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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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Ulysses navigation

Ulysses, a cooperative NASA and ESA project, measures charged and neutral particles, magnetic fields, and electromagnetic wave emissions from the Sun's polar regions and the out of elliptic heliospheric environment. ESA supplied the spacecraft and one half of the instruments, and is in control of the spacecraft and its attitude. NASA supplied the power supply, one half of the instruments, the launch vehicle, and tracks the spacecraft and performs the navigation. Orbit determination results mapped to the time of Jupiter's arrival show improved accuracy and consistency over the course of the mission to date. Solar radiation pressure model uncertainties are major contributors to orbit determination errors, but are being estimated more accurately as data are accumulated.

H. J. Gordon

Contamination Control and Assessment Strategy for Martian Moons Exploration (MMX)

Martian Moons eXploration (MMX) is a sample return mission from the Martian moon Phobos. The MMX spacecraft is scheduled for launch in 2026 and return to Earth in 2031. The primary science objective of MMX is to reveal the origin of the Martian moons, thereby advancing the understanding of planetary system formation and material transport in the solar system, as well as to observe processes affecting the circumplanetary and surface environments of Mars. The returned sample will be transported to the curation facility at ISAS/JAXA, and the subsequent curation and sample analysis activity will be conducted. As a sample return mission, MMX requires strict contamination control to prevent the intrusion of terrestrial materials.

H Sugahara

Design and Optimization of an Open Rotor Stage

Open rotor propulsors enable greatly increased effective bypass ratios over current aircraft engines, resulting in significantly improved efficiencies. One of the most promising of these geometries is the “open fan”, which consists of a single rotor followed by a single stator. This configuration will be referred to as an “open rotor stage” for design work at NASA. In this work we consider the multidisciplinary design and optimization of an open rotor stage using a variety of 2D and 3D techniques. The 2D aerodynamic techniques used for design include a 2D Trefftz plane method, axisymmetric throughflow, and quasi-3D blade-to-blade CFD. Aerodynamic performance is prioritized, while structural requirements are met and some acoustic considerations are included. Between the rotor, stator, and hub profiles, a total of 101 design variables are used. Differences in the process of designing an open rotor stage vs. designing other high-speed propellers are also discussed. The current design, the NASA Optimized Propulsor for Efficiency and Noise (N-OPEN-1), achieves 84.7% net efficiency as predicted by 3D CFD, with further improvements expected to be possible. This design makes effective use of a slower rotor and a less tip-loaded work distribution than typical single-rotation propellers, allowing the stator to produce 14.8% of the thrust. Laminar flow on the blades was responsible for a 1.7% efficiency benefit and warrants further study.

Open rotors

Design and Optimization of an Open Rotor Stage

Open rotor propulsors enable greatly increased effective bypass ratios over current aircraft engines, resulting in significantly improved efficiencies. One of the most promising of these geometries is the “open fan”, which consists of a single rotor followed by a single stator. This configuration will be referred to as an “open rotor stage” for design work at NASA. In this work we consider the multidisciplinary design and optimization of an open rotor stage using a variety of 2D and 3D techniques. The 2D aerodynamic techniques used for design include a 2D Trefftz plane method, axisymmetric throughflow, and quasi-3D blade-to-blade CFD. Aerodynamic performance is prioritized, while structural requirements are met and some acoustic considerations are included. Between the rotor, stator, and hub profiles, a total of 101 design variables are used. Differences in the process of designing an open rotor stage vs. designing other high-speed propellers are also discussed. The current design, the NASA Optimized Propulsor for Efficiency and Noise (N-OPEN-1), achieves 84.7% net efficiency as predicted by 3D CFD, with further improvements expected to be possible. This design makes effective use of a slower rotor and a less tip-loaded work distribution than typical single-rotation propellers, allowing the stator to produce 14.8% of the thrust. Laminar flow on the blades was responsible for a 1.7% efficiency benefit and warrants further study.

turbomachinery

Laser Beam Welding Advancements for In-Space Servicing, Assembly, and Manufacturing

NASA is currently working to develop in-space servicing, assembly, and manufacturing (ISAM) capabilities for low Earth orbit and the lunar surface. One crucial technology for this effort is laser beam welding. Laser systems can perform joining, cleaning, cutting, and repair activities, which will enable the construction of large in-space structures that could not fit on a single launch vehicle, such as trusses for solar panels, radiators, or communications infrastructure. Multiple projects studying laser welding for space applications are currently underway at NASA Marshall Space Flight Center. One of these, the DIsk-Shaped Configurable and Modular vAcuum uNit (DISCMAN), is a compact vacuum chamber designed to support parameter development for laser welding in microgravity. It contains a rotating platen with weld samples made from aluminum, steel, and titanium, a high-power infrared laser, and integrated pumps for pulling vacuum inside the sample cartridge. The DISCMAN payload is planned to launch to the International Space Station, where welds will be performed under sustained microgravity inside the Bishop Airlock. Another effort underway at Marshall is the Lunar Assembly and Servicing by Autonomous Robotics (LASAR) initiative. This project uses a space-rated robotic arm equipped with a laser weld head, wire feeder, and multiple cameras to perform welds in a thermal vacuum chamber simulating the lunar surface environment. Some of these welds are done on snowflake joints, which are specially designed to slot together to join segments of trussN structures, allowing for the construction of tall surface infrastructure. DISCMAN, LASAR, and other projects are being carried out to advance the technological maturity of in-space laser beam welding, collect data to inform computational models, and learn reliable processes for creating weld joints in space. This work supports NASA’s greater goals to expand humanity’s presence in low Earth orbit, establish a permanent moon base, and eventually send crewed missions to Mars and beyond.

Robotics

Improvement of Odor Control for the UWMS Hard-Sided Fecal Canister and the Alternate Fecal Canister

On longer range exploration missions, the mass and volume of critical hardware and consumables required to support crew will pose a big stowage challenge. This includes the hardware for the collection and storage of human metabolic solid waste. The amount of stowage needed for this hardware both before (empty) and after (full) use will be a significant burden on the overall spacecraft habitable volume, layout, and design. To help with this challenge, the National Aeronautics and Space Administration (NASA) Mars Campaign Office (MCO) Logistics Reduction (LR) Portfolio has developed a collapsible canister for the collection and containment of fecal deposits. The Alternate Fecal Canister (AFC) is a collapsible alternative to the exploration toilet Hard-sided Fecal Canister (HFC). The AFC in its empty state has a volumetric benefit to smaller vehicles on longer missions. The current designs for HFC and AFC were tested with human fecal material for odor containment at White Sands Test Facility (WSTF) where the tests on both were unsuccessful. The source of the lack of containment was isolated to a gasket used on both HFC and AFC. The gasket used was found to be open cell in design. This paper provides a summary of the materials selection and testing process to identify a replacement gasket material with the intention to replace the gaskets on both existing units as well as incorporate it into the designs going forward for future builds for exploration. Details will be provided on the design of the canisters interface with the odor bacteria lid which led to the selection of the thickness of the desired replacement. Finally, the paper will provide an update on the testing in advance of a return to WSTF for final testing and detail plans to complete testing and perform a demonstration on ISS with UWMS.

ECLSS

Laser Beam Welding Advancements for In-Space Servicing, Assembly, and Manufacturing

NASA is currently working to develop in-space servicing, assembly, and manufacturing (ISAM) capabilities for low Earth orbit and the lunar surface. One crucial technology for this effort is laser beam welding. Laser systems can perform joining, cleaning, cutting, and repair activities, which will enable the construction of large in-space structures that could not fit on a single launch vehicle, such as trusses for solar panels, radiators, or communications infrastructure. Multiple projects studying laser welding for space applications are currently underway at NASA Marshall Space Flight Center. One of these, the DIsk-Shaped Configurable and Modular vAcuum uNit (DISCMAN), is a compact vacuum chamber designed to support parameter development for laser welding in microgravity. It contains a rotating platen with weld samples made from aluminum, steel, and titanium, a high-power infrared laser, and integrated pumps for pulling vacuum inside the sample cartridge. The DISCMAN payload is planned to launch to the International Space Station, where welds will be performed under sustained microgravity inside the Bishop Airlock. Another effort underway at Marshall is the Lunar Assembly and Servicing by Autonomous Robotics (LASAR) initiative. This project uses a space-rated robotic arm equipped with a laser weld head, wire feeder, and multiple cameras to perform welds in a thermal vacuum chamber simulating the lunar surface environment. Some of these welds are done on snowflake joints, which are specially designed to slot together to join segments of trussN structures, allowing for the construction of tall surface infrastructure. DISCMAN, LASAR, and other projects are being carried out to advance the technological maturity of in-space laser beam welding, collect data to inform computational models, and learn reliable processes for creating weld joints in space. This work supports NASA’s greater goals to expand humanity’s presence in low Earth orbit, establish a permanent moon base, and eventually send crewed missions to Mars and beyond.

Manufacturing

Thermal Design and Thermal Vacuum Testing of the StarBurst Instrument

The StarBurst Multimessenger Pioneer is a small satellite mission serving as a wide-field gamma-ray observatory designed to capture the initial emissions of short gamma-ray bursts, electromagnetic signatures of neutron star mergers. This paper presents the final thermal design and analysis of the StarBurst Instrument, comprising the bus-to-instrument interface plate, control electronics, and twelve crystal detector units, which form the core of the mission’s science capability. The passive thermal control system design requires consideration of restrictive keep-out zones, unknown orbital parameters, and narrow temperature limits of the detectors. Also summarized is the instrument level thermal vacuum cycle test, correlated model refinements, and updated model results. Following successful completion of the instrument test campaign, the hardware was integrated with the spacecraft bus for spacecraft level testing, including additional thermal vacuum testing. The results from the spacecraft level thermal vacuum test will further inform the instrument thermal model, ensuring accurate flight temperature predictions. StarBurst launches as a secondary payload in 2027 and has a mission duration of at least one year.

StarBurst

High temperature resistant jet fuels

The thermal stability of aviation fuels is evaluated according to the ASTM D 2341 method. This characteristic is linked to the presence of generators of instability, mainly diolephins and N and S derivates. The objectives of the present work are as follows: to obtain, in the laboratory, kerosene which is thermally stable; the isolation and identification of generators of instability; and the regeneration of thermally unstable kerosenes.

Luis M. Peloche

Lunar Igneous Rocks and the Nature of the Lunar Interior

Lunar igneous rocks, properly interpreted, can give useful information about mineral assemblages and mineral chemistry as a function of depth in the lunar interior. Though intensely brecciated, terra rocks reveal, in their chemistry, evidence for a magmatic history. Partial melting of feldspathic lunar crustal material occurred in the interval 4.6 to 3.9 Gy. Melting of ilmenite-bearing cumulates at depths near 100 km produced parent magmas for Apollo 11 and 17 titaniferous mare basalts in the interval 3.8 to 3.6 Gy. Melting of ilmenite-free olivine pyroxenites (also cumulates?) at depths greater than 200 km produced low-titanium mare basalts in the interval 3.4 to 3.1 Gy. No younger igneous rocks have yet been recognized among the lunar samples and present-day melting seems to be limited to depths greater than 1000 km.

James Fred Hays

Impact of Inertia, Friction, and Backlash upon Force Control in Telemanipulation

The mechanical behavior of master controllers of telemanipulators has been a concern of both designers and implementors of telerobotic systems. In general, the literature recommends that telemanipulator systems be constructed that minimize inertia, friction, and backlash in an effort to improve telemanipulative performance. For the most part, these recommendations are founded upon theoretical analysis or simply intuition. Although these recommendations are not challenged on their merit, the material results are measured of building and fielding telemanipulators that possess less than ideal mechanical behaviors. Experiments are described in which forces in a mechanical system with human input are evaluated as a function of mechanical characteristics such as inertia, friction, and backlash. Results indicate that the ability of the human to maintain gripping forces was relatively unaffected by dynamic characteristics in the range studied, suggesting that telemanipulator design in this range should be based on task level force control requirements rather than human factors.

Neil A Duffie

Remote Sensing-Driven Hydrodynamic Modeling in Data-Scarce Regions: Integrating ICESat-2, Sentinel-2, SWOT and Re-analysis Models for Coastal Monitoring

Hydrodynamic models in coastal and estuarine systems are typically constrained by sparse bathymetry, boundary, and validation data, especially in regions where field campaigns are costly or impractical. Here we develop and test a fully satellite-driven framework for hydrodynamic modeling in South Africa’s Langebaan Lagoon without using any local in situ measurements. Bathymetry is derived by training multispectral Sentinel-2 reflectance against ICESat-2 ATL24 photon-derived depths using an XGBoost model optimized with Bayesian search. The final satellite-derived bathymetry reproduces independent ATL24 points with RMSE = 0.45 m and R 2 = 0.97. This bathymetry was used in a depth-averaged Delft3D Flexible Mesh model driven at the open boundary by TPXO tidal harmonics and by ERA5 winds. We validate modeled water surface elevation against 16 SWOT low-rate (250 m, unsmoothed) passes in 2023. SWOT–model comparisons yield an overall RMSE of 0.11 m and R 2 = 0.61, with typical point differences <0.10 m (∼7% of the 1.5 m tidal range), and showed consistent spatial gradients in water level from the offshore boundary, through Saldanha Bay, and into the lagoon. At the offshore boundary, TPXO and SWOT sea surface heights agree closely (R 2 = 0.86). A simple phase adjustment of ∼26,min between TPXO and SWOT lowers the RMSE from 0.18,m to 0.11,m, showing that phase offset accounts for some of the discrepancy, with additional errors likely linked to non-tidal signals. Our results demonstrate that combining passive optical, photon-counting LiDAR, radar interferometry, and global tidal/atmospheric models enables robust, transferrable hydrodynamic modeling in data-scarce coastal systems, offering a cost-effective pathway for monitoring.

ICESat-2

Thermal Performance of Common Bulk-Fill Cryogenic Insulation Materials in Helium and Hydrogen Background Gases

Maritime shipping of vast quantities of liquid hydrogen (LH 2 ) will be necessary to facilitate a global hydrogen ecosystem; with some studies estimating volumes up to 172,000 m 3 for individual tanker ships, and requiring stationary storage tanks at terminals of 50,000 m 3 to 100,000 m 3 —ten to fifteen times larger than the current largest tank, located at launch pad B at NASA Kennedy Space Center (KSC). Such a radical scale-up will push the boundary of traditional, vacuum-insulated tank designs. Hence, a potential need exists for non-vacuum solutions, which necessitates exploring the thermal performance of insulation materials in non-condensable background gasses at LH 2 temperatures, namely helium and hydrogen. Testing of two bulk-fill insulation materials common to large LH 2 storage tanks, perlite and glass bubbles, in helium and hydrogen was recently conducted by the Cryogenics Test Laboratory at KSC using the Cryostat-100 liquid nitrogen boiloff calorimeter per the ASTM C1774 standard methodology. Effective thermal conductivity (k e ) and heat flux (q) results for each insulation/gas combination are presented across the full vacuum range, as well as thermal profiles through the insulation thickness between 78 K and 293 K.

A M Swanger

Mariner Mars 1971 battery design, test, and flight performance

The design, integration, fabrication, test results, and flight performance of the battery system for the Mariner Mars spacecraft launched in May 1971 are presented. The battery consists of 26 20-Ah hermetically sealed nickel-cadmium cells housed in a machined magnesium chassis. The battery package weighs 29.5 kg and is unique in that the chassis also serves as part of the spacecraft structure. Active thermal control is accomplished by louvers mounted to the battery baseplate. Battery charge is accomplished by C/10 and C/30 constant current chargers. The switch from the high-rate to low-rate charge is automatic, based on terminal voltage. Additional control is possible by ground command or onboard computer. The performance data from the flight battery is compared to the data from various battery tests in the laboratory. Flight battery data was predictable based on ground test data.

Bogner, R. S.

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

Unraveling the Complex History of Aqueous Alteration and Metamorphism in CV Chondrite, Camel Donga 040

Camel Donga (CD) 040 is a CV breccia collected from Australia in 1988. Initial studies of CD 040 revealed two lithologies, both containing chondrules up to 1 mm in diameter (some with fine-grained rims) and abundant troilite, but each with remarkably different olivine compositions. Lithology 1 was characterized as petrologic type 3 material, while lithology 2 was described as being “heated to ~1100°C”. CD 040 was initially classified as an ungrouped C3; however, subsequent analyses of oxygen isotopes and bulk rock compositions confirmed that both lithologies were CV chondrite material. Though CD 040 was one of the earliest examples of a CV chondrite containing metamorphosed material, it was never extensively studied. Here we report the results of a detailed study of CD 040, focusing primarily on the petrography and mineral chemistry of metamorphosed lithology.

T L Dunn

Numerical Predictions of the Flow and Heat Transfer Characteristics in the Film Boiling Regime During Tube Quenching

Cryogenic fluid management plays a major role in refueling of spacecrafts while in space for NASA’s future human space exploration missions. Due to the low boiling points of cryogens, storage, transport and handling of these fluids becomes difficult and may result in inefficient operation of the space propulsion systems. For refueling applications in space, the cryogenic fluids have to be transported across different locations and hence, the transfer of cryogenic fluids through pipes become critical. The cryogenic chill-down process is characterized by different regimes of flow boiling, viz., film boiling, transition boiling and nucleate boiling. The prediction of these regimes in a single CFD framework available in the literature is challenging and the present work attempts to address this challenge by initially modeling the film boiling regime accurately and to incorporate an user-defined function for transition and nucleate boiling at a later stage. Hence, the aim of the present work is to numerically model and validate the film boiling regime of the chilldown curve for liquid nitrogen experiments available in the literature. The validations are carried out at different inlet mass fluxes to have a robust simulation methodology. A dispersed mixture model is used to predict the vapor-liquid interface dynamics with the phase change phenomena modeled using the Lee model.

line chilldown

Extending mARC II Arc-Jet Test Duration via Design and Implementation of Model System Cooling Sleeve

The mARC II is a 30 kW arc-jet facility at NASA Ames Research Center used to generate high-enthalpy flows for low-cost thermal protection system (TPS) technology development. Sustained operation of downstream instrumentation and material samples is constrained by thermal loading transmitted through the arc-jet test environment, limiting achievable run times and experimental throughput. This work presents the design, integration, and validation of a cooling sleeve implemented on the sweep arm drive motor feedthrough to mitigate thermal accumulation during testing. The addition of the cooling sleeve is a simple, robust upgrade that translates directly into enhanced facility capability by supporting longer run durations, reduced turnaround time, and higher throughput.

numerical simulations