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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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Physics-Based Modeling and Simulation of Emerging Battery Technologies for Aerospace

Recently there is a growing interest in the aviation sector to reduce air and noise pollution. Electrochemical energy storage devices such as batteries coupled with a distributed electric propulsion system can reduce noise concerns as well as emissions and allow the concept of Urban Air Mobility to come to fruition. The battery performance needs to improve considerably compared from current state-of-art Li-ion battery (about 200Wh/Kg) to realize all-electric passenger jet for short flights (up to 690 miles). NASA is exploring lithium-oxygen battery chemistry to power hybrid (battery powered electrical system) and all-electric aircraft for short distance and long-distance flights. Li-O2 is one of the advanced Li-ion technologies that promise to provide specific energy of more than 750Wh/Kg. For this presentation, we present our work on improving power density of Li-O2 batteries through the use of multiphysics simulations. Next, a path is outlined to port these model to simulate performance for a new battery chemistry for space application, Li-CO2. Li-CO2 uses carbon dioxide as the active material instead of oxygen. Although this technology is in its early development, the offers two benefits: it can be used as a CO2 scrubber, as oxygen is one of the by-products on charging, and as a backup or a standalone battery for various Mars or Venus missions, where the carbon dioxide content in the atmosphere is high and need battery to operate at higher temperatures.

Mehta, Mohit

Battery Cell Balancing System and Method

A battery cell balancing system is operable to utilize a relatively small number of transformers interconnected with a battery having a plurality of battery cells to selectively charge the battery cells. Windings of the transformers are simultaneously driven with a plurality of waveforms whereupon selected battery cells or groups of cells are selected and charged. A transformer drive circuit is operable to selectively vary the waveforms to thereby vary a weighted voltage associated with each of the battery cells.

Davies, Francis J.

Model Correlation and Thermal Analysis of xEMU Boot at Lunar South Pole Temperatures

The National Aeronautics and Space Administration (NASA) Artemis program plans to send astronauts to the lunar south pole, a region of the moon that is colder than previous lunar missions and low earth orbit operations. The spacesuit boots that will be used on these missions will be directly impacted by these extremely cold temperatures (down to ~50 K). To assess the performance of the Exploration Extravehicular Mobility Unit (xEMU) lunar boot in these extreme temperatures, the boot was tested at the Jet Propulsion Lab (JPL) in the Cryogenic Ice Transfer, Acquisition Development, and Excavation Laboratory (CITADEL) thermal vacuum (TVAC) chamber. This data was used to correlate thermal models to predict operational performance of the boots on the lunar south pole. This paper documents the data analysis, thermal boot model correlation, and operational predictions conducted using data from the xEMU TVAC test. Data from the test series was used to determine expected thermal conductances within the boot and between the boot and environment. These conductances were used to correlate a Thermal Desktop model of the xEMU boot across 10 different test points which varied external temperature, internal boot ventilation flowrate, and contact pressure. The correlated model was then used to predict operational performance in the lunar south pole. While the predictions indicate promising evidence for performance of the boots at the 100K test point, there is still substantial uncertainty in performance, particularly at the 48K test point. The results of this test series and model correlation stress the importance of improved testing for characterizing the expected thermal resistance between the outside of the boot and the lunar surface.

xEMU

Model Correlation and Thermal Analysis of xEMU Boot at Lunar South Pole Temperatures

The National Aeronautics and Space Administration (NASA) Artemis program plans to send astronauts to the lunar south pole, a region of the moon that is colder than previous lunar missions and low earth orbit operations. The spacesuit boots that will be used on these missions will be directly impacted by these extremely cold temperatures (down to ~50 K). To assess the performance of the Exploration Extravehicular Mobility Unit (xEMU) lunar boot in these extreme temperatures, the boot was tested at the Jet Propulsion Lab (JPL) in the Cryogenic Ice Transfer, Acquisition Development, and Excavation Laboratory (CITADEL) thermal vacuum (TVAC) chamber. This data was used to correlate thermal models to predict operational performance of the boots on the lunar south pole. This paper documents the data analysis, thermal boot model correlation, and operational predictions conducted using data from the xEMU TVAC test. Data from the test series was used to determine expected thermal conductances within the boot and between the boot and environment. These conductances were used to correlate a Thermal Desktop model of the xEMU boot across 10 different test points which varied external temperature, internal boot ventilation flowrate, and contact pressure. The correlated model was then used to predict operational performance in the lunar south pole. While the predictions indicate promising evidence for performance of the boots at the 100K test point, there is still substantial uncertainty in performance, particularly at the 48K test point. The results of this test series and model correlation stress the importance of improved testing for characterizing the expected thermal resistance between the outside of the boot and the lunar surface.

thermal analysis

Molecular Inventory and Comparative Organic Profiling of A Homogenized Aggregate Sample From Asteroid (101955) Bennu

Evaluating the distribution and diversity of solvent-soluble organic molecules in extraterrestrial materials provide information about the physicochemical environments where prebiotic chemistry occurred and is essential for assessing the inventory of prebiotic compounds available to the early Earth. In this work, we conducted a comprehensive molecular characterization of solvent-soluble organic compounds in a homogenized aggregate sample (ID: OREX-800107-128) of unsorted regolith from asteroid (101955) Bennu returned by NASA’s OSIRIS-REx mission. Using two-dimensional gas chromatography coupled with high-resolution time-of-flight mass spectrometry (GC×GC-HRMS), we identified 87 organic compounds across several molecular classes, including alkanes, polycyclic aromatic hydrocarbons, and nitrogen-, oxygen-, and sulfur-bearing species. Comparison with the organic inventory of CI (Orgueil), C2-ungrouped (Tagish Lake and Tarda), and CM2 (Murchison) carbonaceous chondrites revealed that Bennu sample OREX-800107-128 is most similar to Tagish Lake and Tarda yet compositionally distinct from all of these meteorites. This Bennu sample exhibits a relatively high abundance of low-molecular-weight aromatics (e.g., toluene), pyridine derivatives, and sulfur species such as dimethyl sulfite, consistent with episodic low-temperature aqueous alteration. The presence of these organic compounds suggests that this material experienced chemically diverse processes in the parent body conducive to complex organic synthesis, including aldol condensation reactions responsible for N- and O-bearing compounds. We also compared the molecular distributions of this Bennu sample and previously analyzed samples from (162173) Ryugu to assess potential common origins between these two carbonaceous asteroids. Bennu shows more chemically diverse and nitrogen-rich organic materials than Ryugu. While both asteroids share broadly similar primitive compositions, the observed chemical differences indicate distinct evolutionary histories within a likely common formation environment though whether Bennu and Ryugu derive from a single compositionally heterogeneous parent body or from multiple closely related progenitors remains unresolved. Further detailed comparative analyses of material from Bennu, Ryugu, and specific carbonaceous meteorites (e.g., Tagish Lake and Tarda) will provide new insights into how the N-rich molecular profile observed in Bennu samples was formed and evolved in the outer Solar System.

sample return

Design of an AI Trash Sorting Machine for Use on the Moon and Mars

As NASA prepares for Mars colonization, resource conservation will be critical for survival. Artificial Intelligence (AI) powered waste sorting technologies, already emerging on Earth, offer promising solutions for recycling and material recovery. These systems use advanced sensors and machine learning algorithms to identify and separate materials with remarkable accuracy. On Mars, where every item has significant value, efficient recycling will be essential to reduce resupply needs and support closed-loop life support systems. This paper explores how terrestrial AI-based trash sorting technologies can be adapted for Martian conditions, focusing on challenges such as the harsh surface environment, minimizing system mass, power, volume, and estimating waste composition. Addressing these issues will be key to enabling sustainable operations on the Red Planet.

Sorting

Calculations of the Moon's Thermal History at Different Concentrations of Radioactive Elements, Taking Into Account Differentiation on Melting

Calculations of the thermal history of the moon were carried out by solving the thermal conductivity equation for the case in which the heat sources are the long-lived radioactive elements Th, U, and K 40 . The concentrations of these elements were adjusted to give four variations of the heat flow: 1.35 x 10 -8 and 0.91 x 10 -6 cal cm -2 s -1 (I and I**), 0.61 x 10 -6 (variant II, the terrestrial mixture of Lyubimova and Starkova), and 0.236 x 10 -6 (variant III, the chondrite model of Urey and MacDonald). In the same calculations, we considered layering of the differentiated material with transport to the surface of the radioactive elements after the temperature of the layer rose to 200 K above the melting temperature, which is considered in five variants that differ in the amount of transported radioactive elements: 100 percent ( n = 1), 80 percent n = 0.8), 40 percent, 20 percent ( n = 0.6, 0.4, 0.2). During fusion the heat capacity and heat conductivity were changed. We considered two variants of an initially cold (273 K) and hot (900 K) Moon. Calculations show that the interior of the Moon was heated to melting during the first 0.7 to 2.3 x 10 9 years. The maximum fusion involved practically the entire Moon to a distance from 15 to 45 km beneath the surface, and started 3.5 to 4.0 x 10 9 years ago (I, I**), or 2.5 to 3.0 x 10 9 years ago (II, III) and continued for 1 to 2 x 10 9 years. Today the Moon is cooling. The current thickness of the solid crust is from 150 to 200 km and the heat flow exceeds the stationary value 1.5 fold. Apparently the most realistic variant is II (terrestrial mixture) for an initially hot Moon, and gives, regardless of the moderate concentration of radioactive elements, a heat flow of 0.9 to 0.95 x 10 -6 cal cm -2 s -1 , which agrees with the radioastronomical measurements of Troitsky and Krotikov and with the Apollo 15 data.

O I Ornatskaya

Evaluation of AMSOIL® -ANT PGW Coolant Formula Change and Super Space AMSOIL Development

AMSOIL ® Propylene Glycol Water (PGW), is the baselined internal thermal control fluid for multiple manned spacecraft including Gateway (HALO, IHAB, and ALM modules) and Orion. The use of AMSOIL-ANT PGW was originally validated through extensive NASA/Collins materials-compatibility testing (circa 2008–2015). However, in late 2019, AMSOIL implemented an unannounced change in its PG inhibitor package. Because of this reformulation, concerns around materials compatibility arose. Therefore, NASA initiated corrosion rate and coolant stability testing in 2024. Results showed that the reformulated AMSOIL PG produced substantially elevated corrosion rates in aluminum alloys (about two times when compared to the original AMSOIL PG formula) accompanied by visible surface degradation. Coolant stability testing indicated accelerated propylene-glycol breakdown as well, with glycolate levels about nine times higher than the original formulation. Based on these findings, NASA Materials & Processes and Thermal Control Systems groups have baselined the use of the original PGW chemistry for all spacecraft use. In response, AMSOIL produced a reformulated variant, “Super Space AMSOIL” (ANT-SSA), compliant with MPCV 70156.This paper documents the reformulation testing completed, details on the formulation change, and the development of Super Space AMSOIL.

Woody Beringer

Evaluation of AMSOIL ® -ANT PGW Coolant Formula Change and Super Space AMSOIL ® Development

AMSOIL ® Propylene Glycol Water (PGW), is the baselined internal thermal control fluid for multiple manned spacecraft including Gateway (HALO, IHAB, and ALM modules) and Orion. The use of AMSOIL-ANT PGW was originally validated through extensive NASA/Collins materials-compatibility testing (circa 2008–2015). However, in late 2019, AMSOIL implemented an unannounced change in its PG inhibitor package. Because of this reformulation, concerns around materials compatibility arose. Therefore, NASA initiated corrosion rate and coolant stability testing in 2024. Results showed that the reformulated AMSOIL PG produced substantially elevated corrosion rates in aluminum alloys (about two times when compared to the original AMSOIL PG formula) accompanied by visible surface degradation. Coolant stability testing indicated accelerated propylene-glycol breakdown as well, with glycolate levels about nine times higher than the original formulation. Based on these findings, NASA Materials & Processes and Thermal Control Systems groups have baselined the use of the original PGW chemistry for all spacecraft use. In response, AMSOIL produced a reformulated variant, “Super Space AMSOIL” (ANT-SSA), compliant with MPCV 70156.This paper documents the reformulation testing completed, details on the formulation change, and the development of Super Space AMSOIL.

David Brockett

Isotopic Evidence for A Cold and Distant Origin of 3I/Atlas

Interstellar objects provide the only directly observable samples of icy planetesimals formed around other stars, and can therefore provide insight into the diversity of physical and chemical conditions occurring during exoplanet formation1−3. Here we report isotopic measurements of the interstellar comet 3I/ATLAS, which reveal an elemental composition unlike any Solar System body. The water in 3I/ATLAS is enriched in deuterium, at a level of D/H = (0.98 ± 0.06)%, which is more than an order of magnitude higher than in known comets, while its range of 12 C/ 13 C ratios (141–191 for CO 2 and 123–172 for CO) exceeds typical values found in the Solar System, as well as nearby interstellar clouds and protoplanetary disks. Such extreme isotopic signatures indicate formation at temperatures ≲ 30 K in a relatively metal-poor environment. When interpreted with respect to models for Galactic chemical evolution, the carbon isotopic composition implies that 3I/ATLAS may have accreted as long ago as 12 billion years, following a period of intense, early star formation. 3I/ATLAS thus represents a preserved fragment of an ancient planetary system.

Martin A Cordiner

Design of an AI Trash Sorting Machine for Use on the Moon and Mars

As NASA prepares for Mars colonization, resource conservation will be critical for survival. Artificial Intelligence (AI) powered waste sorting technologies, already emerging on Earth, offer promising solutions for recycling and material recovery. These systems use advanced sensors and machine learning algorithms to identify and separate materials with remarkable accuracy. On Mars, where every item has significant value, efficient recycling will be essential to reduce resupply needs and support closed-loop life support systems. This paper explores how terrestrial AI-based trash sorting technologies can be adapted for Martian conditions, focusing on challenges such as the harsh surface environment, minimizing system mass, power, volume, and estimating waste composition. Addressing these issues will be key to enabling sustainable operations on the Red Planet.

AI

Properties of a Ni19.5Pd30Ti50.5 High-Temperature Shape Memory Alloy in Tension and Compression

Potential applications involving high-temperature shape memory alloys have been growing in recent years. Even in those cases where promising new alloys have been identified, the knowledge base for such materials contains gaps crucial to their maturation and implementation in actuator and other applications. We begin to address this issue by characterizing the mechanical behavior of a Ni 19.5 Pd 30 Ti 50.5 high-temperature shape memory alloy in both uniaxial tension and compression at various temperatures. Differences in the isothermal uniaxial deformation behavior were most notable at test temperatures below the martensite finish temperature. The elastic modulus of the material was very dependent on strain level; therefore, dynamic Young’s Modulus was determined as a function of temperature by an impulse excitation technique. More importantly, the performance of a thermally activated actuator material is dependent on the work output of the alloy. Consequently, the strain-temperature response of the Ni 19.5 Pd 30 Ti 50.5 alloy under various loads was determined in both tension and compression and the specific work output calculated and compared in both loading conditions. It was found that the transformation strain and thus, the specific work output were similar regardless of the loading condition. Also, in both tension and compression, the strain-temperature loops determined under constant load conditions did not close due to the fact that the transformation strain during cooling was always larger than the transformation strain during heating. This was apparently the result of permanent plastic deformation of the martensite phase with each cycle. Consequently, before this alloy can be used under cyclic actuation conditions, modification of the microstructure or composition would be required to increase the resistance of the alloy to plastic deformation by slip.

High-Temperature Shape Memory Alloy

The Evolution of the Moon and the Terrestrial Planets

The thermal evolutions of the Moon, Mars, Venus, and Mercury are calculated theoretically starting from cosmochemical condensation models. An assortment of geological, geochemical, and geophysical data are used to constrain both the present-day temperatures and the thermal histories of the planets' interiors. Such data imply that the planets were heated during or shortly after formation and that all the terrestrial planets started their differentiations early in their history. Initial temperatures and core formation play the most important roles in the early differentiation. The size of the planet is the primary factor in determining its present-day thermal state. The Moon, smallest in size, is characterized as a differentiated body with a crust, a thick solid mantle, and an interior region which may be partially molten. It is presently cooling rapidly and is relatively inactive tectonically. Mercury, which probably has a large core, may have a 500-km-thick solid lithosphere and a partially molten core, if it is assumed that some heat sources exist in the core. If this is not the case, the planet's interior temperatures are everywhere below the melting curve for iron. The thermal evolution is dominated by the core separation and the high conductivity of iron that makes up the bulk of Mercury. Mars, intermediate in size, is assumed to have differentiated an Fe-FeS core. While the formation of an early crust is evident, large-scale melting and differentiation of the mantle silicates has occurred at least up until 1 b.y. ago. Present-day temperature profiles indicate moderate tectonic activity at the present time. Venus is characterized as a planet not unlike the Earth in many respects. Core formation has occurred probably during the first billion years after the formation. The present-day temperatures indicate a partially molten upper mantle overlain by a 100-km-thick lithosphere and a molten Fe-Ni core. We can expect that today Venus may have tectonic processes similar to the Earth's.

M Nafi Toksöz

Simulations of Yarn Micro-Mechanics of Woven Heat Shield Materials

Carbon and phenolic fibers are commonly used in ablative thermal protection materials, such as 3-dimensional Mid-Density Carbon Phenolic (3MDCP), a 3D-woven composite comprised of mixed-fiber yarn bundles. Predicting the micro-mechanical response and fracture of twisted yarns composed of brittle and ductile fibers requires a modeling approach that captures per-fiber yielding, fiber fracture, and inter-fiber friction and contact. This work presents an extended bonded particle model (BPM) for discrete element method (DEM) simulation of fiber and yarn mechanics, implemented in LAMMPS. The model builds on the incremental bond formulation of Guo et al. and introduces a piecewise elasto-plastic constitutive law for axial extension, enabling representation of fibers that yield before failure. 3MDCP yarns were constructed using measured fiber radius distributions and helical twist geometry. Tensile simulations of single-ply 3MDCP yarns show good agreement with vender stress–strain results. Fiber breakage models also show details on yarn breakage propagration, centered radially in the yarn. Yarn breakage of multi-ply 3MDCP also matched experimental observations in per-ply breakage; however, predicted yarn breakage strength were found higher than experimental observations.

Discrete Element Method

A Review of Direct Ink Writing of Polymer Derived Ceramics

With the growing demand for materials capable of withstanding extreme temperatures and pressures, ceramic components with exceptional corrosion resistance and reliable mechanical properties have experienced a significant surge in demand. However, traditional ceramic forming methods involve high-temperatures and energy-intensive processes that often struggle to produce complex parts or composites efficiently. Polymer-Derived Ceramics (PDCs) offer a transformative solution by using polymeric precursors that can be converted into a wide variety of silicon-based and non-silicon-based ceramics through heat treatment. The polymeric nature of PDC precursors enables the fabrication of geometrically intricate components using conventional polymer-forming techniques at significantly lower processing temperatures. Furthermore, PDCs are well-suited for additive manufacturing (AM), allowing the production of complex structural and functional components through cost-effective, low-temperature processes. By leveraging the diverse properties of PDC materials – each with unique advantages and limitations – manufacturers can optimise performance for specific applications. This review provides an overview of the types of PDCs developed to date and their broad range of applications. Specifically, it delves into the Direct Ink Writing (DIW) process, exploring its rheological requirements and the critical role of fillers in tailoring the rheological properties of polymeric precursors to meet the specific demands of DIW.

Victoria Bishop

Chapter 3: Thermal Exchanges and Temperature Stress

Thermal comfort during space flight is discussed. Heat production of man during space flight and wear loss as a mean of dissipating heat are described. Water cooled garments are also considered, along with tolerance for extreme heat and body heat storage. Models of human temperature regulation are presented in the form of documented FORTRAN programs.

Paul Webb

A Frank Discussion on Lessons Learned From Adopting and Applying NASA-STD-6030 for Spaceflight Systems

With the advancement and adoption of Additive Manufacturing (AM) for spaceflight systems, numerous lessons have been learned during the qualification and certification of AM components. The lessons learned covered in this presentation will provide an overview of the challenges faced by NASA centers and commercial partners working to design AM hardware that complies with NASA-STD-6030 Additive Manufacturing Requirements (AMR). Topics of interest include tailoring of requirements for specific projects, documentation requirements, and addressing conservative approaches towards mechanical property development and analysis. In addition to that, this presentation aims to impress that these lessons learned will influence the future revisions of the NASA technical standard to facilitate and advance AM technology adoption on NASA projects.

Additive Manufacturing

Simulations of Yarn Micro-Mechanics of Woven Heat Shield Materials (3MDCP)

Carbon and phenolic fibers are commonly used in ablative thermal protection materials, such as 3-dimensional Mid-Density Carbon Phenolic (3MDCP), a 3D-woven composite comprised of mixed-fiber yarn bundles. Predicting the micro-mechanical response and fracture of twisted yarns composed of brittle and ductile fibers requires a modeling approach that captures per-fiber yielding, fiber fracture, and inter-fiber friction and contact. This work presents an extended bonded particle model (BPM) for discrete element method (DEM) simulation of fiber and yarn mechanics, implemented in LAMMPS. The model builds on the incremental bond formulation of Guo et al. and introduces a piecewise elasto-plastic constitutive law for axial extension, enabling representation of fibers that yield before failure. 3MDCP yarns were constructed using measured fiber radius distributions and helical twist geometry. Tensile simulations of single-ply 3MDCP yarns show good agreement with vender stress–strain results. Fiber breakage models also show details on yarn breakage propagration, centered radially in the yarn. Yarn breakage of multi-ply 3MDCP also matched experimental observations in per-ply breakage; however, predicted yarn breakage strength were found higher than experimental observations.

Woven