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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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NASA NTRS2026

Raising TRL of Your Lunar Payload

Preparing payloads for the lunar surface requires rigorous testing that accurately captures the extreme environmental and operational conditions. This presentation provides an overview of the lunar relevant test capabilities at NASA JSC’s Astromaterials Research and Exploration Science (ARES) laboratories as well as the Energy System Test Area (ESTA) Lunar Development and Test Facility. These facilities allow teams to assess hardware performance in dusty vacuum environments, characterize interactions with high fidelity lunar regolith simulants, evaluate mechanical and thermal durability, and understand the effects of micrometeoroid and orbital debris impacts—critical factors for certifying payloads that will operate on the lunar surface or in orbit. While Lunar power challenges such as variable illumination, extreme temperatures, and dust driven degradation will be briefly summarized, the focus of this talk is on how JSC’s test infrastructure enables developers to validate designs, reduce mission risk, and ensure compatibility with CLPS and Artemis objectives. NASA JSC’s expertise and experience help industry, academic, and government teams prepare robust hardware ready for successful delivery and operation on the surface of the Moon.

Lunar Regolith Simulant↗

NASA NTRSDate not supplied

Battery Evaluation Profiles for X-57 and Future Urban Electric Aircraft

Battery energy density is one of the most critical design parameters for sizing all-electric aircraft, however it’s easily overestimated. Establishing the effective, usable energy density is confused by varying degrees of margin needed to account for structural and thermal management between different cell chemistry and pack designs. Therefore, a better methodology is needed to fairly compare emerging battery technologies for electric aircraft. Currently, there is a loss of critical information when vehicle trade studies are performed using “nominal” published cell-level performance metrics. Aircraft power demands rarely match these nominal power profiles, and aircraft designers lack the ability to accurately simulate the battery performance and temperature off-nominally unless the battery chemistry is well established. Conversely, battery suppliers have no generalized reference cases to publish more realistic performance metrics. This can lead to poor assumptions, such as aircraft studies assuming a fixed discharge efficiency of a battery, when in reality the usable energy in a pack is dependent on the power and thermal profile. Information needed to properly assess weight penalties for thermal management is also typically poorly characterized when assessing candidate batteries. This paper serves to better inform battery development, and similarly, provide aircraft designers with more realistic assumptions for applying knockdown margins in their designs. Detailed power and thermal performance estimates are provided, which provide a starting point for sizing power and thermal budgets using experimentally derived battery models. Results show that the X-57 battery-to-shaft efficiency is 77.3% for a particular optimized mission. Considering a 25% reserve on the battery capacity, this means that only roughly half of the original 55.3kWh ‘nominal’ pack energy can be converted to useful work during a mission. Further estimates on a clean-sheet VTOL optimization show an average 82.7% battery-to-shaft efficiency, using 98% peak efficiency inverters and 97.4% peak efficiency motors. Although higher battery efficiencies are possible, the resulting weight penalty negates improvement in vehicle performance. These trade-offs and resulting power profiles are provided as a starting point to better assess future battery designs.

Battery Electric Aircraft↗

NASA NTRSDate not supplied

Pragmatic Stress Prediction on Additively Manufactured Coupons

Prediction of residual stresses from process parameters for additively manufactured large metal parts is computationally expensive. NASA is currently developing meter-scale parts with direct energy deposition. Practically, the predictive computational methods need to efficiently scale-up to meter-scale parts. Coupled thermal-mechanical multi-physics simulations have been developed with the pragmatic method using ABAQUS, COMSOL Multiphysics, ALE3D software. The residual stresses are a result of the manufacturing process which creates thermal cycling of the build layers. The pragmatic method uses lumped thermal layers for stress predictions to reduce computational costs. The stress predictions as well as deformations of the different codes are compared with each other and with ANSYS Additive using identical material models, boundary and initial conditions. The codes were used to simulate three different geometries: a thin wall, hollow cylinder and twin-cantilever part. The coupon parts were then manufactured with Inconel-625. The residual stresses in these parts were measured using X-ray diffraction as well as neutron beam diffraction at NIST. The stress measurements for the two technologies are compared. The pragmatic stress prediction method enabled predictions of the multi-centimeter scale parts using desktop computer workstations in only a few hours for each coupon. The results of the simulated stress predictions compared favorably with the measured stresses even though thermally lumped layers were employed. Finally, a two-meter scale nozzle was simulated using ANSYS Additive. The simulations were used to examine the build orientation trade-space with respect to resulting geometric deformation. The predicted deformations were compared to measurements of an actual subscale part manufactured with direct energy deposition.

pragmatic method↗

NASA NTRS1985

Nickel-cadmium Battery Cell Reversal from Resistive Network Effects

During the individual cell short-down procedures often used for storing or reconditioning nickel-cadmium (Ni-Cd) batteries, it is possible for significant reversal of the lowest capacity cells to occur. The reversal is caused by the finite resistance of the common current-carrying leads in the resistive network that is generally used during short-down. A model is developed to evaluate the extent of such a reversal in any specific battery, and the model is verified by means of data from the short-down of a f-cell, 3.5-Ah battery. Computer simulations of short-down on a variety of battery configurations indicate the desirability of controlling capacity imbalances arising from cell configuration and battery management, limiting variability in the short-down resistors, minimizing lead resistances, and optimizing lead configurations.

Zimmerman, A. H.↗

NASA NTRS1997

The Role of Tribology in the Development of an Oil-Free Turbocharger

Gas-turbine-based aeropropulsion engines are technologically mature. Thus, as with any mature technology, revolutionary approaches will be needed to achieve the significant performance gains that will keep the U.S. propulsion manufacturers well ahead of foreign competition. One such approach is the development of oil-free turbomachinery utilizing advanced foil air bearings, seals, and solid lubricants. By eliminating oil-lubricated bearings and seals and supporting an engine rotor on an air film, significant improvements can be realized. For example, the entire oil system including pipes, lines, filters, cooler, and tanks could be removed, thereby saving considerable weight. Since air has no thermal decomposition temperature, engine systems could operate without excessive cooling. Also, since air bearings have no diameter-rpm fatigue limits (D-N limits), engines could be designed to operate at much higher speeds and higher density, which would result in a smaller aeropropulsion package. Because of recent advances in compliant foil air bearings and high temperature solid lubricants, these technologies can be applied to oil-free turbomachinery. In an effort to develop these technologies and to demonstrate a project along the path to an oil-free gas turbine engine, NASA has undertaken the development of an oil-free turbocharger for a heavy duty diesel engine. This turbomachine can reach 120000 rpm at a bearing temperature of 540 C (1000 F) and, in comparison to oil-lubricated bearings, can increase efficiency by 10 to 15 percent because of reduced friction. In addition, because there are no oil lubricants, there are no seal-leakage-induced emissions.

Christopher Dellacorte↗

NASA NTRS2006

20V, 40 Ah Lithium Ion Polymer Battery for the Spacesuit

Objective: Consider a new battery design for EMU. Results: a) Electrovaya s aerospace cell production line is improving, but must further improve to achieve acceptable reliability; b) Completed functional, vibration, and thermal cycling of LIB; c) So far, electrical safety tests have produced good results; d) Completed functional, vibration, thermal cycling, power quality and EMI of LIB Charger; e) Completed CDR on 9/23/04; and f) Manufacturing Readiness Review for flight cell/battery production scheduled for Dec 04.

Darcy, Eric↗

NASA NTRS2026

Raising TRL of Your Lunar Payload

Laboratories↗

NASA NTRS2026

NASA Talks: Space Shuttle Columbia - Lessons Learned

On February 25, 2026, two NASA Talks were held regarding the Space Shuttle Columbia (Columbia Launch & Recovery, Columbia Reconstruction, Investigation, Causes & Key Takeaways). Crew & Thermal System Division (EC) partnered with Kennedy Space Center (KSC) and Engineering Directorate (EA) to bring these talks to Johnson Space Center (JSC) centering on what led up to and transpired after the Space Shuttle Columbia accident. Some recovered debris was on exhibit during the talks. NASA Mishap Program Specialist David Erickson and retired NASA Columbia Vehicle Manager Scott Thurston presented these talks. Mr. Erickson supports NASA mishap investigations and assists with the development of NASA's new Columbia Learning Center at KSC. Mr. Thurston brought a wealth of knowledge from his mission experience. These talks were timely and a solemn reminder of the critical importance of diligence, safety, and excellence in our work. EA Director Julie Kramer White welcomed the 400+ center-wide in-person audience, and EC Division Chief Rubik Sheth introduced the speakers. This event was held in the JSC Teague Auditorium, recorded, and executed by the EC in-house STAR Productions team.

Space Shuttle Columbia↗

NASA NTRS2017

Legacy of the Asteroid Redirect Robotic Mission (ARRM)

NASA’s proposed Asteroid Redirect Robotic Mission (ARRM) began with the recognition in a 2010 NASA study that emerging high-power solar electric propulsion technology could be used to rendezvous with, capture, and return an entire, very small (~10,000 kg), near Earth asteroids to the International Space Station. A 2011 workshop by the Keck Institute for Space Studies (KISS) extended the earlier NASA study to asteroid masses of order 500,000 kg by returning them to cislunar space. Subsequent detailed NASA studies in 2013-2014 confirmed the feasibility of this concept. This led to the establishment of the Asteroid Redirect Mission program that consisted of a robotic mission to return multiple tons of asteroid material to cislunar space and a crewed mission to rendezvous with the robotic vehicle, perform two extra vehicular activities (EVAs), collect samples of the asteroid material, and return this material to Earth. Implementation of ARRM got midway through Phase B before being cancelled in April 2017. Although ARRM was cancelled, it has left a near-term legacy of positive impacts to the human spaceflight community, the planetary defense community, the deep space science community, and asteroid mining interests.

John R Brophy↗

NASA NTRS2005

The Cassini/Huygens Doppler Wind Experiment: Results from the Titan Descent

The primary objective of the Doppler Wind Experiment (DWE), one of the six scientific investigations comprising the payload of the ESA Huygens Probe, is a determination of the wind velocity in Titan's atmosphere. Measurements of the Doppler shift of the S-band (2040 MHz) carrier signal to the Cassini Orbiter and to Earth were recorded during the Probe descent in order to deduce wind-induced motion of the Probe to an accuracy better than 1 m s-1. An experiment with the same scientific goal was performed with the Galileo Probe at Jupiter. Analogous to the Galileo experience, it was anticipated that the frequency of the Huygens radio signal could be measured on Earth to obtain an additional component of the horizontal winds. Specific secondary science objectives of DWE include measurements of: (a) Doppler fluctuations to determine the turbulence spectrum and possible wave activity in the Titan atmosphere; (b) Doppler and signal level modulation to monitor Probe descent dynamics (e.g., spinrate/spinphase, parachute swing); (c) Probe coordinates and orientation during descent and after impact on Titan.

M K Bird↗

NASA NTRS1962

A Design Solution to the Spacecraft Look-Angle Problem

As the state of the art of the design of spacecraft has progressed, one of the difficult problems which has arisen is the positioning and articulating of spacecraft elements which must “see” in different directions without interference. Some of these elements are: solar panels or collectors, Sun sensors, communication antennas, star seekers, planet tracking and scanning devices, rocket motors, attitude-control jets, and scientific instruments. This Report presents a method of testing a spacecraft design to determine how well it satisfies these look-angle requirements. This method is applied to both simple and complex cases, and examples of its use are presented. A means of assessing spacecraft constraints on trajectories is discussed. The method was developed for the Mariner interplanetary spacecraft, but should be applicable to other cases.

MARINER PROGRAM↗

NASA NTRS2002

The Design and Use of Calorimeters For Characterization of High-Enthalpy Flows in Arc-Heated Test Facilities

High-enthalpy, arc-heated flows used for aerothermal testing present a challenging environment for flow characterization. This paper describes the design and use of cooled dwell probes used for heat-transfer and pressure characterization of the NASA and United States Department of Defense (DoD) arc facilities located at Moffett Field, CA, and Arnold Air Force Base, TN. Dwell calorimeters designed, fabricated, and tested by Thermal Technologies, Inc. (TTI) in the NASA IHF and the USAF H1 and H2 arc test facilities provide heat flux and pressure data with excellent repeatability. These calorimeters use standard Gardon calorimeter gages and pressure ports with unique cooling systems enabling them to withstand the severe arc-heated environments for durations sufficient for acquisition of steady-state data. The TTI probes have proven very robust in the extreme aerothermal environments of these facilities. This paper provides an overview of calorimeter instruments typically used in arc facilities, discusses design features of the TTI dwell probes, presents selected data acquired by the TTI calorimeters, and provides comparisons with data acquired from using measurement techniques.

D Mark Smith↗

NASA NTRS1977

The Chemical Composition of the Cores of the Terrestrial Planets and the Moon

Using models of the quasi-chemical theory of solutions, the activity coefficients of silicon are calculated in the melts Fe-Si, Ni-Si, and Fe-Ni-Si. The calculated free energies of solution of liquid nickel and silicon in liquid iron in the interval 0 to 1400 kbar and 1500 to 4000 K, shows that Fe-Ni-Si alloy is stable under the conditions of the outer core of the Earth and the cores of the terrestrial planets. The oxidation-reduction conditions are studied, and the fugacity of oxygen in the mantles of the planets and at the core-mantle boundary are calculated. The mechanism of reduction of silicon is analyzed over a broad interval of P and T. The interaction between the matter of the core and mantle is studied, resulting in the extraction of silicon from the mantle and its solution in the material of the core. It is concluded that silicon can enter into the composition of the outer core of the Earth and Venus, but probably does not enter into the composition of the cores of Mercury, Mars, and the Moon, if in fact the latter possesses one.

O L Kuskov↗

NASA NTRS1997

Radiation Temperature and Extinction of Transient Gaseous Diffusion Flames in Microgravity

The absence of buoyancy-induced flows in micro-g and the resulting increase in the reactant residence time significantly alters the fundamentals of many combustion processes. Substantial differences between 1-g and micro-g flames have been reported in experiments on candle flames, flame spread over solids, droplet combustion and others. These differences are more basic than just in the visible flame shape. Longer residence times and higher concentration of combustion products in the flame zone create a thermochemical environment which changes the flame chemistry and the heat and mass transfer processes. Processes such as flame radiation (and its interaction with flame chemistry), that are often ignored under normal gravity, become very important and sometimes even controlling. This is particularly true for conditions at extinction of a micro-g diffusion flame.

Arvind Atreya↗

NASA NTRS2026

NASA Talks: Space Shuttle Columbia - Lessons Learned: Columbia Reconstruction, Investigation, Causes and Key Takeaways

On February 25, 2026, this NASA Talk was held regarding the Space Shuttle Columbia (Columbia Launch & Recovery, Columbia Reconstruction, Investigation, Causes & Key Takeaways). Crew & Thermal System Division (EC) partnered with Kennedy Space Center (KSC) and Engineering Directorate (EA) to bring these talks to Johnson Space Center (JSC) centering on what led up to and transpired after the Space Shuttle Columbia accident. Some recovered debris was on exhibit during the talks. NASA Mishap Program Specialist David Erickson presented this talk. Mr. Erickson supports NASA mishap investigations and assists with the development of NASA's new Columbia Learning Center at KSC. This talk was timely and a solemn reminder of the critical importance of diligence, safety, and excellence in our work. EA Director Julie Kramer White welcomed the 400+ center-wide in-person audience, and EC Division Chief Rubik Sheth introduced the speakers. This event was held in the JSC Teague Auditorium, recorded, and executed by the EC in-house STAR Productions team. This record includes an mp4 video with a run time of 32 min. 31 sec.; in color; with sound.

NASA Talks↗

NASA NTRS2026

Hybrid Modeling Study on Grain Evolution in the Metal Welding Process and Its Potential Lunar Application

Metal is most commonly used structural material in a wide range of spacecraft, and welding is the principal method for joining metal components into functional systems. However, conducting welding experiments under extreme environments—such as microgravity or vacuum conditions in space—is prohibitively expensive and experimentally challenging. To overcome these limitations, multi-physics computational welding models provide a cost-effective and versatile alternative. In this work, the authors have developed a coupled thermal (fluid) microstructure simulation framework to model metal welding under varying gravity conditions. The framework integrates a mixed-mode heat transfer formulation (conduction, convection, and radiation) with molten pool fluid dynamics, enabling accurate prediction of temperature fields and weld-pool geometry. A grain growth model is further incorporated to capture the spatial and temporal evolution of microstructure, including grain size distribution and morphological transitions during solidification. This approach provides detailed insight into molten pool evolution and grain-level microstructure development throughout the welding process. By explicitly parameterizing environmental conditions, the model supports extrapolation to off-Earth manufacturing scenarios such as welding on the lunar surface. Tantalum—chosen in this study due to its high melting point, oxidation resistance, and mechanical stability at elevated temperatures—serves as the material system for model demonstration. Beyond Tantalum, the integrated multi-physics framework offers broad applicability for predictive welding simulations of various structural and refractory metals or alloys used in extreme terrestrial or extraterrestrial environments.

kinetic Monte Carlo (SPPARKS)↗

NASA NTRS1967

Space Programs Summary 37-43, Vol. VI, Space Exploration Programs and Space Sciences For the Period November 1 to December 31, 1966

The Space Programs Summary is a six-volume bimonthly publication designed to report on JPL space exploration programs and related supporting research and advanced development projects. The titles of all volumes of the Space Programs Summary are: Vol. I. The Lunar Program (Confidential) Vol. 11. The Planetary-Interplanetary Program (Confidential) Vol. 111. The Deep Space Network (Unclassified) Vol. IV. Supporting Research and Advanced Development (Unclassified) Vol. V. Supporting Research and Advanced Development (Confidential) Vol. VI. Space Exploration Programs and Space Sciences (Unclassified) The Space Programs Summary, Vol. VI, consists of: an unclassified digest of appropriate material from Vols. I, II, and III; an original presentation of the JPL quality assurance and reliability efforts, and the environmental- and dynamic-testing facility-development activities; and a reprint of the space science instrumentation studies of Vols. I and 11. This instrumentation work is conducted by the JPL Space Sciences Division and also by individuals of various colleges, universities, and other organizations. All such projects are supported by the Laboratory and are concerned with the development of instruments for use in the NASA space flight programs.

MARINER PROGRAM↗

NASA NTRS2026

List of Commercial and Advanced Developmental Niobium-Based Alloys of the Space Age

This report compiles a list of commercial and developmental niobium-based alloys developed during the Space Age (late 1950s through mid-1970s) for extreme-temperature applications, including rocket engine thrust chambers, hypersonic re-entry thermal protection systems, and space fission reactor loops. Niobium (Nb) was widely pursued because it provided the lowest density (~8.6 g/cc) among the primary refractory metals, a high melting temperature (~2470°C), exceptional low-temperature ductility, good formability, and compatibility with liquid alkali metals. An evaluation of physical metallurgy mechanisms, focusing on solid-solution strengthening via heavy refractory solutes (W, Mo, Ta), dual-purpose reactive solutes (Hf, Zr, Ti), and dispersion strengthening using carbides, nitrides, and oxides is presented. Additionally, the report compares Western and Soviet Union metallurgical approaches, explaining how supply chain factors and manufacturing infrastructure influenced element selection, interstitial chemistry, and alloy identification/naming conventions. Cataloging these historical alloy chemical compositions serves as a foundational reference for modern alloy additive manufacturing, thermodynamic CALPHAD modeling, and machine-learning discovery pipelines for next-generation extreme-environment niobium-based alloys.

Physical Metallurgy↗