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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 NTRSDate not supplied

A Prognostics Framework for Battery Health Monitoring Integrated with Thermal Modeling

Urban Air Mobility (UAM) promises to revolutionize transportation in major cities, offering passenger travel, cargo delivery, and emergency medical services through a network of electric vertical takeoff and landing (eVTOL) aircraft. However, the limited range of current eVTOLs, due to the low specific energy of lithium-ion batteries along with a possibility of thermal runaway conditions poses significant safety concerns, leading to potentially compromising operational safety. To address this critical challenge, researchers are actively evaluating the impact of flight and environmental conditions on onboard lithium-ion battery health. This involves carefully assessing the performance of battery packs under laboratory and operational conditions for developing models to estimate future health using prognostics framework. This study examines the effectiveness of evaluating battery degradation leading to catastrophic failures under varying operational conditions in laboratory. These are captured using physics based models of underlying phenomenons and integrated into the prognostics framework. A fully charged battery undergoes controlled discharge cycles at varying C-rates based on the simulated power draw profile, with current and voltage, temperature data recorded throughout the experiment. The observed data provides valuable insights into how different operating conditions and mission profiles affect battery performance. This information is crucial for developing strategies to optimize battery systems, enhance range, and ultimately ensure the safe and reliable operation of UAM vehicles.

Thermal Modeling↗

NASA NTRSDate not supplied

A Prognostics Framework for Battery Health Monitoring Integrated with Thermal Modeling

Thermal Modeling↗

NASA NTRS2026

Fuel Heating System Design and Thermal Modeling for Aviation Combustion Research

Aviation fuels offer substantial heat-sink capability that can be applied to aircraft thermal-management strategies and advanced propulsion-system concepts. Accurate control of fuel temperature is critical for understanding combustion behavior and supporting high temperature fuel experimental studies. This work describes the modeling and experimental validation of a portable, high temperature fuel-conditioning system designed for multiple NASA Glenn Research Center’s combustion facilities. The system utilizes a circulating-oil heating unit and modular tube-in-tube heat exchangers capable of conditioning Jet-A to temperatures approaching 600 K. A Thermal Desktop model was created to analyze heat exchanger configurations and predict performance across a range of operating conditions. Model predictions were compared with measurements collected in the CE-13C test facility, showing good agreement across the tested flow range except at low fuel flow rate around 2 kg/hr. Results provide guidance for sizing future fuel heating system for combustion research applications.

Jet fuel heating system↗

DOE OSTI2024

Highly Ordered Eutectic Mesostructures via Template‐Directed Solidification within Thermally Engineered Templates

Template-directed self-assembly of solidifying eutectics results in emergence of unique microstructures due to diffusion constraints and thermal gradients imposed by the template. Here, the importance of selecting the template material based on its conductivity to control heat transfer between the template and the solidifying eutectic, and thus the thermal gradients near the solidification front, is demonstrated. Simulations elucidate the relationship between the thermal properties of the eutectic and template and the resultant microstructure. The overarching finding is that templates with low thermal conductivities are generally advantageous for forming highly organized microstructures. When electrochemically porosified silicon pillars (thermal conductivity < 0.3 Wm −1 K −1 ) are used as the template into which an AgCl-KCl eutectic is solidified, 99% of the unit cells in the solidified structure exhibit the same pattern. In contrast, when higher thermal conductivity crystalline silicon pillars (≈100 Wm −1 K −1 ) are utilized, the expected pattern is only present in 50% of the unit cells. The thermally engineered template results in mesostructures with tunable optical properties and reflectances nearly identical to the simulated reflectances of perfect structures, indicating highly ordered patterns are formed over large areas. This work highlights the importance of controlling heat flows in template-directed self-assembly of eutectics.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Probing the fatigue enhancement in a thermally aged cast duplex stainless steel by in situ neutron diffraction

After long-term thermal aging at 400 °C for 3000 h and 10,000 h, a cast duplex stainless steel exhibits promoted fatigue performance, including enhanced three-stage cyclic hardening and prolonged fatigue life. Utilizing in situ neutron diffraction, the phase-specific stresses are resolved, and their evolutions over entire fatigue cycling reveal the underlying mechanisms of the fatigue enhancement. It is found that the ferrite phase bears a much higher stress than the austenite matrix under both as-received and aged conditions. The enhanced cyclic hardening in Stage I is attributed to the strengthening of both phases due to thermal aging, while the enhancement in Stage III results from the martensitic transformation induced strengthening. The fatigue life is prolonged thanks to the cyclic hardening and the delay of martensitic transformation in the austenite phase after thermal aging.

Yu, Dunji [ORNL] (ORCID:0000000189467851)↗

DOE OSTI2024

Thermally unstable roosts influence winter torpor patterns in a threatened bat species

Abstract Many hibernating bats in thermally stable, subterranean roosts have experienced precipitous declines from white-nose syndrome (WNS). However, some WNS-affected species also use thermally unstable roosts during winter that may impact their torpor patterns and WNS susceptibility. From November to March 2017–19, we used temperature-sensitive transmitters to document winter torpor patterns of tricolored bats (Perimyotis subflavus) using thermally unstable roosts in the upper Coastal Plain of South Carolina. Daily mean roost temperature was 12.9 ± 4.9°C SD in bridges and 11.0 ± 4.6°C in accessible cavities with daily fluctuations of 4.8 ± 2°C in bridges and 4.0 ± 1.9°C in accessible cavities and maximum fluctuations of 13.8 and 10.5°C, respectively. Mean torpor bout duration was 2.7 ± 2.8 days and was negatively related to ambient temperature and positively related to precipitation. Bats maintained non-random arousal patterns focused near dusk and were active on 33.6% of tracked days. Fifty-one percent of arousals contained passive rewarming. Normothermic bout duration, general activity and activity away from the roost were positively related to ambient temperature, and activity away from the roost was negatively related to barometric pressure. Our results suggest ambient weather conditions influence winter torpor patterns of tricolored bats using thermally unstable roosts. Short torpor bout durations and potential nighttime foraging during winter by tricolored bats in thermally unstable roosts contrasts with behaviors of tricolored bats in thermally stable roosts. Therefore, tricolored bat using thermally unstable roosts may be less susceptible to WNS. More broadly, these results highlight the importance of understanding the effect of roost thermal stability on winter torpor patterns and the physiological flexibility of broadly distributed hibernating species.

Biodiversity & Conservation↗

DOE OSTI2025

Chlorine isotope separations using thermal diffusion

In a chloride molten salt fast reactor (Cl-MSFR), the fuel salt might be comprised of a specific eutectic composition of alkali and alkaline chlorides that solubilize major and minor actinide chlorides as the fertile component(s). Each of the chloride species contain the natural abundance ( 35 Cl ~76% and 37 Cl ~24%) of the two stable isotopes of chlorine 35 Cl and 37 Cl. There has been an ongoing controversy for the operation of the Cl-MSFRs concerning the potential of the 35 Cl(n,γ) 36 Cl, 35 Cl(n,p) 35 S, 35 Cl(n,α) 32 S reactions to produce 36 Cl, 32 S, and 32 P at relevant energies [Bulmer 1956]. The undesirable attributes of irradiated 35 Cl are enumerated further below.

07 ISOTOPE AND RADIATION SOURCES↗

NASA NTRS2026

A Modular Conjugate Heat Transfer Optimization Framework for Thermal Management of Electric Aircraft

Conjugate heat transfer (CHT) analysis and optimization is a powerful method for improving thermal management, as it simultaneously resolves the temperature distribution in both fluid and solid domains. This paper presents a modular, discrete adjoint-based CHT optimization capability integrated within the OpenMDAO/MPhys framework. A unique feature of the proposed framework is its flexibility to extend to multidisciplinary optimization, including aero-structural-thermal applications. The fluid domain is modeled using a finite-volume Computational Fluid Dynamics (CFD) solver, and the solid domain with a conduction heat transfer solver. A mixed Neumann-Dirichlet boundary condition is developed to enable full submersion of the solid geometry within the fluid domain, while ensuring consistent temperature and heat flux coupling at the CHT interface. Gradient-based optimization is performed; the gradients are efficiently computed using the discrete adjoint solvers implemented in DAFoam. To demonstrate the method, this paper considers two cases related to electric aircraft thermal management: a U-bend heat exchanger and an actively cooled battery pack. The U-bend case aims to minimize pressure loss while maximizing heat flux by changing the pipe geometry. The optimized design reduces pressure loss by 52.7% and increases total heat flux by 2.3%. In the battery pack case, a 3-by-3 cell configuration is cooled by ambient airflow, with constant heat generation prescribed in the cells. The battery casing shape serves as the design variable, and the objective function is a weighted sum of pressure loss and pack weight, subject to a maximum temperature constraint. The optimized design achieves a 44.6% reduction in pressure loss and a 1.5% reduction in weight, while satisfying the thermal constraint. To ensure the reliability of the optimized designs, this study validates coarse-mesh, steady-state predictions against fine-mesh unsteady simulations, demonstrating consistency within acceptable errors. This work demonstrates the potential of the developed framework to enable rapid, high-fidelity design of thermal management systems for electric aircraft.

heat transfer↗

DOE OSTI2026

Flash Heating of a Hollow Rod to Determine Thermal Properties

In a nuclear reactor, prolonged exposure to high neutron flux levels can change material properties of reactor components. Due to the danger posed to personnel by highly radioactive components such as spent fuel, noncontact methods must be used to determine these properties. The objective of the current research is to test the viability of using a flash-heating method to determine the thermal diffusivity of a silicon carbide (SiC) tube, which could be used as cladding for a nuclear fuel rod. The flash-heating experiment was conducted at Oak Ridge National Laboratory and temperature results were analyzed as a two-Dimensional cross section which assumed axial symmetry. The model was fitted iteratively to the temperature measurements using nonlinear regression which required values for thermal diffusivity, Biot number and a term to determine the magnitude of the heat absorbed by the flash. The method could be expanded in the future to estimate the thermal diffusivity of spent nuclear fuel rods in an effort to increase the certainty of new reactor designs using precise thermal properties throughout the core life. A statistical analysis of the results of this work is provided as part of the analysis.

McMasters, Robert L [Virginia Military Institute, ↗

NASA NTRS1993

Charge-exchange erosion studies of accelerator grids in ion thrusters

A particle simulation model is developed to study the charge-exchange grid erosion in ion thrusters for both ground-based and space-based operations. Because the neutral gas downstream from the accelerator grid is different for space and ground operation conditions, the charge-exchange erosion processes are also different. Based on an assumption of now electric potential hill downstream from the ion thruster, the calculations show that the accelerator grid erosion rate for space-based operating conditions should be significantly less than experimentally observed erosion rates from the ground-based tests conducted at NASA Lewis Research Center (LeRC) and NASA Jet Propulsion Laboratory (JPL). To resolve this erosion issue completely, we believe that it is necessary to accurately measure the entire electric potential field downstream from the thruster.

Xiaohang Peng↗

NASA NTRSDate not supplied

NASA Small Spacecraft and Distributed Systems: Recent and Upcoming Technology Demonstrations and Development Efforts

NASA’s Small Spacecraft & Distributed Systems (SSDS) program strengthens U.S. ability to conduct unique missions by rapidly developing and demonstrating capabilities for SmallSat exploration, science, and commercial space. In collaboration with NASA Centers, other government agencies, commercial industry, and academia, SSDS advances next generation SmallSat technologies like power, processing, propulsion, communications, autonomous navigation, architectures (swarms), and applications (AI/ML/Edge Computing)—to extend missions beyond LEO into cislunar and planetary space. Various investment mechanisms exist for SSDS to select and fund projects that will ultimately advance NASA’s Moon to Mars Architecture. Presented here are the latest achievements and findings from recently completed SSDS projects, along with updates from ongoing efforts and planned future work. Successful missions like Starling and CAPSTONE continue to demonstrate their capability after several years on-orbit. Advancements in next generation swarm configurations are being implemented by Starling for space traffic monitoring and management applications. Findings from recent SSDS flight projects are discussed: DiskSat, a unique SmallSat platform alternative to canisterized nanosatellites, launched December 2025 and is gathering data; the PTD series of missions concluded in December 2025. Current SSDS efforts are focused on addressing NASA Shortfalls relating to rendezvous and proximity operations, neuromorphic computing, and space situational awareness.

Roger Hunter↗

DOE OSTI2025

Microstructure, mechanical, and thermal properties of compositionally complex (Hf,Zr,Nb,Ti)B 2 ‒LaB 6 ceramics

Novel compositionally complex borides, (Hf,Zr,Nb,Ti)B 2 and (Hf,Zr,Nb,Ti)B 2 ‒LaB 6 , were fabricated using spark plasma sintering process. (Hf,Zr,Nb,Ti)B 2 ‒LaB 6 exhibits a dual-phase microstructure, in which (Hf,Zr,Nb,Ti)B 2 is a primary phase with the hexagonal structure and LaB 6 is a secondary phase with a cubic structure. The mechanical properties of both (Hf,Zr,Nb,Ti)B 2 and (Hf,Zr,Nb,Ti)B 2 ‒LaB 6 are comparable, with a combination of high hardness and moderate fracture toughness. Thermal diffusivity and conductivity of (Hf,Zr,Nb,Ti)B 2 are much lower than the individual transition metal borides but are significantly increased by the addition of LaB 6 . Herein, it is implied that the thermal properties of boride ceramics can be controlled through the appropriate design of principal metal element compositions.

borides↗

NASA NTRS1994

Resistance of Silicon Nitride Turbine Components to Erosion and Hot Corrosion/Oxidation Attack

Silicon nitride turbine components are under intensive development by AlliedSignal to enable a new generation of higher power density auxiliary power systems. In order to be viable in the intended applications, silicon nitride turbine airfoils must be designed for survival in aggressive oxidizing combustion gas environments. Erosive and corrosive damage to ceramic airfoils from ingested sand and sea salt must be avoided. Recent engine test experience demonstrated that NT154 silicon nitride turbine vanes have exceptional resistance to sand erosion, relative to superalloys used in production engines. Similarly, NT154 silicon nitride has excellent resistance to oxidation in the temperature range of interest - up to 1400 C. Hot corrosion attack of superalloy gas turbine components is well documented. While hot corrosion from ingested sea salt will attack silicon nitride substantially less than the superalloys being replaced in initial engine applications, this degradation has the potential to limit component lives in advanced engine applications. Hot corrosion adversely affects the strength of silicon nitride in the 850 to 1300 C range. Since unacceptable reductions in strength must be rapidly identified and avoided, AlliedSignal and the NASA Lewis Research Center have pioneered the development of an environmental life prediction model for silicon nitride turbine components. Strength retention in flexure specimens following 1 to 3300 hour exposures to high temperature oxidation and hot corrosion has been measured and used to calibrate the life prediction model. Predicted component life is dependent upon engine design (stress, temperature, pressure, fuel/air ratio, gas velocity, and inlet air filtration), mission usage (fuel sulfur content, location (salt in air), and times at duty cycle power points), and material parameters. Preliminary analyses indicate that the hot corrosion resistance of NT154 silicon nitride is adequate for AlliedSignal's initial engine applications. Protective coatings and/or inlet air filtration may be required to achieve required ceramic component lives in more aggressive environments.

Nitride↗

NASA NTRS1991

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↗

NASA NTRS1994

Extended Duration Orbiter Medical Project Microbial Air Sampler (STS-50/USML-1)

The Microbial Air Sampler was used on mission days 1, 7, and 13 in the Spacelab during STS-50/USML-1. Microbial air samples were collected using two types of media strips containing agar (Rose Bengal for yeast and molds, TSA for bacteria). The bacterial level found on day 1 was lower than experienced on previous Spacelab missions. A high level of fungi was present on day 1, however subsequent samples on days 7 and 13 did not indicate fungal growth. Bacterial growth was also minimized in this microgravity environment as the mission progressed. No pathogenic microorganisms were isolated, and the health risk from airborne microbes was minimal throughout the mission.

Duane L Pierson↗

DOE OSTI2024

QED corrections to the thermal neutrino interaction rate

Abstract Motivated by precision computations of neutrino decoupling at MeV temperatures, we show how QED corrections to the thermal neutrino interaction rate can be related to the electron-positron spectral function as well as an effective$$\overline{\nu }\nu \gamma $$vertex. The spectral function is needed both in a timelike and in a spacelike domain, and for both of its physical polarization states (transverse and longitudinal with respect to spatial momentum). Incorporating an NLO evaluation of this spectral function, an estimate of the$$\overline{\nu }\nu \gamma $$vertex, and HTL resummation of scatterings mediated by soft Bose-enhancedt-channel photons, we compute the interaction rate as a function of the neutrino momentum and flavour. Effects on the – (0. . .2)% level are found, noticeably smaller than a previous estimate of a related quantity.

Physics↗

NASA NTRS2026

The Future of in-Situ Sequencing-Based Microbial Monitoring: Development of a Shelf-Stable Method for Artemis and Beyond

Microbial monitoring onboard the International Space Station (ISS) is essential for assessing the efficiency of the Environmental Control and Life Support Systems (ECLSS) and providing insight into potential risk to both crew and spacecraft. Historically, this monitoring required the need to culture organisms onboard, return these cultures to Earth, and then complete the identifications, a process that would take months. Over the past decade, and through numerous payloads, advances in molecular biology have enabled in-flight microbial identifications using nanopore sequencing. The swab-to-sequencer method resulting from these efforts was transitioned from research to operations for microbial monitoring under the Crew Health Care Systems (CHeCS) BioMole. Collectively, these accomplishments have propelled the swab-to-sequencer method to be selected as the Microbial Surface Monitor (MSM) for Gateway, as well as a payload on Artemis IV. However, the lack of cold stowage availability for Artemis requires modifications to the entire method due to the thermal instability of the reagents required for sample preparation. To achieve this, new development, optimization, and validations were undertaken. Key considerations included enzyme concentration, buffer compatibility, and equal or enhanced sensitivity and specificity. At each step, thorough side-by-side comparisons with the current ISS method were performed. The development of a robust shelf-stable method will ensure continued sequencing-based microbial monitoring for Artemis and beyond, providing data in near real-time, enhancing risk response time, and yielding clear insight into the microbiome of spacecraft.

Christian G Mena↗

DOE OSTI2026

NOx mediated formation of ε – UO 3 during thermal decomposition of uranyl nitrate hexahydrate under static air conditions

The thermal decomposition of uranyl nitrate hexahydrate in air at temperatures of 650 – 800 °C is expected to yield α – U 3 O 8 through intermediate UO 3 phases. Here, n this study, Raman spectroscopy complimented by powder X-ray diffraction revealed the unexpected formation of ε – UO 3 as an accompanying phase during thermal decomposition of UNH at 700 °C under static air conditions. Experiments demonstrated that ε – UO 3 does not form during the initial ramp up stage nor during the high temperature heating period; but instead forms during the cooling stage between 250 – 400 °C. Additional experiments revealed that UNH initially decomposes through an amorphous UO 3 intermediate prior to α – U 3 O 8 formation. Attempts to bypass the U 3 O 8 precursor in the formation of ε – UO 3 were unsuccessful, supporting the necessity of U 3 O 8 (α – U 3 O 8 in this study) in the formation of ε – UO 3 . The observed phase evolution is proposed to result from the NOx species generated during UNH thermal decomposition, which create localized oxidizing conditions within the furnace under static air conditions. Furthermore, a predominantly phase pure ε – UO 3 was synthesized under static air conditions through the addition of an extra plateau at 250 °C during the cooling step. These findings demonstrate the importance of gas-phase chemistry and cooling conditions in uranium oxide phase evolution and provide additional insight into ε – UO 3 formation pathways.

Epsilon uranium trioxide↗