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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

Stationary Testing of a Pulse Tube Cryocooler Designed to Rotate at 6800 RPM with the Superconducting Rotor of an Electric Machine

Electrified aircraft are being developed to increase the efficiency and reduce the cost of operating subsonic transport aircraft. Achieving a substantial impact necessitates focusing on single- and twin-aisle aircraft which use propulsion systems with >20 MW ratings. For these aircraft, multi-MW superconducting electric machines are being developed due to their high specific power and high efficiency. Most of these electric machines employ superconductors on their rotor, thereby requiring cryogenic cooling of the rotating system. An attractive solution is to conductively cool the rotor using a cryocooler that rotates with the rotor. NASA has been developing a 50 K pulse tube cryocooler for its High Efficiency Megawatt Motor (HEMM) that can operate while rotating at up to 6,800 rpm. The first non-rotating tests of the fully assembled HEMM cryocooler have been completed, and initial testing has yielded a no-load temperature of 112 K. A small helium leak into the vacuum system has been identified as the major bottleneck to performance, and based on measurements with the motor turned off there is an observed vacuum-side heat leak of approximately 30 W at 115 K. Immediate next steps for testing are to locate and mitigate the apparent helium leaks into the vacuum chamber. Thus far, compressor performance and the apparent heat lift after correcting for the heat leak are on par with expectations.

Electrified Aircraft Propulsion↗
NASA NTRS1993

The Flight Performance of the Galileo Orbiter USO

Results are presented from an analysis of radio metric data received by the DSN stations from the Galileo spacecraft using an Ultrastable Oscillator (USO) as a signal source. These results allow the health and performance of the Galileo USO to be evaluated, and are used to calibrate this Radio Science instrument and the data acquired for Radio Science experiments such as the Red-shift Observation, Solar Conjunction, and Jovian occultations. Estimates for the USO-referenced spacecraft-transmitted frequency and frequency stability were made for 82 data acquisition passes conducted between launch (October 1989) and November 1991. Analyses of the spacecraft-transmitted frequencies show that the USO is behaving as expected. The USO was powered off and then back on in August 1991 with no adverse effect on its performance. The frequency stabilities measured by Allan deviation are consistent with expected values due to thermal wideband noise and the USO itself at the appropriate time intervals. The Galileo USO appears to be healthy and functioning normally in a reasonable manner.

D D Morabito↗
NASA NTRS2026

Artemis Suit Material Effects of Calendaring Woven Fabrics on Dust Resistance

This paper presents one element of an ongoing NASA technology-infusion effort to design, fabricate, and test a new outer shell fabric for a lunar Extravehicular Activity (EVA) space suit, a critical component of sustained lunar exploration. A primary challenge for suit textiles is preventing lunar dust, which is highly abrasive, electrostatically charged, and capable of infiltrating even tightly woven fabrics from penetrating the Environment Protection Garment (EPG) and compromising suit durability and astronaut safety. To enhance dust-blocking performance, the Artemis Suit Materials Team investigated calendaring, a continuous roll to roll mechanical finishing process in which fabric passes through heated rollers under high pressure to compress and flatten the weave, thereby reducing pore size and modifying surface texture without significantly affecting other properties. Targeted testing of calendared Teflon™ T-162 and Ortho Fabric samples provides new insight into how calendaring influences dust resistance, informing future material development and advancing EVA suit technology for long-duration lunar missions.

Dust↗
NASA NTRS2026

Artemis Suit Material Effects of Calendaring Woven Fabrics on Dust Resistance

This paper presents one element of an ongoing NASA technology-infusion effort to design, fabricate, and test a new outer shell fabric for a lunar Extravehicular Activity (EVA) space suit, a critical component of sustained lunar exploration. A primary challenge for suit textiles is preventing lunar dust, which is highly abrasive, electrostatically charged, and capable of infiltrating even tightly woven fabrics from penetrating the Environment Protection Garment (EPG) and compromising suit durability and astronaut safety. To enhance dust-blocking performance, the Artemis Suit Materials Team investigated calendaring, a continuous roll to roll mechanical finishing process in which fabric passes through heated rollers under high pressure to compress and flatten the weave, thereby reducing pore size and modifying surface texture without significantly affecting other properties. Targeted testing of calendared Teflon™ T-162 and Ortho Fabric samples provides new insight into how calendaring influences dust resistance, informing future material development and advancing EVA suit technology for long-duration lunar missions.

Dust↗
NASA NTRS2026

Influences of Introduced Yttrium Oxide Particles on Superalloy 718

Additive manufacturing has proven useful for introducing oxide particles into superalloys, to provide oxide dispersion strengthening (ODS) at high temperatures. This study screened how such an approach can influence microstructure and failure modes for superalloy 718. The objective of this study was to compare tensile and creep failure modes for additively manufactured superalloy 718 having introduced oxide particles. Fine yttrium-oxide (yttria) particles were introduced into 718 powder using two different powder mixing methods. Additive manufacturing by laser powder bed fusion was then used to prepare specimen blanks for each case, oriented parallel and transverse to the building direction. These were subsequently given consistent stress relief, hot isostatic pressurization, and final heat treatments, then subjected to tensile and creep tests at varied temperatures. Additively manufactured 718 without ODS (“no-ODS”) had nearly equiaxed grains at 50 μm in width. Roll-mixed ODS material had a bimodal grain size distribution, with fine grains at 9 μm and coarse grains at 66 μm in average width. The fine grains were elongated about 5x in the building direction. Acoustic-mixed ODS materials had grains at 10 μm in width that were elongated about 10x in the build direction. Compared to no-ODS, roll-mixed and acoustic mixed ODS materials did not show improved tensile strengths at room temperature, 760 °C, and 1093 °C. The tensile failure strains parallel to the building direction of roll-mixed ODS material were lowest in these tests. Flattened clumps of yttria had formed transverse to the building direction in roll-mixed material, which were easily cracked. Creep rupture response at 760 °C in the building direction was highest for acoustic-mixed material test. Creep tests at 1093 °C showed varied results, with low rupture lives associated with enhanced cavitation at grain boundaries and surface oxidation. Transverse to the building direction, all three materials had low failure strains in tests at 760 °C. The elongated grain boundaries failed readily in all transverse specimens tested at 760 °C and 1093 °C.

oxide dispersion strengthening↗
NASA NTRSDate not supplied

Battery Relevant Cell Side Wall Rupture Characterization

The propensity for a cell design to experience can side wall rupture (SWR) during thermal runaway is highly influenced by how a battery design mechanically constrains its cells. Testing cells while unsupported has been found to yield false negative results that don't represent this risk in a battery configuration. This talk addresses how to verify the adequacy of battery design measures used to control SWR and how to get results relevant, accurate, and statistically defendable for a proposed battery design.

thermal runaway↗
NASA NTRSDate not supplied

Automatic Dependent Surveillance-Broadcast (ADS-B) In-Trail Procedures (ITP)

Aircraft in oceanic and remote non-radar airspace frequently fly for extended periods of time in the same direction, at the same time, along similar flight paths as other aircraft. Since there is no radar surveillance, controllers use procedural separation to ensure that aircraft remain separated. Procedural separation distances are typically larger than radar separation distances and as a result aircraft operating in oceanic airspace are sometimes held at non-optimal flight levels due to conflicting traffic at intervening flight levels. Automatic Dependent Surveillance-Broadcast (ADS-B) In-Trail Procedures (ITP) were developed to enable flight level change maneuvers that would otherwise not be possible with current procedural separation standards. Aircraft operators choosing to equip with an ADS-B transceiver and an appropriate onboard decision support system would be able to take advantage of these procedures when operating in proximity to aircraft equipped with a suitable ADS-B transmitter (“ADS-B Out”). The ability to perform in-trail maneuvers to achieve more time at optimum altitudes could result in more efficient and predictable flight profiles thereby saving fuel and in some cases allowing operators to make beneficial operational decisions. NASA first began developing ADS-B ITP in 2003 as a result of a desire to develop methodologies, concepts, and procedures to reduce separation requirements for future air transportation systems using airborne ADS-B. The objectives were to provide insight into the details necessary to reduce separation requirements for the future and to develop applications that could provide incentives for operators to voluntarily equip with transformational technologies. From 2003 to 2008, NASA conducted research that supported the development of ITP including batch simulations, human-in-the-loop experiments and avionics and separation standards development. This research showed enough maturity and benefit that in 2008, the FAA Surveillance and Broadcast Services (SBS) program adopted ADS-B ITP as one of their three key, near-term applications to make use of ADS-B-In. The FAA developed an agreement with NASA to transition the technology and established an FAA project for the purpose of performing an operational trial of ADS-B ITP in revenue service in the summer of 2011. The objectives of the project are to a) validate the operational performance and economic benefits of ITP; and b) develop and validate ADS-B ITP Minimum Operational Performance Specifications (MOPS) material. As a part of this project, the FAA established agreements with United Airlines and Honeywell. The agreements include the work necessary for the development, certification and installation of onboard systems for twelve United Airlines 747-400s. ITP system development is nearly complete and certification activities are underway. The FAA project has also been working with Oakland Oceanic Control Center (ZOA) and the FAA’s Oceanic and Offshore Operations Office to develop controller procedures and safety analyses that are required to support the flight trial. The FAA has also been working on the development of an ITP Operational Specification that should be approved this April. The presentation will cover some of the key aspects of the development, challenges, and integration required to successfully transition ADS-B ITP from a concept in 2003 to flight trials in revenue service in 2011.

Kenneth M Jones↗
NASA NTRS1983

The Telecommunications and Data Acquisition Progress Report 42-74

This publication reports on developments in programs managed by JPL's office of Telecommunications and Data Acquisition (TDA). In space communications, radio navigation, radio science, and ground based radio astronomy, it reports on activities of the Deep Space Network (DSN) and its associated Ground Communications Facility (GCF) in planning, in supporting research and technology, in implementation and in operations. In geodynamics, the publication reports on the application of radio interferometry at microwave frequencies for geodynamic measurements. This publication also reports on implementation and operations for searching the microwave spectrum.

E C Posner↗
NASA NTRS1991

Bipolar lead acid battery development

A modular bipolar battery configuration is under development at Johnson Control, Inc. (JCI) and the Jet Propulsion Laboratory (JPL). The battery design, incorporating proven lead acid electrochemistry, yields a rechargeable, high-power source that is light weight and compact. This configuration offers advantages in power capability, weight, and volume over conventional monopolar batteries and other battery chemistries. The lead acid bipolar battery operates in a sealed, maintenance-free mode allowing for maximum application flexibility. It is ideal for high-voltage and high-power applications.

Eskra, Michael↗
NASA NTRS1984

Test Results of a Ten Cell Bipolar Nickel-hydrogen Battery

A study was initiated to design and evaluate a new design concept for nickel-hydrogen cells. This concept involved constructing a battery in a bipolar stack with cells consisting of a one plate for each nickel and hydrogen electrode. Preliminary designs at the system level of this concept promised improvements in both volumetric and gravimetric energy densities, thermal management, life extension, costs, and peak power capability over more conventional designs. Test results were most encouraging. This preprototype battery, built with less than ideal components and hardware, exceeded expectations. A total of 2000 LEO cycles at 80 percent depth of discharge were accrued. A cycle life goal of 30,000 cycles appears achievable with minor design changes. These improvements include advanced technology nickel electrodes, insulated bipolar plates and specifically designed frames to minimize shunt currents. The discharge rate capability of this design exceeds 25C. At the 10C discharge rate, 80% of the battery capacity can be withdrawn in six minutes. This data shows that the bipolar design is well suited for those applications requiring high peak power pulses.

Cataldo, R. L.↗
NASA NTRS1982

Improved multilayer insulation applications

Multilayer insulation blankets used for the attenuation of radiant heat transfer in spacecraft are addressed. Typically, blanket effectiveness is degraded by heat leaks in the joints between adjacent blankets and by heat leaks caused by the blanket fastener system. An approach to blanket design based upon modular sub-blankets with distributed seams and upon an associated fastener system that practically eliminates the through-the-blanket conductive path is described. Test results are discussed providing confirmation of the approach. The specific case of the thermal control system for the optical assembly of the Space Telescope is examined.

George Mikk↗
NASA NTRS1984

Solar Absorptance and Thermal Emittance of Some Common Spacecraft Thermal-Control Coatings

Solar absorptance and thermal emittance of spacecraft materials are critical parameters in determining spacecraft temperature control. Because thickness, surface preparation, coatings formulation, manufacturing techniques, etc. affect these parameters, it is usually necessary to measure the absorptance and emittance of materials before they are used. Absorptance and emittance data for many common types of thermal control coatings, are together with some sample spectral data curves of absorptance. In some cases for which ultraviolet and particle radiation data are available, the degraded absorptance and emittance values are also listed.

John H Henninger↗
NASA NTRS2026

Fatigue Behavior of Laser Powder Bed Fused HAYNES 214: Effects of Different Surface Treatments

In this study, under NASA’s Rapid and Analysis Manufacturing Propulsion Technology (RAMPT) project, effects of different surface post-treatments on surface texture and fatigue behavior of L-PBF Alloy 214 were investigated. Various subtractive SPTs including abrasive flow machining (AFM), machining (M), shot peening (SP), vapormatt (VM), dry electropolishing (DE), chemical milling (CM), chemical-mechanical polishing (CMP), electro chemical (ECP) were applied to study the variations of the surface texture, microstructure and uniaxial fatigue behavior under fully reversed strain-controlled condition at four different strain amplitudes of 0.005, 0.004, 0.003, and 0.0025 mm/mm. The insights gained regarding the relationship between structural and mechanical properties for different SPTs can help establish guidelines for selecting the most effective process to enhance the performance of Laser Powder Bed Fusion (L-PBF) Alloy 214, especially for critical aerospace applications.

Post-Processing↗
NASA NTRSDate not supplied

Solvent-Free Preparation of High Energy, Binder-Free Electrodes Enabled by Dry Compressible Holey Graphene

Graphene is an atomically thick sheet consisting of a graphitic carbon network with excellent mechanical strength, electrical and thermal conductivity, and chemical stability. Holey graphene, a structural derivative of graphene, has an array of through-the-thickness holes across the lateral surface of the nanosheet. The presence of these holes has minimal detrimental effect on the graphene properties and leads to enhanced performance in applications such as electronics, sensors, and energy storage. For example, these holes allow more facile cross-plane ion and gas transport than intact graphene, making holey graphene an ideal electrode material for electrochemical energy storage. This presentation will focus on the ability of holey graphene to be compression molded into robust articles or architectures under solvent-free conditions without the need for potentially parasitic binders. The unique dry compressibility of holey graphene has enabled facile fabrication of high mass loading electrodes with both high density and high porosity, which have found use in supercapacitors and various high-energy battery systems such as lithium-oxygen, lithium-sulfur, and lithium-selenium batteries.

Yi Lin↗
NASA NTRS2026

Raising TRL of Your Lunar Payload

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

Lunar Regolith Simulant↗
NASA NTRS2016

NASA Alternative Orion Small Cell Battery Design Support

The NASA Orion Crew Module Reference Design was produced to address large scale thermal runaway (TR) hazard with specific safety controls for the Orion Spacecraft. The design presented provides the description of a full scale battery design reference for implementation as a drop in replacement to meet all spacecraft energy requirements with compatible 120 Vdc electrical and mechanical interface using small cell technology (18650) packaging. The 32V SuperBrick incorporates unique support features and an electrical bus bar arrangement that allows cells negative can insertion into heat sink that is compressively coupled to the battery enclosure to promote good thermal management. The housing design also provides an internal flame suppression "filter tray" and positive venting path internal to the enclosure to allow hot effluent ejecta to escape in the event of single cell TR. Virtual cells (14P Banks) that are supported to provide cell spacing with interstitial materials to prevent side can failures that can produce cell to cell TR propagation. These features were successfully test in four separate TR run with the full scale DTA1 test article in February 2016. Successfully Completed Test Objectives - Four separate TR test runs with Full-Scale DTA1 housing with Two SuperBricks, Two SuperBrick Emulators All Tests resulted in "clean" gas with less than 6 C rise at Battery vent All Tests resulted in less than 2 C temperature rise on cold-plate outlet All Tests resulted in less than 6 psi pressure rise in the battery housing Test Run 1 -One neighbor cell TR, highest remaining neighbor 139 C. Ejecta shorted to bus caused prolonged additional heating, One shorted cell did experience TR after 12 minutes, remaining cells had adequate thermal margin Test Run 2 - No cell to cell propagation, highest neighbor cell 112 C; Test Run 3 - No cell to cell propagation, highest neighbor cell 96 C; Test Run 4 - No cell to cell propagation, highest neighbor cell 101 C; Primary TR testing and analysis were completed and reviewed for endorsement by NASA Engineering and Safety Center team members. All Key Test Objectives were met and the small cell design alternative was demonstrated and selected to be a feasible drop in replacement for the MPCV Orion CM Battery for EM2 mission.

Haynes, Chuck↗
NASA NTRS1989

Up-and-Coming IMCs

While the good oxidation and environmental resistance, high melting points, and comparatively low densities of such ordered intermetallics as Ti 3 Al, NiAl, FeAl, and NbAl 3 render them good candidates for advanced aerospace structures, their poor toughness at low temperatures and low strength at elevated temperatures have prompted the development of fiber-reinforced intermetallic-matrix composites (IMCs) with more balanced characteristics. Fabrication methods for continuous-fiber IMCs under development include the P/M 'powder cloth' method, the foil/fiber method, and thermal spraying. The ultimate success of IMCs depends on fibers truly compatible with the matrix materials.

Randy Bowman↗
NASA NTRS2026

Raising TRL of Your Lunar Payload

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

Laboratories↗