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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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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS1999

Miniature Heat Transport System for Nanosatellite Technology

The scientific understanding of key physical processes between the Sun and the Earth require simultaneous measurements from many vantage points in space. Nano-satellite technologies will enable a class of constellation missions for the NASA Space Science Sun-Earth Connections. This recent emphasis on the implementation of smaller satellites leads to a requirement for development of smaller subsystems in several areas. Key technologies under development include: advanced miniaturized chemical propulsion; miniaturized sensors; highly integrated, compact electronics; autonomous onboard and ground operations; miniatures low power tracking techniques for orbit determination; onboard RF communications capable of transmitting data to the ground from far distances; lightweight efficient solar array panels; lightweight, high output battery cells; lightweight yet strong composite materials for the nano-spacecraft and deployer-ship structures. These newer smaller systems may have higher power densities and higher thermal transport requirements than seen on previous small satellites. Furthermore, the small satellites may also have a requirement to maintain thermal control through extended earth shadows, possibly up to 8 hours long. Older thermal control technology, such as heaters, thermostats, and heat pipes, may not be sufficient to meet the requirements of these new systems. Conversely, a miniature two-phase heat transport system (Mini-HTS) such as a Capillary Pumped Loop (CPL) or Loop Heat Pipe (LBP) is a viable alternative. A Mini-HTS can provide fine temperature control, thermal diode action, and a highly efficient means of heat transfer. The Mini-HTS would have power capabilities in the range of tens of watts or less and provide thermal control over typical spacecraft ranges. The Mini-HTS would allow the internal portion of the spacecraft to be thermally isolated from the external radiator, thus protecting the internal components from extreme cold temperatures during an eclipse. The Mini-HTS would transport the beat from these components to a radiator during their operational modes, and it would be shutdown during non-operational or eclipse modes. Shutdown of the Mini-HTS would be accomplished with small heaters and has been successfully demonstrated on numerous occasions, both in the lab and on flight experiments. Efforts are now underway to miniaturize two-phase heat transport systems for the Nanosatellite project, with potential application to other small satellite programs. 'ne goal of this project is to design, build, and test miniature heat transport systems (MHTS) that would demonstrate the feasibility of a small Capillary Pumped Loop (CPL) or Loop Heat Pipe (LBP).

Douglas, Donya M,↗
NASA NTRS2021

Topical: Solid Fuel Combustion in Partial and Micro-Gravity

The risk of fire remains an ever-present danger in spaceflight. Most fire safety hazards originate in or eventually involve solid fuels, whether they be cellulosic (e.g., cotton fabric), hydrocarbons (e.g., plastics) or high-energy density electrode materials (e.g., batteries). A key approach to ensuring safety has been to focus on reducing the potential flammability of these materials – achieved by limiting their ignitability, potential for flame spread, and ultimate heat-release potential if ignited [1-3]. This approach has been relatively effective despite several close calls [4]. The limits of our understanding, however, are continually being challenged as future spaceflight missions incorporate partial gravity, enhanced oxygen, new types and classes of materials (e.g., composites), and higher energy-density batteries. This presents both an exciting scientific opportunity to enhance our understanding of solid fuel combustion processes while also posing a dire threat to future long-duration missions to the Moon and Mars.

Michael Gollner↗
NASA NTRS2011

Composite Thermal Switch

Lithium primary and lithium ion secondary batteries provide high specific energy and energy density. The use of these batteries also helps to reduce launch weight. Both primary and secondary cells can be packaged as high-rate cells, which can present a threat to crew and equipment in the event of external or internal short circuits. Overheating of the cell interior from high current flows induced by short circuits can result in exothermic reactions in lithium primary cells and fully charged lithium ion secondary cells. Venting of the cell case, ejection of cell components, and fire have been reported in both types of cells, resulting from abuse, cell imperfections, or faulty electronic control design. A switch has been developed that consists of a thin layer of composite material made from nanoscale particles of nickel and Teflon that conducts electrons at room temperature and switches to an insulator at an elevated temperature, thus interrupting current flow to prevent thermal runaway caused by internal short circuits. The material is placed within the cell, as a thin layer incorporated within the anode and/or the cathode, to control excess currents from metal-to-metal or metal-to-carbon shorts that might result from cell crush or a manufacturing defect. The safety of high-rate cells is thus improved, preventing serious injury to personnel and sensitive equipment located near the battery. The use of recently available nanoscale particles of nickel and Teflon permits an improved, homogeneous material with the potential to be fine-tuned to a unique switch temperature, sufficiently below the onset of a catastrophic chemical reaction. The smaller particles also permit the formation of a thinner control film layer (<50 m), which can be incorporated into commercial high-rate lithium primary and secondary cells. The innovation permits incorporation in current lithium and lithium-ion cell designs with a minimal impact on cell weight and volume. The composite thermal switch (CTS(TradeMark)) coating can be incorporated in either the anode or cathode or both. The coating can be applied in a variety of different processes that permits incorporation in the cell and electrode manufacturing processes. The CTS responds quickly and halts current flow in the hottest parts of the cell first. The coating can be applied to metal foil and supplied as a cell component onto which the active electrode materials are coated.

McDonald, Robert↗
NASA NTRS1992

Material selection and evaluation aimed at resolving deficiencies of a space technology material

NASA-Kennedy Space Center propellant handlers' visors are undergoing conversion from Plexiglass G to a Surlyn 8920-based material; various Surlyn compositions are here subjected to a battery of environmental and mechanical-properties tests under the relevant conditions. Specially-molded Surlyn samples have exhibited much higher impact strengths than either Plexiglass G or Lexan, and passed the ANSI weight-drop test. DSC results show that Surlyn and Plexiglass G exhibit strikingly different thermal transitions.

Ray, Asit K.↗
NASA NTRS2001

Multifunctional Carbon Foams for Aerospace Applications

Carbon foams produced by the controlled thermal decomposition of inexpensive coal extracts exhibit a combination of structural and thermal properties that make them attractive for aerospace applications. Their thermal conductivity can be tailored between 0.5 and 100 W/mK through precursor selection/modification and heat treatment conditions; thus, they can serve in either thermal protection or heat transfer systems such as heat exchangers. Because their structure is essentially a 3D random network of graphite-like members, they also can be considered low-cost, easily fabricated replacements for multi-directional structural carbon fiber preforms. Strengths of over 4000 psi in compression are common. Their density can be designed between 0.1 and 0.8 g/cc, and they can be impregnated with a variety of matrices or used, unfilled, in sandwich structures. These foams also exhibit intriguing electrochemical properties that offer potential in high-efficiency fuel cell and battery applications, mandrels and tooling for composite manufacture, ablative performance, and fire resistance. This paper presents the results of research conducted under NASA SBIR Topic 99.04.01, General Aviation Technology, supported from Langley Research Center. The potential of foam design through precursor selection, cell size and density control, density grading, and heat treatment is demonstrated.

Rogers, D. K.↗
NASA NTRS2011

TPSAS-NF1676L-11812-DND

Reducing the weight of spacecraft will reduce the fabrication costs and the launch costs . The elimination of wiring and wiring harnesses reduces the total mass of the vehicle . Wireless sensor technology can reduce the weight and therefore the costs of spacecraft . The Decadal Survey of Civil Aeronautics survey identified that "self-powered, wireless microelectromechanical sensors" warrant attention over the next decade . Current wireless sensor systems have low data rates and require batteries. The environment of aerospace vehicles is often very harsh, with temperature extremes ranging from cryogenic to very high temperatures during re-entry. For example, X-37B mini unmanned shuttle will require high temperature sensors mounted on the structure, as well as cryogenic sensors for monitoring fuel tanks. Batteries do not work well in either temperature extremes. Also, sensors are typically located in internal structures with limited access, making the periodic changing of batteries costly and time consuming. Passive wireless sensors are needed that operate across an extremely large temperature range and do not require batteries. NASA recently instrumented an all Composite Crew Module for structural testing on the ground. Wireless sensors could have reduced the time to instrument the module and check out the sensor wiring.

W (Cy) Wilson↗
NASA NTRS1994

Composite Solid Electrolyte For Lithium Cells

Composite solid electrolyte material consists of very small particles, each coated with thin layer of Lil, bonded together with polymer electrolyte or other organic binder. Material offers significant advantages over other solid electrolytes in lithium cells and batteries. Features include high ionic conductivity and strength. Composite solid electrolyte expected to exhibit flexibility of polymeric electrolytes. Polymer in composite solid electrolyte serves two purposes: used as binder alone, conduction taking place only in AI2O3 particles coated with solid Lil; or used as both binder and polymeric electrolyte, providing ionic conductivity between solid particles that it binds together.

Peled, Emmanuel↗
NASA NTRSDate not supplied

Development of Flexible Energy Storage Device for Wearable Electronics using All-organic Composites

As the demands and applications of wearable electronics increase, the need of power supply for wearable electronics becomes the critical issue. Both batteries and capacitors can be used as power supplier. In terms of energy storage device, capacitors have many advantages over the batteries, but have a lower energy storage density. To improve the energy density, composites, in which inorganic particles are embedded in a polymer matrix, have been identified as a promising approach to create the dielectrics with a higher energy storage density. The physics behind the composite approach is that the inorganics have a higher dielectric constant and polymers can stand with a higher electric field so that the composites can exhibit a relative dielectric constant and stand with a relative electric field. Therefore, the composites can exhibit a higher energy storage density. However, the embedment of inorganic particles into polymer severely reduces the flexibility of the polymer. To develop flexible energy storage ultracapacitors as an energy storage device for wearable electronics, an all-organic composite approach, in which a dielectric polymer is mixed with polar organic molecules, is introduced. It is experimentally found that by adding a small amount of polar organic molecules into dielectric polymers, the polymers exhibits a high dielectric constant and can stand with a higher electric field. More importantly, the flexibility of the all-organic composites is better than the polymer matrix. Therefore, the all-organic composites can be a strong and promising candidate for the development of flexible energy storage devices for the wearable electronics. In this study, three different dielectric polymers and three different polar molecules were studied. All the all-organic composite systems exhibit a significant improvement on the energy storage density. These new flexible energy storage devices are being developed to be fabricated with on-demandadditive electronics manufacturing processes, so that they can be fabricated when needed in space on the International Space Station and planned lunar habitat and other future missions. These flexible energy storage devices will provide the storage in concert with other printed power generation devices to allow crew health and structural health monitoring sensor devices and systems to be self-powered, not requiring any external power or batteries.

energy storage↗
NASA NTRS1994

High performance positive electrode for a lead-acid battery

An electrode suitable for use as a lead-acid battery plate is formed of a paste composition which enhances the performance of the plate. The paste composition includes a basic lead sulfate, a persulfate and water. The paste may also include lead oxide and fibers. An electrode according to the invention is characterized by good strength in combination with high power density, porosity and surface area.

Kao, Wen-Hong↗
NASA NTRS2015

Mesoporous Silicon-Based Anodes

For high-capacity, high-performance lithium-ion batteries. A new high-capacity anode composite based on mesoporous silicon is being developed. With a structure that resembles a pseudo one-dimensional phase, the active anode material will accommodate significant volume changes expected upon alloying and dealloying with lithium (Li).

Peramunage, Dharmasena↗
NASA NTRSDate not supplied

Battery Pack Shape Optimization using Transient Heat Conduction Coupled with Cell-Discharge Analysis

Battery electric systems exhibit significant time-dependence, especially when evaluated in the context of an aircraft mission profile with continually changing power demands. Additionally, when evaluating battery-powered aircraft concepts, it is important to accurately compute the temperature of the batteries and properly characterize the thermal response of the system. The temperature of the batteries has a significant impact on cell performance, in addition to safety considerations of maintaining battery temperatures below their operating limit. Because of these considerations, battery models for preliminary design and optimization of aircraft should include the capability to accurately compute the temperature distribution within the battery pack. Furthermore, battery pack designs should be as light-weight as possible to maximize the pack energy density, while also considering battery temperature limits. Here, we demonstrate a simultaneous trajectory and shape optimization of a battery pack concept, using a transient heat transfer finite element model coupled with a time-varying cell-discharge battery model to provide this capability. Including the transient finite element problem in the loop enables accurate temperatures that can be passed back to the cell discharge model, while the cell discharge model can supply the finite element model with time-varying heat boundary conditions to the finite element problem, further benefiting the fidelity of the thermal response of the batteries. We first demonstrate the coupling capability between the battery cell-discharge model and the transient finite-element heat transfer through an optimization which computes the optimal current profile for the battery pack while ensuring the battery temperatures remain below their operational limit. We then build on this optimization by adding shape optimization to the problem, which allows us to consider a composite objective function which also minimizes the mass of the battery pack, while also producing an optimal current discharge profile.

Optimization↗
NASA NTRSDate not supplied

Battery Pack Shape Optimization using Transient Heat Conduction Coupled with Cell-Discharge Analysis

Battery electric systems exhibit significant time-dependence, especially when evaluated in the context of an aircraft mission profile with continually changing power demands. Additionally, when evaluating battery-powered aircraft concepts, it is important to accurately compute the temperature of the batteries and properly characterize the thermal response of the system. The temperature of the batteries has a significant impact on cell performance, in addition to safety considerations of maintaining battery temperatures below their operating limit. Because of these considerations, battery models for preliminary design and optimization of aircraft should include the capability to accurately compute the temperature distribution within the battery pack. Furthermore, battery pack designs should be as light-weight as possible to maximize the pack energy density, while also considering battery temperature limits. Here, we demonstrate a simultaneous trajectory and shape optimization of a battery pack concept, using a transient heat transfer finite element model coupled with a time-varying cell-discharge battery model to provide this capability. The transient finite-element analysis is done using TACS, and the cell-discharge battery model uses OpenMDAO and dymos. Including the transient finite element problem in the loop enables accurate temperatures that can be passed back to the cell discharge model, while the cell discharge model can supply the finite element model with time-varying heat boundary conditions, further benefiting the fidelity of the thermal response of the batteries. We first demonstrate the coupling capability between the battery cell-discharge model and the transient finite-element heat transfer through an optimization which computes the optimal current profile for the battery pack while ensuring the battery temperatures remain below their operational limit. We then build on this optimization by adding shape optimization to the problem, which allows us to consider a composite objective function which also minimizes the mass of the battery pack, while also producing an optimal current discharge profile.

Optimization↗
NASA NTRS2003

Time-Dependent Material Data Essential for the Durability Analysis of Composite Flywheels Provided by Compressive Experiments

Successful spaceflight operations require onboard power management systems that reliably achieve mission objectives for a minimal launch weight. Because of their high specific energies and potential for reduced maintenance and logistics, composite flywheels are an attractive alternative to electrochemical batteries. The Rotor Durability Team, which comprises members from the Ohio Aerospace Institute (OAI) and the NASA Glenn Research Center, completed a program of elevated temperature testing at Glenn' s Life Prediction Branch's Fatigue Laboratory. The experiments provided unique design data essential to the safety and durability of flywheel energy storage systems for the International Space Station and other manned spaceflight applications. Analysis of the experimental data (ref. 1) demonstrated that the compressive stress relaxation of composite flywheel rotor material is significantly greater than the commonly available tensile stress relaxation data. Durability analysis of compression preloaded flywheel rotors is required for accurate safe-life predictions for use in the International Space Station.

Thesken, John C.↗
NASA NTRS2002

Scanning Ultrasonic Spectroscopy System Developed for the Inspection of Composite Flywheels

Composite flywheels are being considered as replacements for chemical batteries aboard the International Space Station. A flywheel stores energy in a spinning mass that can turn a generator to meet power demands. Because of the high rotational speeds of the spinning mass, extensive testing of the flywheel system must be performed prior to flight certification. With this goal in mind, a new scanning system has been developed at the NASA Glenn Research Center for the nondestructive inspection of composite flywheels and flywheel subcomponents. The system uses ultrasonic waves to excite a material and examines the response to detect and locate flaws and material variations. The ultrasonic spectroscopy system uses a transducer to send swept-frequency ultrasonic waves into a test material and then receives the returning signal with a second transducer. The received signal is then analyzed in the frequency domain using a fast Fourier transform. A second fast Fourier transform is performed to examine the spacing of the peaks in the frequency domain. The spacing of the peaks is related to the standing wave resonances that are present in the material because of the constructive and destructive interferences of the waves in the full material thickness as well as in individual layers within the material. Material variations and flaws are then identified by changes in the amplitudes and positions of the peaks in both the frequency and resonance spacing domains. This work, conducted under a grant through the Cleveland State University, extends the capabilities of an existing point-by-point ultrasonic spectroscopy system, thus allowing full-field automated inspection. Results of an ultrasonic spectroscopy scan of a plastic cylinder with intentionally seeded flaws. The result of an ultrasonic spectroscopy scan of a plastic cylinder used as a proof-of-concept specimen is shown. The cylinder contains a number of flat bottomed holes of various sizes and shapes. The scanning system was able to successfully detect all the defects in the material. Ultrasonic spectroscopy results for a second specimen are shown along with a conventional ultrasonic C-scan. The second specimen is a section of a flywheel subcomponent that has a series of drilled holes and notches. This specimen is employed as a defect detection standard to evaluate the various nondestructive evaluation methods under consideration. Scanning results demonstrate the ability of the system to detect flaws on the order of 10 mils in the radial direction and 5 mils in the circumferential direction. Work conducted to date has shown that scanning ultrasonic spectroscopy is a viable tool for the inspection of composite flywheel systems. Ongoing development work is focused on refining the system and scanning parameters for improved resolution and defect detection.

Martin, Richard E.↗
NASA NTRSDate not supplied

Design and Analysis of Battery Thermal Management Systems

Thermal management of battery cell packs is a critically needed technology. The purpose of this work is to design new and improved Battery Thermal Management Systems (BTMS) for use in electric airplanes. The BTMS should be 3D printable and hold twelve to sixteen 18650 batteries. To minimize aircraft’s weight, an actively air-cooled battery pack was chosen to avoid the excess weight of water-cooled and phase change material (PCM) cooled packs. As a result, significant changes were made to remove all metal in the pack and replace it with lower density polymer matrix composites (PMCs) which can be additively manufactured. Two air cooled battery pack configurations (traditional propeller fans & bladeless fans) were designed, modeled, and compared. These packs were first modeled in SolidWorks 2021 3D CAD, then imported into COMSOL MultiPhysics to be studied using the “Heat Transfer in Solids and Fluids” module. The design with the bladeless fans eliminated the need to use high conductivity heavy metal to remove unwanted thermal energy. These bladeless fans were designed entirely out of PMCs. This thermal pack design weighs 0.04 kg less than that of the traditional propeller fans design and has increased the battery pack energy density by 8.25 Wh/kg.

Thermal Management System for Battery Packs↗
NASA NTRS1992

Composite overwrapped nickel-hydrogen pressure vessels

The presentation is made in viewgraph format, the first of which states the purpose, which is to stimulate interest in composite overwrapped pressure vessel technology as applied to nickel hydrogen battery pressure vessels. The next viewgraph presents the history of nickel hydrogen pressure vessels over the last 15 years including materials, operating conditions, and market expansion to internationals. Basic materials properties are itemized such as thermal conductivity, corrosion resistance, and strength to weight ratio. The monolithic and composite overwrapped construction approaches are compared. A detailed description is presented of the advantages of composite overwrapped pressure vessels showing weight savings, manufacturing schedule reductions, and improved fatigue life. A discussion is also presented of B-1 application, the wide range of usable materials, and a sketch of a possible optimized design.

Reagan, John↗
NASA NTRS2004

Time-Temperature Dependent Response of Filament Wound Composites for Flywheel Rotors

Flywheel energy storage offers an attractive alternative to battery systems used in space applications such as the International Space Station. Rotor designs capable of high specific energies benefit from the load carrying capacity of hoop wound carbon fibers but their long-term durability may be limited by time-temperature dependent radial deformations. This was investigated for the carbon/epoxy rotor material, IM7/8552. Coupon specimens were sectioned from filament wound panels. These were tested in compression and tension at room temperature (RT), 95 and 135 C for strain rates from 5x10(exp -6) per second to 5x10(exp -3) per second. Time, temperature and load sign dependent effects were significant transverse to the fiber. At -0.5 percent strain for 72 hr, compressive stresses relaxed 16.4 percent at 135 C and 13 percent at 95 C. Tensile stresses relaxed only 7 percent in 72 hr at 135 C for 0.5 percent strain. Using linear hereditary material response and Boltzmann s principle of superposition to describe this behavior is problematic if not intractable. Micromechanics analysis including the effects of processing residual stresses is needed to resolve the paradoxes. Uniaxial compressive stress relaxation data may be used to bound the loss of radial pre-load stresses in flywheel rotors.

Thesken, John C.↗