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NASA NTRS2015

Characterization of Hybrid CNT Polymer Matrix Composites

Carbon nanotubes (CNTs) have been studied extensively since their discovery and demonstrated at the nanoscale superior mechanical, electrical and thermal properties in comparison to micro and macro scale properties of conventional engineering materials. This combination of properties suggests their potential to enhance multi-functionality of composites in regions of primary structures on aerospace vehicles where lightweight materials with improved thermal and electrical conductivity are desirable. In this study, hybrid multifunctional polymer matrix composites were fabricated by interleaving layers of CNT sheets into Hexcel® IM7/8552 prepreg, a well-characterized toughened epoxy carbon fiber reinforced polymer (CFRP) composite. The resin content of these interleaved CNT sheets, as well as ply stacking location were varied to determine the effects on the electrical, thermal, and mechanical performance of the composites. The direct-current electrical conductivity of the hybrid CNT composites was characterized by in-line and Montgomery four-probe methods. For [0](sub 20) laminates containing a single layer of CNT sheet between each ply of IM7/8552, in-plane electrical conductivity of the hybrid laminate increased significantly, while in-plane thermal conductivity increased only slightly in comparison to the control IM7/8552 laminates. Photo-microscopy and short beam shear (SBS) strength tests were used to characterize the consolidation quality of the fabricated laminates. Hybrid panels fabricated without any pretreatment of the CNT sheets resulted in a SBS strength reduction of 70 percent. Aligning the tubes and pre-infusing the CNT sheets with resin significantly improved the SBS strength of the hybrid composite To determine the cause of this performance reduction, Mode I and Mode II fracture toughness of the CNT sheet to CFRP interface was characterized by double cantilever beam (DCB) and end notch flexure (ENF) testing, respectively. Results are compared to the control IM7/8552 laminate.

Grimsley, Brian W.↗

DOE OSTI2026

A Dendrite-Resistant Sodium/Porous-Carbon Anode for Solid-State Batteries – Strategies and Challenges for Low-Pressure Operation

Sodium solid-state batteries (Na-SSB) have gained interest recently due to the abundance of Na over Li, but they still tend to fail due to dendrites under practical current densities and cycling capacities. To overcome this, Na-SSBs are frequently tested with impractically high applied pressure. In this work, a porous carbon interfacial layer is utilized in conjunction with Na-ß”-Al2O3 solid electrolytes to enable Na-cycling at milder cell pressures. This sodium/porous carbon layer enables improved solid-state Na cycling in symmetric cells, up to a current density of 10 mA cm-2 at 25 °C. Cycling up to 1 mAh cm-2 is challenging with low pressure, but 1 mAh cm-2 capacity can be reliably cycled at 1 mA cm-2 at an elevated temperature of 60 °C in symmetric cells. Finally, the evolution of the interface and sodium/carbon anode is evaluated with cryogenic ion-milling and cross-sectional imaging revealing that, depending on testing temperature, pressure, current density, and capacity, void formation, Na-extraction from porous carbon, delamination of the porous carbon matrix, or a combination of these occurs at the interface between Na-metal and BASE. Despite this, excellent dendrite resistance is achieved, and a full-cell design utilizing a Na-transition metal oxide cathode is still able to achieve an areal capacity of ~ 2.7 mAh cm-2 at 0.125 mA cm-2. This work demonstrates an alternative pathway toward a Na-metal anode for Na-SSBs without the requirement of excessive stack pressure.

low-cost↗

DOE OSTI2025

Enhancing 2D hydrodynamic flood models through machine learning and urban drainage integration

Two-dimensional hydrodynamic flood models are commonly employed for simulating flood extent and inundation depth. However, the influence of urban drainage network (UDN) is frequently overlooked in these models, potentially compromising their accuracy. Furthermore, the expensive computational costs and longer processing times make them challenging for large-scale hydrodynamic simulation. To address these challenges, this paper develops a machine learning (ML)-driven emulator for an open-source flood model, the Two-dimensional Runoff Inundation Toolkit for Operational Needs (TRITON). A TRITON-ML Emulator (TR-Emulator) that utilizes Convolutional Long Short-Term Memory is developed to capture the spatiotemporal features of flood events based on the outputs from TRITON. We further enhance the emulator by integrating UDN parameters (TR-UDN), such as the flow capacity of drainage pipes, pipe size, and pipe length, via an ML stacking technique to improve the water surface elevation (WSE) simulation. Hurricane Harvey 2017 in Houston, TX is used as the case study. We compare WSE results from TRITON, TR-Emulator, TR-UDN, and the United States Geological Survey (USGS) observations to evaluate the performance of these models. The results indicate that the TR-Emulator effectively replicates the WSE simulated by TRITON. Additionally, TR-UDN performs well in capturing WSE patterns and peak flows, aligning more closely with USGS observations, except in areas with milder slopes where conveyance discrepancies are observed. We further test the generalizability of our ML-based models using another smaller event. This paper shows that the TR-Emulator is effective for users and engineers to emulate a 2D hydrodynamic model, and the enhanced version of the TR-Emulator, TR-UDN, can be an efficient tool for predicting WSEs during urban flooding.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

AGC-2 Graphite Preirradiation Data Analysis Report

This report describes the specimen loading order and documents all preirradiation examination material property measurement data for graphite specimens contained within the Second Advanced Graphite Capsule (AGC 2) irradiation capsule. The AGC 2 capsule is the second in six planned irradiation capsules comprising the Advanced Graphite Creep (AGC) test series. The AGC test series is used to irradiate graphite specimens in order to garner quantitative data necessary for predicting the irradiation behavior and operating performance of new nuclear grade graphites. This testing will ascertain the in service behavior of the graphite for pebble bed and prismatic very high temperature reactor designs. Similar to the First Advanced Graphite Capsule (AGC 1) preirradiation examination report, material property tests were conducted on specimens from 18 nuclear grade graphite types. However, AGC 2 tested an increased number of specimens (i.e., 512) prior to loading them into the AGC 2 irradiation assembly. All AGC 2 specimen testing was conducted at Idaho National Laboratory from July 2009 to August 2010. This report also details the specimen loading methodology for graphite specimens inside the AGC 2 irradiation capsule. The AGC 2 capsule design requires “matched pair” creep specimens that have similar dose levels above and below the neutron flux profile mid plane. This provides similar specimens with and without an applied load. Analysis in this document utilizes the neutron flux profile calculated for the AGC 2 capsule design, the capsule dimensions, and the size (i.e., length) of the selected graphite specimens to create a stacking order that produces “matched pairs” of graphite specimens above and below the AGC 2 capsule elevation mid point, thus providing specimens with similar neutron dose levels.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRSDate not supplied

Windform® XT 2.0 Use as 3U CubeSat Primary Structure

CubeSats provide a platform for small-scale space research and technology demonstration at reduced complexity, cost, and development time. These advantages drove the NASA Langley Research Center (LaRC) to develop and launch the GPX2 3U CubeSat to explore the viability of using Commercial Off-The-Shelf (COTS) differential GPS (dGPS) in low earth orbit. To reduce manufacturing costs and increase design flexibility, the project chose additive manufactured Windform® XT 2.0 as the primary bus material rather than traditional subtractive manufactured (milled) metal. The bus is a two-part, Selective Laser Sintered, 3D-print structure consisting of a single-piece, five-walled chassis and single-walled cover. The bus was specially designed to allow the project to accommodate the payload electronics stack as well as antennas, receivers, and deployable mechanisms. By using an additive manufactured solution, LaRC was able to design in features unrealizable through traditional milling, with a lead-time of roughly two weeks. In comparison, traditional subtractive manufacturing limits geometry options due to toolpath reach and bus construction would have required multiple components for each wall. This would have resulted in a more costly, longer lead-time article with more joints, fasteners, and complexity with a commensurate increase in overall mass. A number of lessons-learned were captured during the design, analysis, and testing of the GPX2 CubeSat covering thermal and structural analysis, vibration modeling, and geometric tolerancing. Additionally, a variety of material testing and verification were performed before and during spacecraft design and integration to assure the suitability of Windform® XT 2.0 for the launch and mission environments. This article provides the highlights of designing and testing the GPX2 bus.

CubeSat↗

NASA NTRS1983

Development of a segmented n-type germanium detector, and its application to astronomical gamma-ray spectroscopy

Extensive calculations and simulations have shown that the instrumental background in a coaxial germanium photon detector flown at balloon altitudes or in space, can be substantially reduced by segmenting the outer contact. The contact is divided into horizontal strips around the side of the detector, giving it many characteristics similar to that of a stack of planar detectors. By choosing different segment coincidence requirements in different energy ranges, one can obtain a factor of approx. 2 increase in sensitivity to spectral lines between 40 keV and 1 MeV, compared with an unsegmented detector. The reverse electrode configuration (using n-type germanium), with the p contact outside, is preferred for this application due to its thin dead layer and resistance to radiation damage in space. A small two segment n type detector is being developed to serve as a prototype for larger multisegment devices. Results of this development effort and of detector tests are presented.

Gehrels, N.↗

NASA NTRS1984

The development of a segmented N-type germanium detector, and its application to astronomical gamma-ray spectroscopy

Gehrels, N.↗

NASA NTRS1985

Thermal expansion of selected graphite reinforced polyimide-, epoxy-, and glass-matrix composite

The thermal expansion of three epoxy-matrix composites, a polyimide-matrix composite and a borosilicate glass-matrix composite, each reinforced with continuous carbon fibers, has been measured and compared. The expansion of a composite with a rubber toughened epoxy-matrix and P75S carbon fibers was very different from the expansion of two different single phase epoxy-matrix composites with P75S fibers although all three had the same stacking sequence. Reasonable agreement was obtained between measured thermal-expansion data and results from classical laminate theory. The thermal expansion of a material may change markedly as a result of thermal cycling. Microdamage, induced by 250 cycles between -156 C and 121 C in the graphite/polyimide laminate, caused a 53 percent decrease in the coefficient of thermal expansion. The thermal expansion of the graphite/glass laminate was not changed by 100 thermal cycles from -129 C to 38 C; however, a residual strain of about 10 x 10 to the minus 6 power was measured for the laminate tested.

Tompkins, S. S.↗

NASA NTRS1991

Control of helicopter rotorblade aerodynamics

The results of a feasibility study of a method for controlling the aerodynamics of helicopter rotorblades using stacks of piezoelectric ceramic plates are presented. A resonant mechanism is proposed for the amplification of the displacements produced by the stack. This motion is then converted into linear displacement for the actuation of the servoflap of the blades. A design which emulates the actuation of the servoflap on the Kaman SH-2F is used to demonstrate the fact that such a system can be designed to produce the necessary forces and velocities needed to control the aerodynamics of the rotorblades of such a helicopter. Estimates of the electrical power requirements are also presented. A Small Business Innovation Research (SBIR) Phase 2 Program is suggested, whereby a bench-top prototype of the device can be built and tested. A collaborative effort between AEDAR Corporation and Kaman Aerospace Corporation is anticipated for future effort on this project.

Fabunmi, James A.↗

NASA NTRS2010

A Comparison of Flow-Through Versus Non-Flow-Through Proton Exchange Membrane Fuel Cell Systems for NASA's Exploration Missions

As part of the Exploration Technology Development Program (ETDP) under the auspices of the Exploration Systems Mission Directorate (ESMD), NASA is developing both primary fuel cell power systems and regenerative fuel cell (RFC) energy storage systems within the fuel cell portion of the Energy Storage Project. This effort is being led by the NASA Glenn Research Center (GRC) in partnership with the NASA Johnson Space Center (JSC), Jet Propulsion Laboratory (JPL), NASA Kennedy Space Center (KSC), and industrial partners. The development goals are to improve fuel cell and electrolysis stack electrical performance, reduce system mass, volume, and parasitic power requirements, and increase system life and reliability. A major focus of this effort has been the parallel development of both flow-through and non-flow-through proton exchange membrane (PEM) primary fuel cell power systems. The plan has been, at the appropriate time, to select a single primary fuel cell technology for eventual flight hardware development. Ideally, that appropriate time would occur after both technologies have achieved a technology readiness level (TRL) of six, which represents an engineering model fidelity PEM fuel cell system being successfully tested in a relevant environment. Budget constraints in fiscal year 2009 and beyond have prevented NASA from continuing to pursue the parallel development of both primary fuel cell options. Because very limited data exists for either system, a toplevel, qualitative assessment based on engineering judgement was performed expeditiously to provide guidance for a selection. At that time, the non-flow-through technology was selected for continued development because of potentially major advantages in terms of weight, volume, parasitic power, reliability, and life. This author believes that the advantages are significant enough, and the potential benefits great enough, to offset the higher state of technology readiness of flow-through technology. This paper summarizes the technical considerations which helped form the engineering judgement that led to the final decision.

Hoberecht, Mark A.↗

NASA NTRS2018

NASA's Space Launch System: Secondary Payload Accommodations in Block 1 and Beyond

Launching from pad 39B at Kennedy Space Center no earlier than December 2019, NASA's Space Launch System (SLS) will send the Orion crew vehicle to a distant retrograde lunar orbit in order to test and validate the new systems developed for SLS, Orion and Kennedy Space Center's Exploration Ground Systems (EGS). In addition to these primary mission objectives, the first integrated fight of NASA's new deep space exploration system, Exploration Mission-1 (EM-1), offers accommodations for 13 6U CubeSats, which will be deployed in deep space after Orion separates from the SLS Interim Cryogenic Propulsion Stage (ICPS). In 2017, the SLS Program, managed by NASA's Marshall Space Flight Center (MSFC) in Huntsville, Alabama, completed the ICPS and delivered it to the EGS Program, which has responsibility for stacking and launch operations. The 13 EM-1 secondary payloads will reside in the Orion Stage Adapter (OSA), which connects the ICPS to Orion's spacecraft adapter. The OSA is essentially complete with preparations being made for transporting the hardware to Kennedy Space Center with accommodations for secondary payload dispensers and with the secondary payload avionics unit installed.

Robinson, Kimberly F.↗

DOE OSTI2026

Accelerating computing for the future electric grid (CRADA Final Report)

As a participant in the Cyclotron Road Lab-Embedded Entrepreneurship Program (LEEP), Vellex Computing, Inc. has successfully validated the "Vellex Computing Stack," a breakthrough Analog Neural Computer (ANC) specifically designed for high-performance edge optimization. This project achieved critical milestones in mixed-signal circuit stability and software-hardware co-design, directly addressing national priorities in semiconductor resiliency. The success of this work is deeply rooted in the support from the Cyclotron Road LEEP, which provided the essential "hard tech" runway—funding, mentorship, and access to Lawrence Berkeley National Laboratory’s world-class characterization facilities—allowing Vellex to overcome the "Valley of Death" often faced by deep-tech hardware startups. By leveraging LBNL’s advanced testing infrastructure, Vellex was able to rigorously benchmark the ANC architecture against state-of-the-art digital solutions, a feat that would have been resource-prohibitive independently. This collaboration has not only advanced American leadership in analog computing but has also matured Vellex’s technology to a stage ripe for private sector commercialization.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS1988

Space shuttle phase B wind tunnel model and test information. Volume 2: Orbiter configuration

Archived wind tunnel test data are available for flyback booster or other alternative recoverable configurations as well as reusable orbiters studied during initial development (Phase B) of the Space Shuttle. Considerable wind tunnel data was acquired by the competing contractors and the NASA centers for an extensive variety of configurations with an array of wing and body planforms. All contractor and NASA wind tunnel test data acquired in the Phase B development have been compiled into a data base and are available for applying to current winged flyback or recoverable booster aerodynamic studies. The Space Shuttle Phase B Wind Tunnel Data Base is structured by vehicle component and configuration type. Basic components include the booster, the orbiter, and the launch vehicle. Booster configuration types include straight and delta wings, canard, cylindrical, retro-glide and twin body. Orbiter configuration types include straight and delta wings, lifting body, drop tanks, and double delta wings. Launch configuration types include booster and orbiter components in various stacked and tandem combinations.

Glynn, J. L.↗

NASA NTRS2003

Alternate Communications Spectrum Study (ACSS) for Aviation Data Links (ADL)

The aim of the work was to identify the key factors involved in the use of alternate spectrum in various bands for a future integrated CNS data link. The study focused on systems and spectral bands that can deliver VDL-or-higher data rates in a two-way communication setting (including air-ground, ground-air, and air-air modes of operation), with multiple platforms (aircraft) operating in the same local environment. We begin with a review of the initial task list, and the final task list. The final task list contained a focus upon spectral availability and related systems that could be affected by the deployment of a new aviation data link (ADL) system. Most of this addresses the lower few layers of the communications protocol stack. A brief review of current related efforts in the aeronautical community is then provided, in which we describe several systems and programs of interest. Participation in some of these efforts is recommended. We also delineate several of the advantages and disadvantages of these system/efforts, in view of anticipated requirements of a new ADL. Desired attributes of a new ADL system are then discussed, and a connection with existing systems is made. The need to consider a wider set of alternative systems and technologies is described, and the beneficial aspects of a particular transmission technique- spread spectrum-are discussed. We then discuss in more detail several potential spectral regions, in terms of propagation conditions, available technology, spectrum availability, and waveform selection. Some comments on the need for standardization are also provided. We note that none of the existing systems described will likely meet the full range of desired features of a new ADL, but that several systems and spectral regions offer promise in terms of one or more characteristics. A system design and analysis approach is then provided. In this, we again focus on the lower few layers of the protocol stack, and aim to capture the main features and parameters that must be selected in the design. Two appendices show example versions and initial results of the first few technical steps in the design approach. Some conclusions are then drawn, and in the final section, recommendations are provided, the most important of which are repeated here: 1. Continue the effort begun here. As detailed in this report, we have only uncovered much of the work that needs to be done in order to provide the foundation for a flexible, high- performance, robust ADL. 2. Seize the opportunity to begin testing in the MLS band. The wide bandwidths and low level of usage of this band make it an ideal one for proof-of-concept type testing. Other (non- aeronautical) organizations are likely to make claims on the band if it is not being used. The primary conclusion is that there is a real and pressing need for a new aviation data link. vi

Matolak, David W.↗

NASA NTRS2005

Characterization of the Space Shuttle Ascent Debris using CFD Methods

After video analysis of space shuttle flight STS-107's ascent showed that an object shed from the bipod-ramp region impacted the left wing, a transport analysis was initiated to determine a credible flight path and impact velocity for the piece of debris. This debris transport analysis was performed both during orbit, and after the subsequent re-entry accident. The analysis provided an accurate prediction of the velocity a large piece of foam bipod ramp would have as it impacted the wing leading edge. This prediction was corroborated by video analysis and fully-coupled CFD/six degree of freedom (DOF) simulations. While the prediction of impact velocity was accurate enough to predict critical damage in this case, one of the recommendations of the Columbia Accident Investigation Board (CAIB) for return-to-flight (RTF) was to analyze the complete debris environment experienced by the shuttle stack on ascent. This includes categorizing all possible debris sources, their probable geometric and aerodynamic characteristics, and their potential for damage. This paper is chiefly concerned with predicting the aerodynamic characteristics of a variety of potential debris sources (insulating foam and cork, nose-cone ablator, ice, ...) for the shuttle ascent configuration using CFD methods. These aerodynamic characteristics are used in the debris transport analysis to predict flight path, impact velocity and angle, and provide statistical variation to perform risk analyses where appropriate. The debris aerodynamic characteristics are difficult to determine using traditional methods, such as static or dynamic test data, due to the scaling requirements of simulating a typical debris event. The use of CFD methods has been a critical element for building confidence in the accuracy of the debris transport code by bridging the gap between existing aerodynamic data and the dynamics of full-scale, in-flight events.

Murman, Scott M.↗

NASA NTRSDate not supplied

Vertical Lunar Regolith Conveying as a Flight Experiment in Simulated Lunar-Gravity

Regolith conveying will be an essential task for supplying regolith feedstock to In-Situ Resource Utilization (ISRU) reactor systems for regolith processing on the Moon and Mars. The Vertical Lunar Regolith Conveyor (VLRC) is a technology being developed at NASA Kennedy Space Center (KSC) as a regolith transport task for the GCD ISRU FLEET project led by NASA Glenn Research Center (GRC). Single test loop versions of the VLRC are being developed at NASA KSC as a technology demonstration for a flight experiment. The NASA Flight Opportunities program selected the VLRC for a technology demonstration opportunity on a future Blue Origin New Shepard suborbital launch vehicle to study regolith transport physics in a relevant environment in a vacuum chamber under simulated lunar gravity conditions in order to advance its technology readiness level (TRL) for future space applications. The VLRC system includes four primary subsystems to achieve the objectives of the lunar gravity (Lunar-G) flight experiment. (1) An eccentric vibratory conveyor stack to convey regolith particles consisting of three single-loop helical surface conveyors with each actuated by two vibratory motors that vibrate in unison. One of the three single-loops contains a 0.8°-3.1° inclined helical path and the other two contain a 1.6°-6.2° incline. (2) A stick-slip conveyor stack to convey regolith particles consisting of three single-loop helical surface conveyors with each actuated by the same motor to move in unison in a stick-slip motion. One of the three single-loops contains a 0.8°-3.1° inclined helical path and the other two contain a 1.6°-6.2° incline. (3) A regolith containment system to contain the regolith in each single-loop track during launch before the start of the experiment using containment caps that will be lifted in unison at the start of Lunar-G. (4) COTS cameras will record the motion of regolith and tracer particles. Post-flight analysis of the videos will be used to determine convey speeds and flow rates. The VLRC experiment will use the well-known technique of Particle Image Velocimetry (PIV) image analysis to determine the velocity of tracer particles entrained in the regolith flow. This velocity will be used to calculate the mass flow rate of the regolith being conveyed.

ISRU↗

NASA NTRSDate not supplied

Segmented Hexagonal Antenna Reflector Concentrically Stacked Using Shape Memory Composite Tubular Hinges

A new architecture for solid surface reflector antennas scalable to sizes greater than 10 m is presented. The design combines the compact, lightness and simplicity characteristics of advanced deployable structures to create sub-reflectors that can be assembled in space into larger units using a robotic arm and operations under development by a related parallel project. The seven-panel hexagonal sub-reflector is divided into hexagonal panels of that efficiently stack concentrically and vertically. The central panel is connected to each side panel on the back side by a pair of tubular shape memory composite hinges that enable the required deployment kinematics. A secondary mechanism ultimately closes the interpanel gap. The focus of the paper is on the development of the sub-reflector elements, namely the tubular hinges that use embedded heaters and sensors for actuation, the actuation mechanisms, and the lightweight sandwich construction panels. A finite element analysis parametric study assessed how design features of the hinge affect its stowage and deployment dynamics. The component fabrication and testing plans for the two-panel assembly breadboard model are outlined.

deployable reflectors↗

NASA NTRSDate not supplied

Segmented Hexagonal Antenna Reflector Concentrically Stacked Using Shape Memory Composite Tubular Hinges

deployable reflectors↗