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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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706 records · Page 33

Sodium-sulfur battery flight experiment definition study

Sodium-sulfur batteries are considered to be one of the most likely battery systems for space applications. Compared with the Ni-H2 or Ni-Co battery systems, Na-S batteries offer a mass reduction by a factor of 2 to 4, representing significant launch cost savings or increased payload mass capabilities. The Na-S battery operates at between 300 and 400 C, using liquid sodium and sulfur/polysulfide electrodes and solid ceramic electrolyte; the transport of the electrode materials to the surface of the electrolyte is through wicking/capillary forces. This paper describes five tests identified for the Na-S battery flight experiment definition study, which include the cell characterization test, the reactant distribution test, the current/temperature distribution test, the freeze/thaw test, and the multicell LEO test. A schematic diagram of Na-S cell is included.

Chang, Rebecca

Simplified Aid for Extra-Vehicular Activity Rescue (SAFER) Battery Assessment

In 2013, the Boeing Company model 787-8 Dreamliner commercial aircraft experienced three catastrophic lithium (Li) battery failures. The cause of each failure resulted in a single-cell thermal runaway (TR) condition, which propagated to adjacent battery cells. Two of the failures involved rechargeable lithium-ion (Li-Ion) batteries, and the third event involved a nonrechargeable lithium-manganese dioxide (Li-MnO2) battery. In response to these Li battery failures, the NASA Engineering and Safety Center (NESC) approved a technical assessment of the International Space Station Simplified Aid for Extra-Vehicular Activity Rescue (SAFER) Li non-rechargeable battery. This assessment was conducted to evaluate the SAFER Li nonrechargeable battery safety design features against Boeing 787 Dreamliner Li battery failure lessons learned. Specifically, this investigation focused on assessing the severity of a SAFER battery TR hazard conditions.

Iannello, Christopher J.

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

Development of a Thermal Radiator Optimization Tool with Alternate Coolants

The development of a modeling tool to optimize the design of a thermal radiator based on capacity, rejection temperature, geometry, type and coolant is presented. The radiator size is determined from the desired capacity, environmental conditions and rejection temperature. Flow through the radiator is derived from the overall heat load and prescribed inlet to outlet delta temperature for a given coolant. The tool considers radiator geometry (i.e., tube spacing and diameter, face-sheet thickness, overall size, etc.) and general type (i.e., parallel/manifold versus serpentine) in the optimization. Selection from a handful of potential coolants is also available in the tool which primarily affects necessary tube diameter to maintain turbulent flow and minimize pressure drop. An Equivalent System Mass (ESM) approach is utilized to include pump power in the optimization. Results from the tool and potential future enhancements are also discussed.

Coolant

PC4CAST: A Tool for DSN Load Forecasting and Capacity Planning

Effectively planning the use and evolution of the Deep Space Network (DSN) is a complex problem involving many parameters. The tool that models many of these complexities, yet requires simple structured inputs and provides concise easy-to-understand metrics to aid in the planning process is discussed. The tool, PC4CAST, is used for both load forecasting (predicting how well planned that DSN resources meet expected demand) and as a decision support tool in the capacity-planning process (determining the relative benefits of capacity expansion options). It is now in use in the TDA Planning Office, has been used in numerous studies, and is also being used by the JPL Multimission Operations System Office (MOSO) as an integral part of Resource Allocation Team activities. Experience using the tool has helped to identify additional requirements that will further improve the planning process, which can be met by future PC4CAST versions.

S J Loyola

Engineering and Abuse Testing of Panasonic Lithium-Ion Battery and Cells

This viewgraph presentation reviews the performance testing of Lithium Ion batteries and cells under different conditions of charge and discharge. The tests show that the 0.5 C rate of charge and discharge might be the ideal condition for long term cycling. It reviews the issues of overcharge and overdischarge of the cells. The cells and the battery have adequate protection under both conditions to prevent any catastrophic occurrences. Temperatures above 150 C are required to vent the cells or cause a thermal runaway, Since this situation is non-credible in the cabin of the Space Shuffle or ISS this should not pose a problem. The presentation includes graphs and charts showing the charge and discharge capacities of the battery and also the current and voltage profiles. A view of a circuit board which contains the controlling mechanism for the battery is also shown.

Jeevarajan, Judith A.

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

Development of the METMAN Thermal Desktop Human Model for System Integration

Human thermal analysis and model development inform NASA’s space suit development, vehicle/habitat design, and survivability studies. Historically, human thermal models such as the 41-node metabolic man (METMAN) and the Wissler model have been standalone software tools developed with FORTRAN, a programming language known for its high performance in computationally intensive applications. Though efficient, these standalone programs pose challenges to coupled human-system analysis with detailed life support and thermal control subsystem models in other commercial software. This paper describes the conversion of the METMAN human thermal model from a standalone FORTRAN program to a model in Thermal Desktop (Ansys), a commonly used CAD-based simulation software for engineering that specializes in heat transfer, thermal radiation, and fluid flow analysis. This format was chosen to best facilitate model sharing and compatibility, enabling the direct integration of METMAN human thermal analysis with subsystem models across NASA programs and commercial partners.

Elizabeth Thurston

Skylab Experiment M552: Exothermic Brazing

The M552 Skylab experiment reveals that brazing in space is feasible. It successfully demonstrated the ability to retain molten metal within a braze tube joint system. Surface energy was the dominant operative force system controlling liquid metal for this experiment. The zero gravity environment for brazing resulted in several differences; increased solubility, increased liquid spreading, more uniform menisci (liquid/vapor interface) and a reduction of braze alloy shrinkage defects. The residual radioactive intensity and location of the redistributed isotope was interpreted to provide a sequential history of braze alloy movement during the melt-flow-solidification stages of the process. Convection theory applied to M552 was validated but some results were not explainable by it, i.e., increased nickel transport and the radial mixing of the silver isotope on samples SLN-2 and SLN-4. All characteristics of thermal analysis appeared to react as expected but heat conduction rates increased because of increased extent, rate and uniformity of braze alloy spreading.

J R Williams

Lunar and Planetary Science XXXV: Icy Worlds: Moving and Grooving

Reports from the conference session entitled Icy Worlds: Moving and Grooving, include:Mass Anomalies on Ganymede; Europan Chaos and Lenticulae: A Synthesis of Size, Spacing, and Areal Density Analyses; Thermal and Topographic Tests of Europa Chaos Formation Models; Flexure of Europa s Lithosphere Due to Ridge-Loading; Ridges on Europa: Origin by Incremental Ice-Wedging ; Convergent Boundaries on Europa: a Numerical Approach to Euler Pole Analysis and Its' Implications for Plate Reconstruction; Numerical Simulations of Subsolidus Convection in the Ice Shell of Europa: Implications for the Thermal Evolution and Present State; Effects of Plasticity on Convection in an Ice Shell: Implications for Europa; Non-Newtonian Convection and Compositional Buoyancy: Advances in Modeling Convection and Dome Formation on Europa; Convective Instability in Ice I: Application to Callisto and Ganymede; Crater Size Distributions on Callisto: A Galileo SSI Summary; Neutron Diffraction Studies of Planetary Ices; and H2O2 Synthesis Induced by Irradiation of H2O with Energetic H+ and Ar+ Ions at Various Temperatures.

Source record

Parametric-Based Heat Rejection Trade Study for Lunar and Martian Surface Operations

Establishing and maintaining a sustained presence on the lunar and/or Martian surfaces will require a diverse portfolio of surface elements (e.g., habitation, mobility, power generation, etc.). Many of these systems generate excess heat that must be rejected across a wide range of magnitudes, temperatures, and duty cycles and under variable environmental conditions. To identify the most promising heat rejection approaches for this diverse portfolio, a heat rejection trade study was conducted to evaluate the performance of different technology approaches across a spectrum of surface environments and heat-load requirements. The trade study consisted of three stages: (1) development of a parametric-based modeling framework, (2) creation of a database of heat rejection technologies, surface elements, and environmental conditions for the Moon and Mars, and (3) execution of a quantitative analysis of various heat rejection technologies across different operating conditions and surface elements. The modeling framework is developed in Python and Excel to prioritize small model size and hence low computational cost to enable large parametric sweeps while avoiding the reliance on proprietary software. Individual heat rejection processes are represented as simple Excel models, and a centralized Python script interfaces with the models to coordinate the parametric study. These simple sizing models were developed to take heat load requirements and environmental parameters as inputs and compute mass, power, and volume as outputs. Rather than assess each heat rejection technology separately for each surface element, a unified parametric space was developed to evaluate all technologies across all elements. This parametric space includes factors related to heat load (e.g., magnitude or temperature) and environment (e.g., surface temperature, sky temperature, solar flux). This effort generated a database containing information on over 60 heat rejection technologies and 30 surface elements. For each surface element, the expected heat rejection requirements were documented and analyzed to determine the most common needs shared across all elements. Environmental conditions at various lunar and Martian latitudes were also established for worst-case hot and worst-case cold scenarios. High-fidelity heat rejection models are currently under development. Preliminary trades between heat rejection technologies including radiators, venting technologies, convective coolers, and more have been conducted to identify promising options. This presentation will summarize the preliminary trade results and provide an overview and discussion of the expected heat loads and thermal environments for sustained surface operations on the Moon and Mars.

Heat Rejection

Monte Carlo modeling of atomic oxygen attack of polymers with protective coatings on LDEF

Characterization of the behavior of atomic oxygen interaction with materials on the Long Duration Exposure Facility (LDEF) will assist in understanding the mechanisms involved, and will lead to improved reliability in predicting in-space durability of materials based on ground laboratory testing. A computational simulation of atomic oxygen interaction with protected polymers was developed using Monte Carlo techniques. Through the use of assumed mechanistic behavior of atomic oxygen and results of both ground laboratory and LDEF data, a predictive Monte Carlo model was developed which simulates the oxidation processes that occur on polymers with applied protective coatings that have defects. The use of high atomic oxygen fluence-directed ram LDEF results has enabled mechanistic implications to be made by adjusting Monte Carlo modeling assumptions to match observed results based on scanning electron microscopy. Modeling assumptions, implications, and predictions are presented, along with comparison of observed ground laboratory and LDEF results.

Bruce A. Banks

Battery/Ultracapacitor Evaluation for X-38 Crew Return Vehicle (CRV)

This presentation reported on the evaluation of the battery/ultracapacitor for the crew return vehicle (CRV). The CRV, as part of the international space station (ISS) planning, will be available to return to earth an ill or injured crew person, or if the ISS becomes unsafe, and the shuttle is not available. The requirements of the X-38 CRV are reviewed, and in light of the power requirements, the battery's required performance is reviewed. The ultracapacitor bank, and its test method is described. The test results are reviewed. A picture of the test set up is displayed showing the ultracapacitor bank and the NiMH battery. The presentation continues by reviewing tests of 5 available trade high power cell designs: (1) Hawker lead acid, (2) Bolder lead acid, (3) Energizer NiMH, (4) Sanyo NiCd, and (5) Energizer NiCd. The test methods and results are reviewed. There is also a review of the issues concerning lead acid batteries and conclusions.

Darcy, Eric

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

Analysis of Developing Laminar Flows in Circular Pipes Using a Higher-Order Finite-Difference Technique

A higher-order finite-difference technique is developed to calculate the developing-flow field of steady incompressible laminar flows in the entrance regions of circular pipes. Navier-Stokes equations governing the motion of such a flow field are solved by using this new finite-difference scheme. This new technique can increase the accuracy of the finite-difference approximation, while also providing the option of using unevenly spaced clustered nodes for computation such that relatively fine grids can be adopted for regions with large velocity gradients. The velocity profile at the entrance of the pipe is assumed to be uniform for the computation. The velocity distribution and the surface pressure drop of the developing flow then are calculated and compared to existing experimental measurements reported in the literature. Computational results obtained are found to be in good agreement with existing experimental correlations and therefore, the reliability of the new technique has been successfully tested.

Herbert J Gladden

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

The NASA OSIRIS-REx Sample Catalog: Samples Returned from Investigators

OSIRIS-REx is a sample return mission that collected carbon-rich material from B-type asteroid Bennu. After landing on September 24th, 2023, the science canister was transported to NASA Johnson Space Center (JSC) in Houston, Texas where it was opened and samples were processed by the curation team in pristine sample nitrogen gloveboxes. As the sample analysis phase of the OSIRIS-REx mission concludes, the Sample Analysis Team (SAT) has returned the majority of mission samples to NASA JSC curation and will return the remaining samples on a defined timetable. The curation team processed and documented as many of these samples as possible to include in the spring 2026 catalog update and are steadily working to process hundreds of more samples to include in the fall 2026 catalog update.

OSIRIS-REx

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