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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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The 1992 NASA Aerospace Battery Workshop

This document contains the proceedings of the 23rd annual NASA Aerospace Battery Workshop, hosted by the Marshall Space Flight Center on November 15-19, 1992. The workshop was attended by scientists and engineers from various agencies of the U.S. Government, aerospace contractors, and battery manufacturers, as well as international participation in like kind from a number of countries around the world. The subjects covered included nickel-cadmium, nickel-hydrogen, nickel-metal hydride, and lithium based technologies, as well as advanced technologies including sodium-sulfur and various bipolar designs.

Brewer, Jeffrey C.

The 1997 NASA Aerospace Battery Workshop

This document contains the proceedings of the 30th annual NASA Aerospace Battery Workshop, hosted by the Marshall Space Flight Center on November 18-20, 1997. The workshop was attended by scientists and engineers from various agencies of the U.S. Government, aerospace contractors, and battery manufacturers, as well as international participation in like kind from a number of countries around the world. The subjects covered included nickel-cadmium, nickel-hydrogen, nickel-metal hydride, lithium, lithium-ion, and silver-zinc technologies, as well as various aspects of nickel electrode design.

Brewer, Jeffrey C.

The 1998 NASA Aerospace Battery Workshop

This document contains the proceedings of the 31st annual NASA Aerospace Battery Workshop, hosted by the Marshall Space Flight Center on October 27-29, 1998. The workshop was attended by scientists and engineers from various agencies of the U.S. Government, aerospace contractors, and battery manufacturers, as well as international participation in like kind from a number of countries around the world. The subjects covered included nickel-hydrogen, silver-hydrogen, nickel-metal hydride, and lithium-based technologies, as well as results from destructive physical analyses on various cell chemistries.

Brewer, Jeffrey C.

General Purpose Data-Driven System Monitoring for Space Operations

Modern space propulsion and exploration system designs are becoming increasingly sophisticated and complex. Determining the health state of these systems using traditional methods is becoming more difficult as the number of sensors and component interactions grows. Data-driven monitoring techniques have been developed to address these issues by analyzing system operations data to automatically characterize normal system behavior. The Inductive Monitoring System (IMS) is a data-driven system health monitoring software tool that has been successfully applied to several aerospace applications. IMS uses a data mining technique called clustering to analyze archived system data and characterize normal interactions between parameters. This characterization, or model, of nominal operation is stored in a knowledge base that can be used for real-time system monitoring or for analysis of archived events. Ongoing and developing IMS space operations applications include International Space Station flight control, spacecraft vehicle system health management, launch vehicle ground operations, and fleet supportability. As a common thread of discussion this paper will employ the evolution of the IMS data-driven technique as related to several Integrated Systems Health Management (ISHM) elements. Thematically, the projects listed will be used as case studies. The maturation of IMS via projects where it has been deployed or is currently being integrated to aid in fault detection will be described. The paper will also explain how IMS can be used to complement a suite of other ISHM tools, providing initial fault detection support for diagnosis and recovery

Space Propulsion

Proceedings of the 25th International Instrumentation Symposium, May 7-10, 1979, Anaheim, California

The papers deal essentially with the instrumentation needs of the transportation industry, machinery diagnostics, and energy research. The sessions covered include: acoustic emission, reentry vehicle ground and flight testing, performance of nose tip materials, instrumentation for solar heating and cooling systems, vibration measurement, data acquisition and analysis, system for aerospace pressure measurements, wind tunnel instrumentation and control, energy source instrumentation, nondestructive testing, pressure and flow measurements, automated test facilities, strain measurements, electrooptical instrumentation, thermal measurements, microcomputer applications in instrumentation and automation, flight testing, blast pressure measurement, two-phase liquid/gas mass flow measurement, and machinery monitoring and instrumentation.

Conferences

The 1995 NASA Aerospace Battery Workshop

This document contains the proceedings of the 28th annual NASA Aerospace Battery Workshop, hosted by the Marshall Space Flight Center on 28-30 Nov. 1995. The workshop was attended by scientists and engineers from various agencies of the U.S. Government, aerospace contractors, and battery manufacturers, as well as international participation in like kind from a number of countries around the world. The subjects covered included nickel-cadmium, nickel-hydrogen, nickel-metal hybride, and lithium based technologies, as well as flight and ground test data. Nickel-hydrogen modeling was also covered.

Brewer, J. C.

International Ultraviolet Explorer (IUE) spacecraft battery performance update

January 26, 1987 marks the ninth inflight aniversary of the IUE spacecraft, launched into an eccentric synchronous orbit. The orbital path has subjected the spacecraft to 18 solar eclipse seasons since launch. Nine years of inflight operations culminate a major milestone for battery support to a spacecraft, which is well in excess of the initial 3 year design life. A brief outline of events, power system characteristics, and papers presented a previous battery workshops are provided. The IUE battery cell performance is excellent with the exception of the third electrode anomaly and temperature delta between batteries. Data indicates that battery depth-of-discharge (DOD) may be more critical to extend battery life than small operational temperature deltas between batteries. It is predicted that several additional years of battery life may be obtained by a reduction in operational battery DOD.

Tiller, Smith E.

Expanding the Horizons of Polymer Aerogels

As the Space Community endeavors to reach new heights of human exploration, materials for extreme environments are at the forefront of research. One class of materials of particular focus are polymer aerogels; lightweight solids with nanoscale pore size, high internal surface area, and extremely high porosities. These interesting properties allow aerogels to act as superior thermal insulators, IR scattering filters, sensor platforms, and vibro-acoustic mitigating materials. Polymer aerogels also have the potential to combat issues found in lunar environments such as dust and radiation mitigation. Herein, past and present research, synthesis, and applications of polymer aerogels will be discussed.

Stephanie L Vivod

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

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

A Review of Pump Package Assembly Anomalies and Demonstration to Gain Motor Controller Replacement Capability

The International Space Station (ISS) generates heat within the US modules from systems used to operate the station, maintain crew health, and conduct science experiments in the orbiting laboratory. The Internal Thermal Control System (ITCS) collects this heat in water loops and transfers it to the external ammonia system for rejection to space. The ITCS uses six Pump Package Assemblies (PPA) as the motive force to circulate the water within the Lab, Node 2, and Node 3 (Node 1 is parasitic to the Lab and Node 3 ITCS loops). In the life of ISS, 3 PPAs have had to be replaced and 2 PPAs are currently showing signs of degradation. The first PPA to fail in 2003 was due to early coolant chemistry issues; the remaining pump failures and current pump degradations are determined to be related to the Pump/Fan Motor Controller (PFMC), with their individual signatures all being unique to this point. The PFMC of one of the failed PPAs was returned and testing confirmed its sub-components to be the root cause of the PPA failure. Due to the relative size and weight of the standalone PFMC in comparison to the integrated assembly, it is desired, from a launch and on-orbit stowage perspective, to replace the PFMC component of the degraded PPA instead of the entire PPA. The PPA was not designed for this capability, so on the ground demonstrations are planned using crew tools to show that the PFMC can be replaced on-orbit while maintaining full functionality. This paper will focus on the signatures of the two most recent PPA failures and the two PPAs showing signs of degradation, in addition to presenting the findings from the PFMC demonstration effort.

Aaron Rodriguez

A Review of Pump Package Assembly Anomalies and Demonstration to Gain Motor Controller Replacement Capability

The International Space Station (ISS) generates heat within the US modules from systems used to operate the station, maintain crew health, and conduct science experiments in the orbiting laboratory. The Internal Thermal Control System (ITCS) collects this heat in water loops and transfers it to the external ammonia system for rejection to space. The ITCS uses six Pump Package Assemblies (PPA) as the motive force to circulate the water within the Lab, Node 2, and Node 3 (Node 1 is parasitic to the Lab and Node 3 ITCS loops). In the life of ISS, 3 PPAs have had to be replaced and 2 PPAs are currently showing signs of degradation. The first PPA to fail in 2003 was due to early coolant chemistry issues; the remaining pump failures and current pump degradations are determined to be related to the Pump/Fan Motor Controller (PFMC), with their individual signatures all being unique to this point. The PFMC of one of the failed PPAs was returned and testing confirmed its sub-components to be the root cause of the PPA failure. Due to the relative size and weight of the standalone PFMC in comparison to the integrated assembly, it is desired, from a launch and on-orbit stowage perspective, to replace the PFMC component of the degraded PPA instead of the entire PPA. The PPA was not designed for this capability, so on the ground demonstrations are planned using crew tools to show that the PFMC can be replaced on-orbit while maintaining full functionality. This paper will focus on the signatures of the two most recent PPA failures and the two PPAs showing signs of degradation, in addition to presenting the findings from the PFMC demonstration effort.

Aaron Rodriguez

Exposure of Highly Reflective Far-Ultraviolet Coatings to LEO Environment for TRL Advancement for the Habitable Worlds Observatory

Over the past several years, our team at the NASA Goddard Space Flight Center (GSFC), in collaboration with the Jet Propulsion Laboratory (JPL) and the Naval Research Laboratory (NRL), have developed several new protected Al coating technologies with improved Far-Ultraviolet (FUV) reflectance performance and more robust environmental stability. These include Al protected with lithium-based fluoride (LiF) coatings such as hot deposited LiF (eLiF), XeF 2 -passivated LiF coatings (XeLiF), Li 3 AlF 6 overcoats, AlF 3 (plasma passivated), and XeF 2 passivated MgF 2 coatings (XeMgF 2 ). However, despite these developments, relatively little experimental information exists regarding the long-term stability of these coatings after simultaneous exposure to the Low Earth Orbit (LEO) environment. To evaluate their environmental durability and advance their Technology Readiness Level (TRL), representative samples of these coating technologies, Al+XeLiF, Al+eLiF, Al+Li 3 AlF 6 , Al+AlF 3 , Al+XeMgF 2 , and bare Al as reference samples, were flown onboard the International Space Station (ISS) as part of the Materials International Space Station Experiment 20 (MISSE-20). The MISSE platform is operated by Aegis Aerospace for relatively long-duration (e.g. 6 months) external exposure experiments in a space environment. The coatings were deposited on ULE and Zerodur substrates, and witness samples deposited on the same coatings runs, but on glass slides were left on Earth as control. A subset of the flight samples were fitted with MgF 2 windows to reduce direct exposure to atomic oxygen (AO) and charged particles, and still let through UV and other types of radiation on these samples. After approximately 6 months of exposure in the forward-facing (RAM) direction, the samples were returned to Earth and characterized by performing FUV/NUV/VIS/NIR reflectance measurements to quantify degradation, spectroscopic ellipsometry to evaluate coating thickness and optical constants, atomic force microscopy (AFM) to quantify surface roughness evolution during the flight in the ISS. The MgF 2 protective windows were also analyzed through FUV transmission measurements. Comparison with the witness samples left on the ground and with the flown bare Al samples (with just the naturally occurring Al 2 O 3 layer) provided a quantitative assessment of coating thickness variations, optical performance degradation, and morphological changes induced by prolonged exposure to the LEO environment.

Far Ultraviolet (FUV)

Microgravity Game Changers: Recent Accomplishments of Microgravity Assisted Materials Experiments on the ISS

This paper discusses important new materials, devices and technology produced in low-Earth orbit (LEO) that have been developed with funding from NASA’s In Space Production Applications (InSPA) Portfolio. In coordination with the International Space Station (ISS) National Laboratory, InSPA supports innovative small businesses and other research & development organizations to develop microgravity-assisted applications that make significant impacts in a wide variety of industries on Earth. These technology development efforts are using the microgravity of orbital space to overcome gravity-induced defects on Earth to create high-value products for terrestrial markets in the areas of semiconductors, pharmaceuticals, and communications. Through 24/7/365 operation on ISS for 25 years, coupled with commercial space transportation and services to, in, and from orbit, the microgravity environment has enabled pioneering science and significant commercial applications, including novel medical advances. World-leading researchers, innovators, and space payload developers provide compelling evidence through demonstrations on the ISS that materials processing in microgravity improves outcomes for a wide range of materials and products at all levels of the organization of matter, from quantum entities such as Bose-Einstein condensates, to crystals, alloys, composites, thin films, and photonics, to stem cells, medical diagnoses, medical treatments, and medical devices for humans. As of 2026, numerous examples proved by demonstration on ISS show the potential of these technologies in various fields. In this paper, a summary of four important experiments is presented.

microgravity medical devices

Laser Forming of Sheet Metal for In-Space Manufacturing Applications

As the in-space economy matures, the migration of typically Earth-bound manufacturing methods, such as metal forming and joining, up to space will be required to meet the increasing demand for refueling and supply depots, habitats, laboratories, lunar surface structures, and sites for deep-space exploration shipbuilding. Only in this way can the magnitude of individual structures begin to exceed what can be launched, deployed, docked, or inflated and allow true economies of scale to be unlocked in space. However, typical terrestrial methods of forming and shaping sheet metal require massive machinery with the ability to deflect reaction forces to a large mass in a fixed reference frame (Earth). To both limit up-mass required for manufacture and to mitigate the issues of reaction forces in the relative reference frames of space, a non-contact, laser-based method of forming metal sheet is proposed. NASA Marshall Space Flight Center (MSFC), in cooperation with DARPA and the University of Florida (UF), have begun investigation of non-contact methods of laser forming sheet metal in thermal vacuum (TVAC) conditions to great success. To date, several grades of aluminum, stainless steel, and titanium coupons have been formed via laser-induced internal stresses in these metals at both ambient atmosphere and vacuum conditions. Temperatures in these tests ranged from -120 to 60 C, and though the total energy required to induce strain does vary with workpiece temperature and environmental pressure, the method remains predictable and controllable for the materials investigated. It is believed that this method will revolutionize manufacturing in-space as it not only continues to build upon the capabilities of the laser (sensing, marking, cutting, drilling, joining, and now forming) as an all-in-one tool, but also reduces the need to counteract forming forces as would be required in mechanical bending. In theory, all required stress to induce bending is generated through thermal gradient and strain within the workpiece, meaning that the need for reaction control and fuel expense on-orbit will be limited. Archimedes once stated, “Give me a lever long enough and a fulcrum on which to place it, and I shall move the world”. With a laser as our lever and our workpiece its own fulcrum, we can move the world’s manufacturing into space.

Laser

The Trash Compaction Processing Systems (TCPS) Ground Unit Control Sample Testing

The Trash Compaction Processing System (TCPS) is being developed by NASA and Sierra Space to process crew trash for long-duration missions. The system compacts and thermally processes mixed spacecraft waste to reduce volume and stabilize the material while managing gas and liquid effluents. A Ground Unit (GU) located at Sierra Space in Madison, Wisconsin was used to run a series of tests using standardized control samples representing different trash conditions, including nominal, high liquid, high cloth, benign, and foam. Gas grab samples were collected during processing and analyzed to identify the compounds present in the effluent stream and compare the concentrations to the NASA spacecraft maximum allowable concentrations (SMACs). Additional testing included odor testing at White Sands Test Facility, aerosol measurements, microbiology, and tile characterization. Overall, the compounds detected in the gas samples were well below the SMAC limits for all trash models tested. The results from this testing are being used to help guide the verification approach and test planning for the TCPS Flight Unit that is planned for on-orbit testing on the International Space Station.

Control Samples

Overview of Past and Future EVA Suit Testing and Training in Chamber B at NASA JSC

The Crew and Thermal System Division’s Chamber B has received an increase in demand for next generation suit testing. Chamber B is the National Aeronautics and Space Administration (NASA) Johnson Space Center’s only human-rated thermal vacuum (TVAC) chamber. Historically it was used in Gemini, Apollo, Skylab, Shuttle, and the International Space Station (ISS) suit tests. Recently, the chamber has been returned to service with new capabilities for suit testing. In 2023, The Exploration Extravehicular Mobility Unit (xEMU) underwent a 5-day, extensive thermal vacuum test that included both a full-bodied Exploration Pressure Garment Suit (xPGS) as well as a high fidelity Short xEMU. SpaceX has also used the chamber for human-in-the-loop (HITL) qualification and acceptance testing on their flight Polaris Dawn suits for the first-ever commercial extravehicular activity (EVA). Current chamber Manlock B2 upgrades include the support of two test subjects at the same time with updated chamber interface and support systems for the next generation of suits. This paper will discuss the history of spacesuit testing in the chamber, the recent testing for commercial and NASA suits, and upgrades to accommodate new test requirements.

Polaris Dawn

Overview of Past and Future EVA Suit Testing and Training in Chamber B at NASA JSC

The Crew and Thermal System Division’s Chamber B has received an increase in demand for next generation suit testing. Chamber B is the National Aeronautics and Space Administration (NASA) Johnson Space Center’s only human-rated thermal vacuum (TVAC) chamber. Historically it was used in Gemini, Apollo, Skylab, Shuttle, and the International Space Station (ISS) suit tests. Recently, the chamber has been returned to service with new capabilities for suit testing. In 2023, The Exploration Extravehicular Mobility Unit (xEMU) underwent a 5-day, extensive thermal vacuum test that included both a full-bodied Exploration Pressure Garment Suit (xPGS) as well as a high fidelity Short xEMU. SpaceX has also used the chamber for human-in-the-loop (HITL) qualification and acceptance testing on their flight Polaris Dawn suits for the first-ever commercial extravehicular activity (EVA). Current chamber Manlock B2 upgrades include the support of two test subjects at the same time with updated chamber interface and support systems for the next generation of suits. This paper will discuss the history of spacesuit testing in the chamber, the recent testing for commercial and NASA suits, and upgrades to accommodate new test requirements.

Human-in-the-loop