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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRSDate not supplied

Modeling Evolvable Water Recovery Systems for Short and Long-Duration Missions in Partial Gravity

Water recovery technologies on the International Space Station (ISS) are designed and optimized for microgravity environments, thus creating a need for innovative systems optimized for mission operations in the presence of gravity. Alternative water recovery technologies under research by the Life Support Systems division were compiled into a series of Partial Gravity Water Recovery System (PGWRS) architectures. Individual unit processes were modeled via fundamental physical-chemical process equations to simulate their method of treatment, including chemical or biological oxidation, flash evaporation, filtration, or a combination of adsorption and ion exchange processes. Dimension and sizing data were then utilized to scale each architecture. Modeling was completed on an assortment of architectures assuming three scenarios in which treatment methods could take advantage of partial gravity: a short-duration mission with a temporary surface habitat, a longer duration mission with a more permanent habitat, and a long duration mission without resupply. Total system mass was estimated to quantitatively compare architectures within scenarios, but qualitative observations were also made regarding system robustness, flexibility, and capacity to meet more stringent demands. Technologies that traded most favorably between the scenarios were those that included a pre-oxidation stage to minimize mass loading to downstream absorption and ion exchange beds, exploited gravity in liquid-vapor separation processes, and reconstituted wastewater components into recyclable material streams.

Avery L. Carlson↗
DOE OSTI2025

Myna: Connecting powder bed fusion build data to simulation tools for digital twin applications

Additive manufacturing (AM), as a digital process, can generate a detailed digital thread linking a part’s design and manufacturing to its operational performance. As AM systems advance, an increasing amount of process data is stored in manufacturing databases. In principle, this data can be utilized by simulation-based digital twin approaches, such as real-time process control and asynchronous post-processing guidance. However, few tools currently exist for systematically integrating digital thread data with computational tools. Here, in this study, we propose a software package, called Myna, for connecting data from powder bed fusion processes to simulation tools. The utility of such a platform is demonstrated using build data from the Oak Ridge National Laboratory Manufacturing Demonstration Facility “Peregrine v2023-10” public dataset to automatically configure and run 54 semi-analytical 3DThesis melt pool simulations, 78 numerical Additive FOAM melt pool simulations, and 3 ExaCA microstructure simulations. The simulated, spatially registered microstructures are then compared directly with electron backscatter diffraction characterization of the corresponding as-built part locations. The resulting simulated microstructure showed variation as a function of process parameters, particularly stripe width; however, the experimental data had little variation between the microstructure texture and grain size resulting from different processing conditions. Analysis of the discrepancies suggest that it is possible a two-phase ferritic-austenitic solidification model is needed to accurately predict grain size and texture for certain stainless steel 316L feedstock compositions under powder bed fusion conditions, providing direction for future research. As illustrated here, due to the number and complexity of the simulations involved in AM process-structure–property predictions, automated methods to connect process data and simulations will remain necessary tools for testing hypotheses and implementing digital twin applications.

Knapp, Gerald L. [Oak Ridge National Laboratory (O↗
DOE OSTI2025

Transformational Nano-confined Ionic Liquid Membrane for Greater than or Equal to 97 Percent Carbon Dioxide Capture from Natural Gas Combined Cycle Flue Gas

A transformational process based on nano-confined ionic liquid (NCIL) membranes was developed for capturing ≥97% CO 2 from natural gas combined cycle (NCCC) flue gas. The NCIL membranes were prepared by loading amino acid ionic liquid into a framework composed of single-walled carbon nanotube mesh filled with graphene oxide quantum dots. The membranes exhibited CO 2 permeance as high as 2,000 GPU with a CO 2 /N2 selectivity of 2,300 for a typical NGCC flue gas composition. When H 2 O vapor sweep was applied in the permeate side, 96.6% CO2 dry-basis purity and 97.6% CO 2 capture rate were achieved for a simulated NGCC flue gas with single stage. In the process design, a highly H 2 O-selective membrane would be needed to recover majority of the H 2 O vapor, and the recovered H 2 O vapor could be recycled to the permeate side of the NCIL membrane. Sulfonated poly(ether ether ketone) membranes were successfully developed for this purpose. These membranes exhibited H 2 O permeance great than 11,000 GPU and H 2 O/CO 2 selectivity greater than 1,000 at 70ºC for a feed mixture consisting of 14.5 vol% H2O and balanced CO 2 . A standalone membrane model using MATLAB platform was developed for process simulation. The model was validated with experimental data. Techno-economic analysis based on the testing data collected during the current program suggests this transformational membrane process can achieve 97% CO 2 capture efficiency with a cost of $47.8/tonne of CO 2 , which is a 21% reduction versus DOE’s reference case B31B.97.

03 NATURAL GAS↗
NASA NTRS1990

Applications of formal simulation languages in the control and monitoring subsystems of Space Station Freedom

The notions, benefits, and drawbacks of numeric simulation are introduced. Two formal simulation languages, Simpscript and Modsim are introduced. The capabilities of each are discussed briefly, and then the two programs are compared. The use of simulation in the process of design engineering for the Control and Monitoring System (CMS) for Space Station Freedom is discussed. The application of the formal simulation language to the CMS design is presented, and recommendations are made as to their use.

Lacovara, R. C.↗
NASA NTRS1982

Experimental simulation of impact cratering on icy satellites

Cratering processes on icy satellites were simulated in a series of 102 laboratory impact experiments involving a wide range of target materials. For impacts into homogeneous clay slurries with impact energies ranging from five million to ten billion ergs, target yield strengths ranged from 100 to 38 Pa, and apparent viscosities ranged from 8 to 200 Pa s. Bowl-shaped craters, flat-floored craters, central peak craters with high or little relief, and craters with no relief were observed. Crater diameters increased steadily as energies were raised. A similar sequence was seen for experiment in which impact energy was held constant but target viscosity and strength progressively decreases. The experiments suggest that the physical properties of the target media relative to the gravitationally induced stresses determined the final crater morphology. Crater palimpsests could form by prompt collapse of large central peak craters formed in low target strength materials. Ages estimated from crater size-frequency distributions that include these large craters may give values that are too high.

Greeley, R.↗
NASA NTRS2001

Transport Phenomena of Off-Axis Sputtering Deposition

Various high quality epitaxial films, especially oxides, have been synthesized using off-axis sputtering deposition. In this presentation, we report the experiment results of ZnO films grown by the off-axis sputtering deposition. Films were synthesized in temperatures ranged from room temperature to 600 C, and pressures from 5 mTorr to 150 mTorr. Film growth rate was measured by surface profilometer, ellipsometer, and wavelength dispersive spectrometry. Due to the collisions between the sputtered species and the residue gases, the kinetic energy of species was reduced and the transport of depositing species changed from a ballistic movement for low pressure to a diffusive drift for high pressure in which the transport species were almost thermalized. The measurements show an increase of growth rates along the gravity vector when the Knudsen number of transport species is less than 0.05, which suggests that gravity affected the transport characterization in off-axis sputtering deposition. Because the product of pressure (p) and travel distance (d) of sputtered species, pd, exceeds several mTorr-cm during film deposition, the classical simulations for sputtering process in high vacuum system may not be applied. Based on these experimental measurements, a transport process of the off-axis sputtering deposition is proposed. Several models including the Monte Carlo method and gravity-driven flow dynamics simulation will be discussed.

Zhu, S.↗
NASA NTRS2001

Transport Phenomena of Off-Axis Sputtering Deposition

Various high quality epitaxial films, especially oxides, have been synthesized using off-axis sputtering deposition. In this presentation, we report the experiment results of ZnO films grown by the off-axis sputtering deposition. Films were synthesized in temperatures ranged from room temperature to 600 C, and pressures from 5 mTorr to 150 mTorr. Film growth rate was measured by surface profilometer, ellipsometer, and wavelength dispersive spectrometry. Due to the collisions between the sputtered species and the residue gases, the kinetic energy of species was reduced and the transport of depositing species changed from a ballistic movement for low pressure to a diffuse drift for high pressure in which the transport species were almost thermalized. The measurements show an increase of growth rates along the gravity vector when the Knodson (Knudsen??) number of transport species is less than 0.05, which suggests that gravity affected the transport characterization in off-axis sputtering deposition. Because the product of pressure (p) and travel distance (d) of sputtered species, p exceeds several mTorr-cm during film deposition, the classical simulations for sputtering process in high vacuum system may not be applied. Based on these experimental measurements, a transport process of the off-axis sputtering deposition is proposed. Several methods including the Monte Carlo method and gravity-driven flow dynamics simulation will be discussed.

Zhu, S.↗
NASA NTRS2011

External Tank - The Structure Backbone

The External Tank forms the structural backbone of the Space Shuttle in the launch configuration. Because the tank flies to orbital velocity with the Space Shuttle Orbiter, minimization of weight is mandatory, to maximize payload performance. Choice of lightweight materials both for structure and thermal conditioning was necessary. The tank is large, and unique manufacturing facilities, tooling, handling, and transportation operations were required. Weld processes and tooling evolved with the design as it matured through several block changes, to reduce weight. Non Destructive Evaluation methods were used to assure integrity of welds and thermal protection system materials. The aluminum-lithium alloy was used near the end of the program and weld processes and weld repair techniques had to be refined. Development and implementation of friction stir welding was a substantial technology development incorporated during the Program. Automated thermal protection system application processes were developed for the majority of the tank surface. Material obsolescence was an issue throughout the 40 year program. The final configuration and tank weight enabled international space station assembly in a high inclination orbit allowing international cooperation with the Russian Federal Space Agency. Numerous process controls were implemented to assure product quality, and innovative proof testing was accomplished prior to delivery. Process controls were implemented to assure cleanliness in the production environment, to control contaminants, and to preclude corrosion. Each tank was accepted via rigorous inspections, including non-destructive evaluation techniques, proof testing, and all systems testing. In the post STS-107 era, the project focused on ascent debris risk reduction. This was accomplished via stringent process controls, post flight assessment using substantially improved imagery, and selective redesigns. These efforts were supported with a number of test programs to simulate combined environments. Processing improvements included development and use of low spray guns for foam application, additional human factors considerations for production, use of high fidelity mockups during hardware processing with video review, improved tank access, extensive use of non destructive evaluation, and producibility enhancements. Design improvements included redesigned bipod fittings, a bellows heater, a feedline camera active during ascent flight, removal of the protuberance airload ramps, redesigned ice frost ramps, and titanium brackets replaced aluminum brackets on the liquid oxygen feedline. Post flight assessment improved due to significant addition of imagery assets, greatly improving situational awareness. The debris risk was reduced by two orders of magnitude. During this time a major natural disaster was overcome when Katrina damaged the manufacturing facility. Numerous lessons from these efforts are documented within the paper.

Welzyn, Kenneth↗
NASA NTRSDate not supplied

Additive Manufacturing (AM) for Propulsion Component and System Applications

NASA MSFC is developing several areas of additive manufacturing (AM) for propulsion component and system applications. These developments include new AM process and material development, large-scale AM pathfinder component fabrication and hot-fire testing, AM-centric design methodology, modeling and simulation, post-processing advancements, and new design applications of AM in aerospace. Some specific areas NASA has focused is the development and commercial infusion of AM supply chain for materials such as copper-alloy GRCop (Cu-Cr-Nb), Hydrogen-resistant alloys (NASA HR-1, JBK-75), refractory-based alloys (C-103, W, Mo, new formulations), and bimetallic and multi-metallic AM processes. Additional efforts have been focused on large scale AM demonstrating complex thin-wall structures up to 60” diameter using directed energy deposition. Material characterization, properties and component hot-fire testing has been completed using many of these newly developed AM alloys/processes. NASA has also focused on improvements to post-processing including powder removal, surface enhancements, and support removal to further realize cost and schedule benefits to the overall supply chain. These developments are part of the NASA Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), Low Cost Upper Stage Propulsion (LCUSP) and Long Life Additive Manufacturing (LLAMA) projects, in addition to internal IRAD, and external collaborations.

Additive Manufacturing↗
NASA NTRS2023

Modeling and Simulation for Exercise Vibration Isolation and Stabilization System Design

The microgravity environment that crew members experience on orbit presents a well-known health challenge, particularly when it comes to loss of muscle and bone mass. To counteract these negative effects, exercise countermeasures play a critical role in the daily routine of the crew on the International Space Station (ISS). To help inform requirements for upcoming exploration missions such as the Gateway Program, a new device, called the European Enhanced Exploration Exercise Device (E4D), is being built by the European Space Agency through their contractor, the Danish Aerospace Company. The E4D is being demonstrated on the ISS and is unique from other current exercise devices in that it provides four separate modalities in a single device: resistive, cycle ergometry, seated aerobic rowing, and rope pulling. To support the integration of E4D on ISS, a passive Vibration Isolation and Stabilization (VIS) system was required by NASA, and this responsibility was given to the Johnson Space Center. This paper describes the end-to-end process of modeling, simulation, and analysis used to inform the mechanical design of the VIS system. The process begins with the collection of representative exerciser motion capture (MoCap) through ground-based testing with the developmental E4D in both the Prototype Immersive Technology (PIT) Laboratory and the Active Response Gravity Offload System (ARGOS) facility at the Johnson Space Center. These collected MoCap data are processed through human biomechanics modeling to create forcing functions as input to a multibody dynamics simulation of the combined E4D/VIS system, with numerous resulting outputs. These outputs include microgravity accelerations, overall system displacements, internal and transmitted loads, as well as collisions. Microgravity accelerations are compared for compliance against ISS requirements while displacements are used for sway space determinations on the design and volumetric constraints within the targeted module. Internal loads are supplied to the supporting stress analysis teams and external loads for structural loads and dynamics teams, both at NASA and ESA. Finally, contact and clearance analysis is performed using the simulation to eliminate potential design issues. To ensure that the elements of the multibody simulation were verified and validated, correlation against multiple VIS related ground hardware testbeds was performed and characterized. In addition to the isolation part of the VIS problem, stabilization is also key to the integrated performance and evaluation. Due to the difficulty in defining ISS requirements in this area, the stability of the exerciser was inspected via analysis. Loss of balance was defined analytically as occurring when the resultant force vector acting on the exerciser lies outside the base of support of the feet. Both the VIS and E4D teams have recently gone through their Critical Design Reviews (CDRs) and the iterative model-based approach has been integral to inform mechanical design, particularly in the case of the VIS. This same end-to-end approach is now being applied for the Gateway Program, where an Exploration Exercise Device (EED) derived from the E4D and notional VIS for the device are under concept development.

Countermeasures↗
DOE OSTI2025

Alquimia v1.0: a generic interface to biogeochemical codes – a tool for interoperable development, prototyping and benchmarking for multiphysics simulators

Alquimia v1.0 is a generic interface to geochemical solvers that facilitates development of multiphysics simulators by enabling code coupling, prototyping and benchmarking. The interface enforces the function arguments and their types for setting up, solving, serving up output data and carrying out other common auxiliary tasks while providing a set of structures for data transfer between the multiphysics code driving the simulation and the geochemical solver. Alquimia relies on a single-cell approach that permits operator splitting coupling and parallel computation. We describe the implementation in Alquimia of two widely used open-source codes that perform geochemical calculations: PFLOTRAN and CrunchFlow. We then exemplify its use for the implementation and simulation of reactive transport in porous media by two open-source flow and transport simulators: Amanzi and ParFlow. We also demonstrate its use for the simulation of coupled processes in novel multiphysics applications including the effect of multiphase flow on reaction rates at the pore scale with OpenFOAM, the role of complex biogeochemical processes in land surface models such as the E3SM Land Model (ELM) and the impact of surface–subsurface hydrological interactions on hydrogeochemical export from watersheds with the Advanced Terrestrial Simulator (ATS). These applications make it apparent that the availability of a well-defined yet flexible interface has the potential to improve the software development workflow, freeing up resources to focus on advances in process models and mechanistic understanding of coupled problems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1993

Characterization of Minnesota lunar simulant for plant growth

Processing of lunar regolith into a plant growth medium is crucial in the development of a regenerative life support system for a lunar base. Plants, which are the core of such a system, produce food and oxygen for humans and, at the same time, consume carbon dioxide. Because of the scarcity of lunar regolith, simulants must be used to infer its properties and to develop procedures for weathering and chemical analyses. The Minnesota Lunar Simulant (MLS) has been identified to date as the best available simulant for lunar regolith. Results of the dissolution studies reveal that appropriately fertilized MLS can be a suitable medium for plant growth. The techniques used in conducting these studies can be extended to investigate the suitability of actual lunar regolith as a plant growth medium. Dissolution experiments were conducted using the MLS to determine its nutritional and toxicity characteristics for plant growth and to develop weathering and chemical analysis techniques. Two weathering regimes, one with water and one with dilute organic acids simulating the root rhizosphere microenvironment, were investigated. Elemental concentrations were measured using inductively-coupled-plasma (ICP) emission spectrometry and ion chromatography (IC). The geochemical speciation model, MINTEQA2, was used to determine the major solution species and the minerals controlling them. Acidification was found to be a useful method for increasing cation concentrations to meaningful levels. Initial results indicate that MLS weathers to give neutral to slightly basic solutions which contain acceptable amounts of the essential elements required for plant nutrition (i.e., potassium, calcium, magnesium, sulfur, zinc, sodium, silicon, manganese, copper, chlorine, boron, molybdenum, and cobalt). Elements that need to be supplemented include carbon, nitrogen, and perhaps phosphorus and iron. Trace metals in solution were present at nontoxic levels.

Oglesby, James P.↗
DOE OSTI2024

Jet quenching: From theory to simulation

With the explosion of data on jet-based observables in relativistic heavy-ion collisions at the Large Hadron Collider and the Relativistic Heavy-Ion Collider, perturbative Quantum Chromodynamics (pQCD)-based simulations of these processes, often interacting with an expanding viscous fluid dynamical background, have taken center stage. This review is meant to bridge the gap between theory, simulation and phenomenology of jet modification in a dense medium. We will demonstrate how the existence of such end-to-end event generators with semi-realistic or even fully realistic final states allows for the most rigorous comparisons between pQCD-based jet modification theory and experiment. State-of-the-art calculations of several jet-based observables are presented. Extensions of this theory to jets in the small systems of p–A and e–A collisions are discussed.

Physics↗
NASA NTRS2004

Reflectance Spectra of CM2 Chondrite Mighei Irradiated with Pulsed Laser and Implications for Low-Albedo Asteroids and Martian Moons

Micrometeoritic bombardment is an important space weathering process modifying surface optical properties of airless solar system bodies. We have used irradiation with a microsecond pulsed laser as an experimental method to simulate such a process on various targets. The experiment discussed here was performed on a powdered sample of CM2 carbonaceous chondrite Mighei. Shingareva et al. report the details of experimental procedure as well as the results of mineralogical and chemical studies of the irradiated material. Here we present reflectance spectra of irradiated Mighei samples and discuss their spectral properties compared to those of non-irradiated meteorite and low-albedo small solar system bodies.

Moroz, L. V.↗
NASA NTRS2016

Predictive Simulation of Gas Adsorption in Fixed-Beds and Limitations due to the Ill-Posed Danckwerts Boundary Condition

The 1-D axially dispersed plug flow model is a mathematical model widely used for the simulation of adsorption processes. Lumped mass transfer coefficients such as the Glueckauf linear driving force (LDF) term and the axial dispersion coefficient are generally obtained by fitting simulation results to the experimental breakthrough test data. An approach is introduced where these parameters, along with the only free parameter in the energy balance equations, are individually fit to specific test data that isolates the appropriate physics. It is shown that with this approach this model provides excellent simulation results for the C02 on zeolite SA sorbent/sorbate system; however, for the H20 on zeolite SA system, non-physical deviations from constant pattern behavior occur when fitting dispersive experimental results with a large axial dispersion coefficient. A method has also been developed that determines a priori what values of the LDF and axial dispersion terms will result in non-physical simulation results for a specific sorbent/sorbate system when using the one-dimensional axially dispersed plug flow model. A relationship between the steepness of the adsorption equilibrium isotherm as indicated by the distribution factor, the magnitude of the axial dispersion and mass transfer coefficient, and the resulting non-physical behavior is derived. This relationship is intended to provide a guide for avoiding non-physical behavior by limiting the magnitude of the axial dispersion term on the basis of the mass transfer coefficient and distribution factor.

Knox, James Clinton↗
NASA NTRS2016

The Effects of Spaceflight on Cellular Aging in Saccharomyces cerevisiae

The conditions encountered during spaceflight place unique stresses on physiological processes that oftentimes lead to deleterious effects. Identifying these effects and better understanding their molecular mechanisms will be essential in enabling long-duration space travel by humans. Studies in Saccharomyces cerevisiae suggest an aging model that involves the accumulation of toxic components, such as excess extrachromosomal rDNA and damaged mitochondria. This build-up then limits the replicative lifespan (the number of times a mother cell can form a new daughter cell). Remarkably, each new daughter cell emerges completely renewed from the senescing mother cell through an asymmetric distribution of aging determinants via mechanisms that are intricately linked to the budding process. When exposed to simulated microgravity, S. cerevisiae undergoes an altered budding process characterized by a breakdown in bud scar polarity. Because the budding process is critical to replicative aging, we hypothesize that the replicative lifespan may be affected by microgravity as well. To measure relative replicative aging rates, we will construct a strain of yeast in which daughter cells are inviable. In this strain, the Cre recombinase will be expressed under the control of the daughter cell specific promoter, pSCW11, and LoxP sites will be inserted at both flanks of two essential genes involved in the cell cycle, UBC9 and CDC20, using a CRISPRCas9 system. Thus, UBC9 and CDC20 will be excised from daughter cells, leading to cell-cycle arrest and eventual death. To mimic the low shear conditions encountered in microgravity, this strain will be grown in rotating wall vessels. The number of viable mother cells will be monitored over time, and this rate will be compared to cells growing in standard conditions. Because asymmetric division also occurs in mammalian cells (e.g. in neural stem cells), this study will provide insight into how cellular aging rates may change in mammals and will help empower humans to thrive in space for extended and even indefinite periods of time.

aging↗
NASA NTRS1987

A space systems perspective of graphics simulation integration

Creation of an interactive display environment can expose issues in system design and operation not apparent from nongraphics development approaches. Large amounts of information can be presented in a short period of time. Processes can be simulated and observed before committing resources. In addition, changes in the economics of computing have enabled broader graphics usage beyond traditional engineering and design into integrated telerobotics and Artificial Intelligence (AI) applications. The highly integrated nature of space operations often tend to rely upon visually intensive man-machine communication to ensure success. Graphics simulation activities at the Mission Planning and Analysis Division (MPAD) of NASA's Johnson Space Center are focusing on the evaluation of a wide variety of graphical analysis within the context of present and future space operations. Several telerobotics and AI applications studies utilizing graphical simulation are described. The presentation includes portions of videotape illustrating technology developments involving: (1) coordinated manned maneuvering unit and remote manipulator system operations, (2) a helmet mounted display system, and (3) an automated rendezous application utilizing expert system and voice input/output technology.

Brown, R.↗