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DOE OSTI2026

Thermal Studies of CMS High-Granularity Calorimeter (HGCAL) Cassettes for the HL-LHC Upgrade

The CMS High Granularity Calorimeter (HGCAL) is a key endcap upgrade for the High-Luminosity LHC, designed to operate in an environment of extreme radiation and high particle rates. Each HGCAL cassette integrates silicon and scintillator modules, front-end ASICs, and a copper cooling plate that provides both mechanical integrity and thermal coupling using two-phase CO₂ cooling. Stable and uniform temperature control is essential to ensure reliable performance of the front-end electronics and to limit radiation-induced leakage currents in the silicon sensors. We present results from thermal characterization studies of pre-series HGCAL cassettes assembled and tested at Fermilab. Embedded RTD/PT1000 temperature sensors were used to measure gradients across copper cooling plates, module layers, and cassette edges under powering conditions representative of operation. The measured thermal behavior demonstrates effective heat transport through the cassette stack and highlights small but systematic variations correlated with geometry and assembly tolerances. These results validate the cooling performance of HGCAL cassettes.

Wang, Jinglu [Northwestern U.]↗

NASA NTRS1993

Edison and radiatively-cooled IR space observatories

Radiative cooling of IR space telescopes is an alternative to embedding within massive cryostats and should offer advantages for future missions, including longer life, larger aperture for a fixed spacecraft size, lower cost due to less complex engineering, and easier ground handling. Relatively simple analyses of conventional designs show that it is possible to achieve telescope temperatures in the range of 25 to 40 K at distances from the sun of about 1 AU. Lower temperatures may be possible with 'open' designs or distant orbits. At approximately 25 K, an observatory will be limited by the celestial thermal background in the near- and mid-IR and by the confusion limit in the far-IR. We outline here our concept for a moderate aperture (approximately 1.75 m; Ariane 4 or Atlas launch) international space observatory for the next decade.

Thronson, H. A.↗

NASA NTRS2019

CAMIEM: Compact Additively Manufactured Innovative Electric Motor

New manufacturing methods are needed to obtain innovative electric motor designs that have much higher power densities and/or efficiencies compared to the current state-of-the-art. Additive manufacturing offers the potential to radically change motor designs so that they have compact designs, multi-material components, innovative cooling, and optimally designed and manufactured components. New component designs enabled by additive manufacturing technologies have been designed and were fabricated to include the housing, rotors, stator cooling ring, a direct printed stator, and a wire embedded stator. The new components were integrated into the motor and tested evaluate the performance gains in comparison to the baseline electric motor configuration. Partners on the sub-project include NASA GRC, NASA LaRC, NASA AFRC, LaunchPoint Technologies, and the University of Texas El Paso.

Halbig, Michael C.↗

NASA NTRS1985

Hot isostatic pressing of ceramics

A mixture containing glass 70 to 95 and BN or B4C powder (0.1-10 microns) 5 to 30 vol. % is used as a secondary pressure medium in hot isostatic pressing of ceramics. Thus, Pyrex beads were mixed with 15% vol. BN powder (average diameter 2 microns), fused at 1400 deg for 2 h, cooled, crushed, and put into a graphite crucible. A Si3N4 sintered body was embedded in the powder, heated in vacuum at 1200 deg for 2 h, treated in a hot isostatic press furnace at 1700 deg and 1000 atm. for 1 h, and cooled to give a Si3N4 ceramic. It was easily separated from the crucible.

Honma, K.↗

NASA NTRS1982

Film-cooling effectiveness with developing coolant flow through straight and curved tubular passages

The data were obtained with an apparatus designed to determine the influence of tubular coolant passage curvature on film-cooling performance while simulating the developing flow entrance conditions more representative of cooled turbine blade. Data comparisons were made between straight and curved single tubular passages embedded in the wall and discharging at 30 deg angle in line with the tunnel flow. The results showed an influence of curvature on film-cooling effectiveness that was inversely proportional to the blowing rate. At the lowest blowing rate of 0.18, curvature increased the effectiveness of film cooling by 35 percent; but at a blowing rate of 0.76, the improvement was only 10 percent. In addition, the increase in film-cooling area coverage ranged from 100 percent down to 25 percent over the same blowing rates. A data trend reversal at a blowing rate of 1.5 showed the straight tubular passage's film-cooling effectiveness to be 20 percent greater than that of the curved passage with about 80 percent more area coverage. An analysis of turbulence intensity detain the mixing layer in terms of the position of the mixing interface relative to the wall supported the concept that passage curvature tends to reduce the diffusion of the coolant jet into the main stream at blowing rates below about. Explanations for the film-cooling performance of both test sections were made in terms differences in turbulences structure and in secondary flow patterns within the coolant jets as influenced by flow passage geometry.

Papell, S. S.↗

NASA NTRS1992

Fate of a perched crystal layer in a magma ocean

The pressure gradients and liquid compressibilities of deep magma oceans should sustain the internal flotation of native crystals owing to a density crossover between crystal and liquid. Olivine at upper mantle depths near 250 km is considered. The behavior of a perched crystal layer is part of the general question concerning the fate of any transient crystal carried away from a cooling surface, whether this be a planetary surface or the roof of an intrusive magma body. For magma bodies thicker than a few hundred meters at modest crustal depths, the major cooling surface is the roof even when most solidification occurs at the floor. Importation of cool surroundings must also be invoked for the generation of a perched crystal layer in a magma ocean, but in this case the perched layer is deeply embedded in the hot part of the magma body, and far away from any cooling surface. Other aspects of this study are presented.

Morse, S. A.↗

NASA NTRS1984

Vortex-generating coolant-flow-passage design for increased film-cooling effectiveness and surface coverage

The thermal film-cooling footprints observed by infrared imagery for three coolant-passage configurations embedded in adiabatic-test plates are discussed. The configurations included a standard round-hole cross section and two orientations of a vortex-generating flow passage. Both orientations showed up to factors of four increases in both film-cooling effectiveness and surface coverage over that obtained with the round coolant passage. The crossflow data covered a range of tunnel velocities from 15.5 to 45 m/sec with blowing rates from 0.20 to 2.05. A photographic streakline flow visualization technique supported the concept of the counterrotating apability of the flow passage design and gave visual credence to its role in inhibiting flow separation.

Papell, S. S.↗

NASA NTRSDate not supplied

Thermal Performance Comparison and Lessons Learned for the Thermal Infrared Sensor Instruments 1 & 2

The Thermal Infrared Sensor (TIRS-1) is one of two instruments on the Landsat-8 Mission, which launched in February of 2013 and remains operational. The TIRS-2 instrument was developed for the Landsat-9 Mission, which is scheduled to launch in September of 2021. The TIRS-2 instrument design was adjusted to account for requirements changes and to include key lessons learned from its predecessor. The overall thermal subsystem design of the TIRS Sensor Unit remained comparable from mission to mission, but there were some areas that needed modifications. The general design is comprised of five thermal zones which range in temperature from less than 43 Kelvin to 320 Kelvin. Most zones are proportional heater controlled. A two-stage cryocooler provided by Ball Aerospace is used to cool the cryogenic subsystem, and excess power dissipation is rejected via ammonia transport heat pipes to a dedicated cryocooler radiator with embedded ammonia heat pipes. The cryogenic subsystem includes a series of shells used to radiatively and conductively isolate the cold stage from the warmer surroundings. The Optical System (telescope) is passively cooled to 180-195 Kelvin using a dedicated radiator with embedded dual-bore ethane heat pipes. The warmer end of the instrument includes a Scene Select Mechanism, an on-board Black Body Calibrator with a dedicated radiator, and a Focal Plane Electronics Box, all of which are attached to the Sensor Unit primary structure. The TIRS-1 thermal subsystem design was successfully verified during an extended testing campaign and during more than 8years of on-orbit operations. The TIRS-2 thermal subsystem design was successfully verified during months of ground testing prior to delivery in August of 2019and at the Observatory level in the Spring of 2021. A detailed comparison of the thermal performance of the two instruments has been made with a focus on key lessons learned during each instrument development, and with the benefit of on-orbit data acquired for the TIRS-1 instrument.

Veronica Otero↗

NASA NTRS1985

Far-infrared line intensities of H2O and CO from warm molecular clouds

Takahashi et al. (1983) have studied the role of H2O in the overall energetics of warm molecular clouds with large optical depths. It was found that in molecular clouds associated with nearby or embedded luminosity sources, the dust is likely to be warmer than the molecular gas. Thus, the warm dust represents the primary source of heat for the gas. In some cases, H2O was found to cool the gas. Takahashi et al. (1983) have presented the formalism for treating H2O in an optically thick molecular cloud with embedded sources of luminosity. The total H2O heating and cooling rates were also calculated. In the present investigation, the emergent intensities of far-infrared lines of H2O and excited, rotational CO transitions from relatively warm molecular clouds based on the large-velocity gradient model of the previous study are calculated. It is found that the dominant submillimeter CO transitions are related to emission, while the H2O transitions can be either absorption or emission lines.

Takahashi, T.↗

NASA NTRS2026

Artemis Suit Material Optical Property Testing of Dust Exposed Fabrics

This paper highlights one aspect of NASA’s ongoing technology-infusion effort to design, fabricate, and test a next-generation outer shell fabric for a lunar Extravehicular Activity (EVA) space suit, a critical component of sustained lunar exploration. Managing thermal loads on the Moon is essential for astronaut safety and suit performance. The suit’s exterior fabric directly influences heat gain and loss through its optical properties: low solar absorptivity minimizes sunlight absorption, while high infrared emissivity aids radiative cooling. Lunar regolith complicates this balance. Its fine, abrasive particles possess unique optical behavior that can lower reflectivity and raise emissivity when embedded in or adhered to fabric surfaces, degrading thermal control and increasing the risk of overheating or cooling inefficiency. To quantify these effects, the Artemis Suit Materials (ASM) team measured solar absorptance and infrared emissivity of clean and dust-soiled Ortho Fabric, establishing beginning-of-life (BOL) and end-of-life (EOL) benchmarks. EOL conditions were simulated with a rotary tumbler abrasion process using lunar dust simulant and ceramic media to reproduce cumulative wear expected during surface operations. Tests also included unmodified fabrics and a fabric/film laminate system containing titanium dioxide to evaluate potential improvements in dust resistance and optical performance. Results from these evaluations provide critical insight into how lunar dust alters fabric thermal behavior and inform the design of bespoke suit materials that maintain required optical properties throughout mission life, supporting safe and effective long-duration EVA on the lunar surface.

space↗

NASA NTRS2026

Artemis Suit Material Optical Property Testing of Dust Exposed Fabrics

Textile↗

DOE OSTI2021

Determination of oxidation rates and volatile oxidation products for HTGR graphite matrix material exposed to steam atmospheres

High-temperature gas-cooled reactors (HTGRs) in operation use tristructural isotropic (TRISO) particles embedded in graphite and carbonized resin matrix to form the fuel element. This graphite matrix material serves as a supportive structural element, heat transfer medium, and neutron moderator. In HTGR designs, fuel compacts are exposed to helium coolant, which facilitates high outlet temperatures (750°C 2 O, 800°C 2 , and H 2 , are quantified in varied oxidant atmospheres using a coupled thermogravimetric analyzer and mass spectrometer. Furthermore, oxidation rates reported here for varied steam (H 2 O [g]) atmospheres are predominantly linear and comparable with literature values in the range of tested temperatures (800–1200°C). Changes in dominant matrix oxidation products from primarily CO to a mixture of CO, CO 2 , and H 2 were observed at higher temperatures (≥1000°C) and steam atmospheres (≥5 kPa pH 2 O). Kinetic data indicates that there was no shift in oxidation regime with chemical oxidation occurring at all temperatures and H2O (g) atmospheres tested. These data provide insight into the oxidation behavior of graphite matrix material and will inform future testing conditions, notably mixed atmospheric conditions, of HTGR fuel elements.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Microstructure of Neutron-Irradiated Al 3 Hf-Al Thermal Neutron Absorber Materials

A thermal neutron-absorbing metal matrix composite (MMC) comprised of Al 3 Hf particles in an aluminum matrix was developed to filter out thermal neutrons and create a fast flux environment for material testing in a mixed-spectrum nuclear reactor. Intermetallic Al 3 Hf particles capture thermal neutrons and are embedded in a highly conductive aluminum matrix that provides conductive cooling of the heat generated due to thermal neutron capture by the hafnium. These Al 3 Hf-Al MMCs were fabricated using powder metallurgy via hot pressing. The specimens were neutron-irradiated to between 1.12 and 5.38 dpa and temperatures ranging from 286 °C to 400 °C. The post-irradiation examination included microstructure characterization using transmission electron microscopy (TEM) and energy-dispersive X-ray spectroscopy. This study reports the microstructural observations of four irradiated samples and one unirradiated control sample. All the samples showed the presence of oxide at the particle–matrix interface. The irradiated specimens revealed needle-like structures that extended from the surface of the Al 3 Hf particles into the Al matrix. An automated segmentation tool was implemented based on a YOLO11 computer vision-based approach to identify dislocation lines and loops in TEM images of the irradiated Al-Al 3 Hf MMCs. This work provides insight into the microstructural stability of Al 3 Hf-Al MMCs under irradiation, supporting their consideration as a novel neutron absorber that enables advanced spectral tailoring.

36 MATERIALS SCIENCE↗

NASA NTRS1987

Submillimeter and Far-Infrared Spectroscopy of M17 and S106: UV-Heated, Quiescent Molecular Gas?

Measurements of CO line emission toward the interface between molecular cloud and HII region in M17, and the center of the bipolar nebula S106 are discussed. The warm quiescent molecular gas is in the interface between the exciting OB stars and the surrounging molecular cloud. Comparison of the submillimeter, far-IR, and millimeter CO line intensities and profiles suggests a model in which clumps of relatively cool gas (T = 50 K) have warm surfaces or are embedded in a warm surrounding medium. Heating of the warm, quiescent molecular gas by collisions with dust grains can be excluded. Slow shocks or heating by photoelectrons are possible. The most promising mechanism is photoelectric heating. The existence of a substantial amount of warm, quiescent molecular gas in UV illuminated regions may be of importance locally in most OB star formation regions and globally in external galaxies with large rates of star formation.

Harris, A. I.↗

NASA NTRS1980

On equilibrium states of heated self-gravitating gas clouds cooling by conduction in an external gravitational field

Exact analytic solutions are presented for equilibrium states of a self-gravitating one-dimensional cloud of gas, embedded in an external gravitational field due to a plane of 'stars' being heated at a rate proportional to the local gas density, and cooling by thermal conduction. It is found that the general topology of the solutions is such that the gas density has a minimum on the plane of 'stars', rising to an infinite but integrable peak away from the plane so that the total mass of gas in the cloud is finite. The results may be of interest in investigations of interstellar molecular clouds and of filamentary structures in supernova remnants as well as in the modeling of gas distributions around 'cocoon' protostars.

Lerche, I.↗

NASA NTRS1992

The structure of NGC at 100, 160, and 200 microns - Continuum dust emission in a quiescent Sb galaxy

Observations of NGC 4565 at 100, 160, and 200 microns with the University of Chicago Far-Infrared Camera and the NASA-Kuiper Airborne Observatory are reported. In order to examine the dependence of FIR emission on spiral structure and star formation activity, these observations of NGC 4565, a quiescent Sb galaxy, are compared with observations of NGC 6946, an active Sc galaxy, made by Engargiola (1991) using the same instruments. Warm dust (30 K) in a bisymmetric spiral pattern superposed on an exponential disk of cool dust (20 K) can account for the FIR morphology of NGC 4565. Optical and IR data suggest that there are more embedded sources heating dust locally in the southeast arm region and more UV radiation from unobscured young stellar associations heating the cool, neutral medium in the northeast arm region.

Engargiola, G.↗

NASA NTRS1990

Ultra high temperature particle bed reactor design

A direct nuclear propulsion engine which could be used for a mission to Mars is designed. The main features of this reactor design are high values for I(sub sp) and very efficient cooling. This particle bed reactor consists of 37 cylindrical fuel elements embedded in a cylinder of beryllium which acts as a moderator and reflector. The fuel consists of a packed bed of spherical fissionable fuel particles. Gaseous H2 passes over the fuel bed, removes the heat, and is exhausted out of the rocket. The design was found to be neutronically critical and to have tolerable heating rates. Therefore, this particle bed reactor design is suitable as a propulsion unit for this mission.

Lazareth, Otto↗

NASA NTRS2004

Shock Effects in the Metal-rich Chondrites QUE 94411, Hammadah al Hamra 237 and Bencubbin

We have studied the metal-rich chondrites QUE94411 (QUE), Hammadah al Hamra 237 (HH237) and Bencubbin with an emphasis on the petrographical and mineralogical effects of the shock processing that these meteorite assemblages have undergone. Iron-nickel metal and chondrule silicates are the main components in these meteorites. These high-temperature components are held together by shock melts consisting of droplets of dendritically intergrown FeNi metal/sulfide embedded in ferrous silicate glass. The silicate glass component of the shock melt is substantially more FeO-rich (FeO: 30 to 40 wt%) than the prevailing chondrule silicates (FeO less than 5 wt%). Fine-grained matrix material, which is a major component in most other chondritic assemblages, is extremely scarce in QUE4411 and HH237; it has not been observed in Bencubbin. This material occurs as rare, hydrated, and fine-grained matrix lumps with major and minor element abundances roughly similar to the ferrous silicate shock melts (and CI). We infer that hydrated, fine-grained material, compositionally similar to these matrix lumps, was originally present between the FeNi metal grains and chondrules, but was preferentially heated by the shock wave and melted. Other shock-related features in QUE94411, HH237, and Bencubbin include a distinct alignment and occasionally strong plastic deformation of metal and chondrule fragments. However, the existence of chemically zoned and metastable FeNi metal condensates condensates in direct contact with shock melts indicates that the shock did not substantially increase the average temperature of the aggregate. TEM analyses of the FeNi metal droplets embedded in the shock melts show martensitic crystal structures, indicating rapid cooling, essentially quenching, of the shock melts. These findings indicate that the preshock temperature of the assemblage was low. Because porphyritic olivine-pyroxene chondrules are absent in QUE94411, HH237, and Bencubbin, it is difficult to determine the precise shock stage of these meteorites, but the shock was probably relatively light (S2- S3; 5-20 GPa) consistent with a bulk temperature increase of the assemblages of less than 200 C. The higher pressures within this range (i.e. 15-20 GPa) are consistent with the findings of shock produced diamonds in Bencubbin. The many mineralogical, petrological and isotopic (e.g. O and N) similarities between Bencubbin, Weatherford, Gujba and QUE/HH237 have been used to argue for a common origin of these meteorites on a single asteroidal parent body. The findings of this study, which indicate similar shock processing, lend support to this view.

Meibom, A.↗