stiffness, has subsequently been denoted as the stiffness-based LIF (SBLIF), providing a framework to calculate the LIF using whatever load-path stiffness approximations are appropriate. Expanding upon the work of Lee, it is shown that the SBLIF and the joint stiffness factor are functions of the stiffnesses of the same load-paths and regions within a PBJ, and thus they should not be treated as independent variables. Mathematical expressions for the SBLIF are presented. Comparisons are shown between the analytically calculated SBLIF, the analytically calculated geometric LIF (GLIF), which is a simple clamped-member thickness ratio, the experimentally derived LIF, and the LIF determined by finite element analysis (FEA). Using experiment and FEA as a benchmark, the SBLIF, using traditional load-path stiffness approximations, enables a more accurate prediction of bolt tensile loading than the GLIF, although it can be unconservative near joint separation. The GLIF generally attributes more of the externally applied tensile load to the bolt than does the SBLIF, potentially resulting in heavier and/or more costly bolted joints. Mathematical relationships between the SBLIF and the GLIF are developed. Supplemental material is provided in the appendixes where the historical practice of using the joint compressive stiffness in place of the joint tensile stiffness is evaluated. The appendixes include step-by-step examples demonstrating the calculation of the SBLIF using traditional stiffness approximations and conclude with the development of the joint diagram in terms of the SBLIF, culminating into formulas for the key features of a joint diagram, which is useful for programming.

Load Path↗
NASA NTRS1990

Laboratory Investigations: Low Earth Orbit Environment Chemistry With Spacecraft Surfaces

Long-term space operations that require exposure of material to the low earth orbit (LEO) environment must take into account the effects of this highly oxidative atmosphere on material properties and the possible contamination of the spacecraft surroundings. Ground-based laboratory experiments at Los Alamos using a newly developed hyperthermal atomic oxygen (AO) source have shown that not only are hydrocarbon based materials effected but that inorganic materials such as MoS2 are also oxidized and that thin protective coatings such as Al2O3 can be breached, producing oxidation of the underlying substrate material. Gas-phase reaction products, such as SO2 from oxidation of MoS2 and CO and CO2 from hydrocarbon materials, have been detected and have consequences in terms of spacecraft contamination. Energy loss through gas-surface collisions causing spacecraft drag has been measured for a few select surfaces and has been found to be highly dependent on the surface reactivity.

Jon B Cross↗
NASA NTRS2026

Impacts of Reduced Pressure Atmospheres on Environmental Control and Life Support Systems (ECLSS) Architectures

The study found that while nine subsystems are viable without modification at 10.2 psia, only three remain acceptable at 8.2 psia. Material flammability presents the most critical hurdle in the 8.2 psia/34-40% O 2 environment, where 70% of the assessed subsystems will require material replacements, many of which have yet to be developed. Ultimately, adapting ISS heritage hardware to these exploration conditions will introduce varied mass, power (e.g., increased fan speeds), and significant schedule impacts driven by the need for extensive testing, redesign, and recertification. The report concludes with specific recommendations for targeted analysis and testing to quantify these impacts and guide necessary design modifications.

Environmental Control and Life Support Systems↗
NASA NTRS1962

ELECTRIC PROPULSION- A NEW TECHNOLOGY

Within the past 3 years, electric thrust devices have passed from the first exploratory feasibility experiments to the flight-engineered hardware phase. This rapid surge of development has been punctuated by equally rapid improvements in the performance figures of electrical thrust devices. The most spectacular advances were made in ion engine technology. Total energy expenditure per ion pair has gone from 35,000 ev in 1958 to about 600 ev at the present time leading to power utilization efficiencies of up to 80 per cent, depending upon the specific impulse. The percentage of the particles intercepting the accelerating and focusing electrodes has been reduced from more than 50 per cent in 1958 to less than 0.01 per cent at the present time. Great improvements in ion current per unit area have also been realized, leading to greater thrust "pressures."

ELECTRIC PROPULSION↗
NASA NTRS2013

Electrochemistry-based Battery Modeling for Prognostics

Batteries are used in a wide variety of applications. In recent years, they have become popular as a source of power for electric vehicles such as cars, unmanned aerial vehicles, and commericial passenger aircraft. In such application domains, it becomes crucial to both monitor battery health and performance and to predict end of discharge (EOD) and end of useful life (EOL) events. To implement such technologies, it is crucial to understand how batteries work and to capture that knowledge in the form of models that can be used by monitoring, diagnosis, and prognosis algorithms. In this work, we develop electrochemistry-based models of lithium-ion batteries that capture the significant electrochemical processes, are computationally efficient, capture the effects of aging, and are of suitable accuracy for reliable EOD prediction in a variety of usage profiles. This paper reports on the progress of such a model, with results demonstrating the model validity and accurate EOD predictions.

battery↗
NASA NTRS2010

Evaluation of Anomaly Detection Capability for Ground-Based Pre-Launch Shuttle Operations

This chapter will provide a thorough end-to-end description of the process for evaluation of three different data-driven algorithms for anomaly detection to select the best candidate for deployment as part of a suite of IVHM (Integrated Vehicle Health Management) technologies. These algorithms were deemed to be sufficiently mature enough to be considered viable candidates for deployment in support of the maiden launch of Ares I-X, the successor to the Space Shuttle for NASA's Constellation program. Data-driven algorithms are just one of three different types being deployed [3],[5]. The other two types of algorithms being deployed include a "rule-based" expert system, and a "model-based" system. Within these two categories, the deployable candidates have already been selected based upon qualitative factors such as flight heritage. For the rile-based system, SHINE (Spacecraft High-speed Inference Engine) has been selected for deployment, which is a component of BEAM (Beacon-based Exception Analysis for Multimissions) [4], a patented technology developed at NASA's JPL (Jet Propulsion Laboratory) and serves to aid in the management and identification of operational modes. For the "model-based" system, a commercially available package developed by QSI (Qualtech Systems, Inc.), TEAMS (Testability Engineering and Maintenance System) [1] has been selected for deployment to aid in diagnosis. In the context of this particular deployment, distinctions among the use of the terms "data-driven," "rule-based," and "model-based," call found in [5]. Although there are three different categories of algorithms that have been selected for deployment, our main focus in this chapter will be on the evaluation of three candidates for data-driven anomaly detection. These algorithms will be evaluated upon their capability for robustly detecting incipient faults or failures in the ground-based phase of pre-launch space shuttle operations, rather than based oil heritage as performed in previous studies [5]. Robust detection will allow for the achievement of pre-specified minimum false alarm and/or missed detection rates in the selection of alert thresholds. All algorithms will also be optimized with respect to all of these same criteria. Our study relies upon the use of Shuttle data to act as was a proxy for and in preparation for application to Ares I-X data, which uses a very similar hardware platform for the subsystems that are being targeted (TVC - Thrust Vector Control subsystem for the SRB (Solid Rocket Booster)).

False Alarms↗
NASA NTRS1993

Failure Modes of Reduced-Order Orbit Determination Filters and Their Remedies

Ways in which failure can occur in reduced-order, orbit determination filter, error covariance calculations are discussed. In the context of this article, reduced-order filters denote nonoptimal filters which include fixed levels of uncertainty in some parameters of the measurement models or in the spacecraft dynamical model which are not explicitly estimated in the filter equations. Failure is defined as an increase in the orbit determination covariance with the addition of data or as an unreasonable growth in the covariance with time, i.e., nonasymptotic behavior of the covariance. Some simple, known cases of failure are discussed along with their traditional remedies. In addition, more modern remedies are discussed which are currently under development at the Jet Propulsion Laboratory. The article first describes the known problems of reduced-order filters when they are employed for orbit determination, and their traditional remedies. Then, having defined these, the relevancy and desirability of the more modern remedies are made apparent.

D J Scheeres↗
NASA NTRSDate not supplied

Characterization of Quicksounder ATMS at Instrument Level TVAC

QuickSounder (QS) is the pathfinder space mission for the next generation of NOAA LEO environmental satellites in the NEON program, follow-on to the JPSS program. It is a collaborative initiative between NASA and NOAA to verify rapid and cost-effective delivery of small Earth observation satellites. QuickSounder is focusing on mission elements other than science performance. In this context, an existing sensor, the refurbished ATMS EDU (Advanced Technology Microwave Sounder, Engineering Development Unit) was chosen as the QuickSounder payload. This poster discusses the performances of QuickSounder ATMS during thermal vacuum (TVAC) calibration to ensure that QS ATMS is characterized and calibrated in the same manner as JPSS ATMS units, even though science performance attributes are not the priority of this mission.

Saji Abraham↗
NASA NTRS2025

Metallurgical and Thermal Properties of 57Ni-40Ti-3Hf (wt%)

Selected properties of 57Ni-40Ti-3Hf (wt%) were measured to further develop this material for use in aerospace rolling-element bearings. The average grain size and microindentation hardness of the material at room temperature were 90 μm and 549 HV, respectively. From room temperature to 500 °C, electrical resistivity increased from 8.9×10–7 to 11.3×10–7 Ω⋅m, thermal expansion coefficients varied from 1.1×10–5 to 1.2×10–5 mm/mm⋅°C, specific heat increased from 0.44 to 0.53 W⋅sec/g⋅K, thermal diffusivity rose from approximately 0.003 to 0.005 cm2/sec and thermal conductivity increased from approximately 0.09 to 0.19 W/cm⋅K. The behavior of the material can be explained by well-known metallurgical theory. These results are expected to provide a basis for design and modeling of future aerospace components.

rule of mixtures↗
NASA NTRSDate not supplied

Carbon Fiber Composite Processing Using Isothermal Resins

To meet future demand for single-aisle composite aircraft production, manufacturing rates are expected to increase by up to six times current production rates. Resin infusion is a manufacturing method that has potential to enable fabrication of structures at the desired rates. However, production cycle times with currently available commercial infusion resins cannot support the rates needed for an estimated 80 aircraft per month. Recently, rapid-curing isothermal resins were developed that can reduce the overall processing time. These resins can be infused, cured, and demolded at a single temperature below 100 °C, thereby eliminating the need for time consuming temperature ramps and shortening the overall cure time. In addition, the low temperatures enable use of low-cost tooling during production. This presentation will discuss the use of resin transfer molding to produce composites with rapid-curing isothermal resins, manufacturing considerations, and performance characteristics of the composites.

John M Gardner↗
NASA NTRS2026

Investigation of Bipropellant Plume-Induced Contamination Effects on Coverglass Materials

Contamination and degradation of external spacecraft materials by unburned and partially combusted species from bipropellant thruster plumes has long been observed as a key component of the induced space environment. Space shuttle flight experiments and returned flight hardware from the International Space Station (ISS) have both experienced microscopic impact features induced by high-velocity thruster plume droplets. Analytical results have shown that droplet impingement angle relative to a receiving surface plays a key role in the surface damage. Although impacts with normal impingement angles contribute more severely to surface degradation than highly oblique angles, surface effects at higher impingement angles should not be dismissed. Thruster plume-induced materials degradation is a complex phenomenon that depends on a variety of parameters, including but not limited to material type, system temperature and pressure, plume composition, and thruster firing specifications such as number of pulses, pulse duration, and sample distance from the thruster. For space applications, attaining the vacuum pressure and temperature conditions necessary for flight-like plume expansion and exposure conditions is not a trivial task. The German Aerospace Center (Deutsches Zentrum für Luft- und Raumfahrt, DLR) is a facility uniquely capable of simulating such conditions. Test coupons were exposed to bipropellant thruster firings under high vacuum at the DLR facility. Percent area coverage (PAC) and droplet size distributions were evaluated for the uncoated and coated solar array coverglass materials over a range of impingement angles (0̊ to 75̊). A post-test imaging workflow was developed that aimed to quantify changes in sample surface morphology obtained from scanning electron microscopy (SEM) images using the Image Processing and Analysis in Java (ImageJ) tool; an opensource image processing software. The goal was to create a framework through which to evaluate the effect of bipropellant-induced PAC and droplet size distribution on solar array coverglass optical transmission losses. Understanding this relationship is important because optical transmission losses are known to lead to current reduction in solar power generation systems. In addition to the development of surface characterization workflows, valuable lessons learned as they pertain to future investigations and experiments will be discussed. The authors hope that sharing these lessons will facilitate more utilization of DLR’s unique capabilities as well as open the conversation for how best to address experimental characterization of flight-like plume expansion and its impacts on materials surface degradation effects.

Gateway↗
NASA NTRS2017

International Space Station Lithium-Ion Battery Start-Up and Cycling

The International Space Station (ISS) primary Electric Power System (EPS) was originally designed to use Nickel-Hydrogen (Ni-H2) batteries to store electrical energy. The electricity for the ISS is generated by its solar arrays, which charge batteries during insolation for subsequent discharge during eclipse. The Ni-H2 batteries were designed to operate at a 35 depth of discharge (DOD) maximum during normal operation in a Low Earth Orbit. In 2010, the ISS Program began the development of Lithium-Ion (Li-Ion) batteries to replace Ni-H2 batteries approaching the end of their useful life and concurrently funded a Li-Ion ORU (Orbital Replacement Unit) and cell life testing project. The first set of 6 Li-ion battery replacements was launched in December 2016 and deployed in January 2017. This paper will discuss the Li-ion battery on-orbit cycling and the status of the Li-Ion cell and ORU life cycle testing.

International Space Station↗