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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 NTRS2001

Performance of Li-Ion Cells Under Battery Voltage Charge Control

A study consisting of electrochemical characterization and Low-Earth-Orbit (LEO) cycling of Li-Ion cells from three vendors was initiated in 1999 to determine the cycling performance and to infuse the new technology in the future NASA missions. The 8-cell batteries included in this evaluation are prismatic cells manufactured by Mine Safety Appliances Company (MSA), cylindrical cells manufactured by SAFT and prismatic cells manufactured by Yardney Technical Products, Inc. (YTP). The three batteries were cycle tested in the LEO regime at 40% depth of discharge, and under a charge control technique that consists of battery voltage clamp with a current taper. The initial testing was conducted at 20 C; however, the batteries were cycled also intermittently at low temperatures. YTP 20 Ah cells consisted of mixed-oxide (Co and Ni) positive, graphitic carbon negative, LIPF6 salt mixed with organic carbonate solvents. The battery voltage clamp was 32 V. The low temperature cycling tests started after 4575 cycles at 20 C. The cells were not capable of cycling. at low temperature since the charge acceptance at battery level was poor. There was a cell in the battery that showed too high an end-of-charge (EOC) voltage thereby limiting the ability to charge the rest of the cells in the battery. The battery has completed 6714 cycles. SAFT 12 Ah cells consisted of mixed-oxide (Co and NO positive, graphitic carbon negative, LiPF6 salt mixed with organic carbonate solvents. The battery voltage clamp was for 30.8 V. The low temperature cycling tests started after 4594 cycles at 20 C. A cell that showed low end of discharge (EOD) and EOC voltages and three other cells that showed higher EOC voltages limited the charge acceptance at the selected voltage limit during charge. The cells were capable of cycling at 10 C and 0 C but the charge voltage limit had to be increased to 34.3 V (4.3 V per cell). The low temperature cycling may have induced poor chargeability since the voltage had to be increased to achieve the required charge input. The battery has completed 6226 cycles. MSA 10 Ah cells consisted of Co oxide positive, graphitic carbon negative, LiPF6 salt mixed with organic carbonate solvents. The battery voltage clamp was 30.8 V. The low temperature cycling tests were started after 2182 cycles at 20 C. The cells were capable of cycling at 10 C and 0 C. Like SAFT, the voltage limit on charge had to be increased to 36 V (4.5 V per cell). There was a cell (cell S/N 13) in the battery that showed poor performance features such as low EOD voltage and high EOC voltage. The battery has completed 3441 cycles. A reconditioning procedure that consisted of C15 charge to a taper current of C/100 and C/20 discharge improved the voltage behavior of SAFT and MSA cells with no significant effect on YTP cells. We have demonstrated that the charge operation with VT clamp at battery rather than at cell level is feasible for onboard Li-Ion battery operation.

Rao, Gopalakrishna M.↗

NASA NTRS1993

Preliminary Design and Implementation of the Baseline Digital Baseband Architecture for Advanced Deep Space Transponders

The baseline design and implementation of the digital baseband architecture for advanced deep space transponders is investigated and identified. Trade studies on the selection of the number of bits for the analog-to-digital converter (ADC) and optimum sampling schemes are presented. In addition, the proposed optimum sampling scheme is analyzed in detail. Descriptions of possible implementations for the digital baseband (or digital front end) and digital phase-locked loop (DPLL) for carrier tracking are also described.

T M Nguyen↗

NASA NTRS1995

Lithium Battery Space Experiment

The In-Space Technology Experiments Program selected the Jet Propulsion Laboratory to conduct a Phase A study of the Lithium Battery Experiment. The experiment will mark the first time a rechargeable lithium battery will be flown in space. The operation of the battery involves lithium deposition and dissolution processed. Micro gravity influences these processes significantly. The experiment will check the rate capability, discharge voltage, capacity and the phenomena affecting cycle life. The paper describes the design and methodology of this experiment.

Mueller, R.↗

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 NTRS1993

Electric Propulsion Orbital Platform

This paper describes the Electric Propulsion Orbital Platform (EPOP), of which the primary objective is to provide an instrumented platform for testing electric propulsion devices in space. It is anticipated that the first flight, EPOP-1, will take place on the Shuttle-deployed Wake Shield Facility in 1996, and will be designed around a commercial 1.8 kW arcjet system which will be operated on gaseous hydrogen propellant. Specific subsystems are described, including the arcjet system, the propellant and power systems, and the diagnostics systems.

V. J. Friedly↗

NASA NTRS1995

Nickel-hydrogen battery state of charge during low rate trickle charging

Battery temperature increase, due to low rate trickle charging, has been determined experimentally, using a six cell battery module in a test setup simulating the anticipated AXAF-1 prelaunch environment. Test results indicate trickle charge rates less than or equal to the self discharge rate do not increase dissipation beyond that due to the self discharge. Significant trickle charge rates (approximately C/500) result in battery temperatures only a few degrees (F) higher than those observed during periods of open circuit stand.

Lurie, C.↗

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 NTRS2026

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

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

H Sugahara↗

NASA NTRSDate not supplied

Helmholtz Motor: A Novel Electric Machine That Enables High Temperature Superconducting Armatures

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. Cryogenic electric machines are a promising technology for multi megawatt electric aircraft drivetrains. Second generation high temperature superconductors (HTS) are the ideal conductor for the field winding (typically the rotor) of superconducting machines, and they have attractive features for the armature winding (typically the stator) of these machines. However, their use in armature windings has been severely limited due to excessive AC losses in conventional electric machines. This presentation will present the working principle, design, and a performance trade study of a novel electric machine – termed a Helmholtz machine – that enables HTS armatures by significantly reducing AC losses. The working principle of the patent pending Helmholtz motor is to optimize the rotor-produced magnetic field (i.e., the field winding) so that it produces a magnetic field almost purely in the plane of the HTS. This is accomplished using 2 rotors that contain a set of matched Helmholtz coil pairs (or matched permanent magnet Halbach arrays). The armature (stator) HTS coils are positioned between the rotors and oriented to minimize the out of plane magnetic field. The armature HTS coils are also designed to minimize the out of plane component of their self field. The presentation will include the lessons learned in the sizing and design of this motor, including equations for how to match the magnet arrays. A performance trade study will be presented for a partially superconducting, radial flux version of the motor. The trade study involved an optimization of a motor design code based on analytical calculations (electromagnetic, AC loss, thermofluid, mechanical, and motor sizing) that determine the motor’s total efficiency and total specific power. The design code will be described in the presentation, with an emphasis on the calculation of magnetic fields, AC loss, and temperature distribution.

Superconducting electric machines↗

NASA NTRS2026

The Canadian Galactic Emission Mapper: A New 8-10 GHz Telescope To Map the Polarization of the Northern Sky

The Canadian Galactic Emission Mapper (CGEM) radio telescope is mapping polarized Galactic foregrounds from 8-10 GHz to aid in the search for B-modes in the Cosmic Microwave Background (CMB). Here we describe the design and early on-sky characterization of the CGEM optics. CGEM employs an on-axis, hat feed optical design that is a body of revolution (BOR) and exhibits excellent intrinsic polarization purity. We describe how we have optimized the optics with a novel framework that can directly minimize simulated intensity to polarized intensity (T → P) leakage in angular power spectrum space. The optimized optics exhibit simulated T → P leakage that is orders of magnitude below anticipated CℓBB for r = 10 −3 when scaled from 8-10 GHz to the CMB observing window near 95 GHz. We go on to describe the mechanical design of the optics, including a novel secondary mirror support made from Astroquartz composite that has low loss, low dielectric constant, and preserves the BOR symmetry of the optics. We then showcase the early on-sky performance of the optics with observations of the Sun and satellites, which probe the beam to 40dB down from the peak. A beam model for the deployed CGEM optics based on electromagnetic simulations is in excellent agreement with the on-sky data.

cosmic microwave background↗

NASA NTRS2010

The Extravehicular Maneuvering Unit's New Long Life Battery and Lithium Ion Battery Charger

The Long Life (Lithium Ion) Battery is designed to replace the current Extravehicular Mobility Unit Silver/Zinc Increased Capacity Battery, which is used to provide power to the Primary Life Support Subsystem during Extravehicular Activities. The Charger is designed to charge, discharge, and condition the battery either in a charger-strapped configuration or in a suit-mounted configuration. This paper will provide an overview of the capabilities and systems engineering development approach for both the battery and the charger

Russell, Samuel P.↗

NASA NTRS2026

Development and Validation of a High-Vacuum Thermal Conductivity Testbed for Aerospace Interface Materials

Thermal Interface Materials (TIMs) are critical components in spacecraft thermal management systems, where thermal performance is strongly influenced by vacuum conditions, interface contact resistance, and layered metallic joint behavior. However, manufacturer-reported thermal conductivity values are often derived under idealized conditions and may not accurately represent performance within operational aerospace applications. To address this limitation, the Testbed for Advanced Interface Materials in Vacuum (TAIMV) was developed as a modular vacuum-compatible thermal conductivity characterization platform capable of evaluating aerospace-relevant TIM configurations under both ambient and high-vacuum environments. The testbed was derived from the ASTM C1044-16 guarded hot plate methodology and incorporates interchangeable layers of stainless steel coupon geometries, independently controlled main and guard heaters, embedded resistance temperature detectors (RTDs), thermocouples, multi-layer insulation (MLI), and a temperature-controlled cold plate to characterize through-thickness thermal gradients across layered interfaces. In the current configuration, interface compression is limited to the nominal contact pressure generated by the experimental stack assembly. Initial experimental campaigns were conducted at ambient pressure and below 1×10-5 torr for vacuum cases using multiple interface materials including Braycote 601EF and Krytox-based greases across a range of thermal operating conditions. In parallel, a coupled numerical Python thermal model was developed to predict temperature distribution throughout the stack while accounting for conduction, radiation, and parasitic heat transfer pathways and effective interface resistance effects. Experimental measurements and numerical predictions showed consistent thermal trends across multiple operating conditions and environmental states. Results also revealed measurable differences between ambient and vacuum thermal behavior, demonstrating the importance of interface resistance, parasitic heat transfer mechanisms, and stack geometry in determining effective thermal performance within layered thermal interfaces. The presented work establishes a foundation for future thermal model correlation efforts and expanded characterization of aerospace thermal interface materials under representative environmental conditions. Future work will focus on the integration of a load cell system to enable controlled pressure-dependent characterization of thermal interface materials under compressive loading. This capability will allow investigation of the influence of contact pressure on effective thermal conductivity, interface resistance, and thermal performance within layered aerospace thermal interfaces under representative operational conditions.

Thermal Development Testing↗

NASA NTRS1971

The 20 kW battery study program

Six battery configurations were selected for detailed study and these are described. A computer program was modified for use in estimation of the weights, costs, and reliabilities of each of the configurations, as a function of several important independent variables, such as system voltage, battery voltage ratio (battery voltage/bus voltage), and the number of parallel units into which each of the components of the power subsystem was divided. The computer program was used to develop the relationship between the independent variables alone and in combination, and the dependent variables: weight, cost, and availability. Parametric data, including power loss curves, are given.

Source record↗

NASA NTRS1995

CAE for Thermal Management of Aerospace Electronic Boards Using the BETAsoft Program

Aerospace electronic boards require special attention to thermal management due to constraints such as their need to be light, small, and maintain high power densities. Also, cooling is mainly through conductive and radiative modes with minor or negligible convective cooling. Due to these particular requirements, thermal design has become an integrated part of the electronic design process in order to avoid expensive repeat prototyping and to ensure high reliability. To achieve high speed simulations, the BETAsoft code uses semi-empirical formulations and an advanced finite difference scheme that incorporates local adaptive grids. Detailed conduction, convection and radiation heat transfer is considered. Various benchmark verifications of the software simulation compared to infrared images typically prove to be within 10% of each other. The thermal analysis of a sample avionic card in a natural convection environment is shown. Then, the individual effects of attaching metal screws to the casing, increasing radiative emissivities of the casing, increasing the conductance of the wedge lock, adding an aluminum core to the board, adding metal strips in board layers, inserting conduction pads under components, and adding heat sinks to components are demonstrated.

Kimberly Bobish↗

NASA NTRS1995

Hubble Space Telescope nickel-hydrogen battery testing: An update

The Marshall Space Flight Center (MSFC) began testing the HST Ni-H2 Six Battery Test and the 'Flight Spare Battery' Tests approximately one year before the launch of the HST. These tests are operated and reported on by the MSFC, but are managed and funded by Goddard Space Flight Center in direct support of the HST program. The HST Ni-H2 batteries are built from Eagle Picher RNH-90-3 cells. The HST EPS (electrical power system) is a direct energy transfer power system. The HST Ni-H2 Six Battery Test is a breadboard of the HST EPS. The batteries in the test are composed of test module cells and packaged into three battery modules identical to the flight modules. This test is the HST EPS testbed. The 'Flight Spare Battery' Test is a simulation of one of the six battery channels on the HST. The cells in the test are from the flight spare lot of cells, which are the same lot of cells that three of the six HST flight batteries are made from. This test is the battery life test for the HST program.

Whitt, Thomas H.↗

NASA NTRS2011

Thermal Cycling and Isothermal Deformation Response of Polycrystalline NiTi: Simulations vs. Experiment

A recent microstructure-based FEM model that couples crystal-based plasticity, the B2<-> MB190 phase transformation and anisotropic elasticity at the grain scale is calibrated to recent data for polycrystalline NiTi (49.9 at.% Ni). Inputs include anisotropic elastic properties, texture and differential scanning calorimetry data, as well as a subset of recent isothermal deformation and load-biased thermal cycling data. The model is assessed against additional experimental data. Several experimental trends are captured - in particular, the transformation strain during thermal cycling monotonically increases and reaches a peak with increasing bias stress. This is achieved, in part, by modifying the martensite hardening matrix proposed by Patoor et al. [Patoor E, Eberhardt A, Berveiller M. J Phys IV 1996;6:277]. Some experimental trends are underestimated - in particular, the ratcheting of macrostrain during thermal cycling. This may reflect a model limitation that transformation-plasticity coupling is captured on a coarse (grain) scale but not on a fine (martensitic plate) scale.

Phase Transformations↗

NASA NTRS2026

Hydrofluoroether (HFE) Cleaning Fluid Replacement and Qualification

This NASA Engineering and Safety Center (NESC) Technical Assessment Report addresses the urgent need to identify, test, and qualify replacement cleaning solvents and technologies following 3M’s decision to discontinue production of hydrofluoroether (HFE) products, including Novec HFE-7100, by the end of 2025. HFE-7100 is widely used across NASA for precision cleaning of ground and flight hardware, especially in oxygen system components, and as a heat transfer fluid in high-power-density thermal control systems. The assessment evaluates commercially available replacement solvents, alternative cleaning technologies, and their compatibility with NASA’s operational requirements. Key findings include the identification of viable solvent replacements, their performance in contaminant removal, materials compatibility, and oxygen system safety. The report also explores novel cleaning approaches, including aqueous, supercritical CO₂, cryogenic aerosol, plasma, UV-ozone, magnetically optimized fluids, and induced charge active filtration, highlighting their merits, limitations, and readiness for NASA adoption. The NESC provides recommendations for solvent selection, facility adaptation, and continued technology maturation to ensure mission continuity and regulatory compliance.

Alternative Cleaning Technologies↗