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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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1,533 records · Page 54

Spray Combustion Stability

The central purpose of this project is the improvement of liquid-fueled rocket motor design technology in order to assist the establishment of economical commercial access to space through the development of engines with enhanced performance and reliability. Specific research effort is focused on spray physics and associated combustion instability phenomena. Results concerning high pressure droplet gasification model, droplet turbulent dispersion model, and spray atomization model will contribute to the development of new computational tools for design of stable liquid propellant rocket engines.

Pak-Yan Liang

Effect of Microgravity on Several Visual Functions During STS Shuttle Missions

Many astronauts and cosmonauts have commented on apparent changes in their vision while on-orbit. Comments have included statements of supposed improved distance acuity to decreased near vision capability. The purpose of this study was to assess not only changes in visual acuity, but expand the assessment to several other visual functions for a comprehensive battery of tests. Vision was assessed using an innovative device, the Visual Function Tester - Model 1 (VFT-1), which presents the tests at optical infinity and includes critical flicker fusion, stereopsis to 10 seconds-of-arc, visual acuity in small steps to 20/7.7, cyclophoria, lateral and vertical phoria, and retinal rivalry. Vision was assessed 2 times prelaunch at L-14 days and L-7 days, 3-4 times while on-orbit, at landing, and 2 times postlanding at L+3 days and L+7 days. There were 26 STS astronauts that participated, with data on 20 astronauts used for analysis. There was a typical wide variability between subjects in baseline visual performance for each parameter at the prelaunch sessions. There was a slight but statistically significant decrease in visual acuity while on-orbit that was not clinically significant. For stereopsis (i.e. depth perception), there was a small improvement on-orbit that was not statistically significant. There were no changes during space flight for any of the other visual parameters tested. A few individuals showed apparent changes in acuity and stereopsis. The possibility exists that microgravity affects the visual system of some individuals differently, as with space adaptation syndrome. Repeat data on 2 astronauts showed good repeatability between the 2 flights. These results pertain to only short term space flight on the STS shuttle, and longer flights are necessary to determine if there is any relationship between mission duration and these visual functions.

Melvin R O'Neal

Global Model Estimates of Atmospheric Al, Ca, Fe, Si, and Ti from Dust and Non-Dust Aerosols Informed by EMIT Surface Mineralogy and Evaluated Against Observations

Atmospheric deposition of micro-nutrients like Fe has been shown to be important for ocean biogeochemistry. The largest source of atmospheric Fe and other elements (e.g., Ca, Al, Si, and Ti) is desert dust, although there are significant non-dust sources in some regions. However, past estimates of these elements have been substantially uncertain due to limited information about the composition of the desert source regions. Here we use elemental distributions estimated from new Earth Surface Mineral Dust Source Investigation (EMIT) observations, which provide mineralogical composition at the surface of the Earth based on imaging spectroscopy measurements from the International Space Station. We add in other sources of these elements (anthropogenic and natural) and compare to a compilation of available surface concentration data from stations over land and from shipborne observations. Our results suggest that the modeled distribution is similar to available observations, but discrepancies still exist in both natural desert dust regions as well as regions dominated by anthropogenic sources. Global budgets for the elements Ca, Al, Fe, Si, and Ti suggest that desert dust remains the dominant source for these elements but anthropogenic or volcanic sources are also important for these elements. Changes in elemental distributions since preindustrial times were also estimated.

aerosols

RCA SATCOM Battery in Orbit Performance Update and Accelerated Life Test Results

No significant degradation of nickel cadmium battery performance in SATCOM F1 and F2 after almost 8 and 7-3/4 years in orbit was shown. Battery minimum discharge voltage data are presented for these spacecraft. In addition, 2 groups of nickel cadmium cells which are representative of those in orbit are undergoing real time eclipse-reduced suntime cycling in the laboratory. These groups of cells, which are being cycled at a maximum of 53% and 62% depth of discharge (based on actual capacity), have completed 14 and 15 eclipse seasons, respectively. Data for these groups of cells are presented and are compared with the in-orbit battery data.

Gaston, S. J.

Overview of Past and Future EVA Suit Testing and Training in Chamber B at NASA JSC

The Crew and Thermal System Division’s Chamber B has received an increase in demand for next generation suit testing. Chamber B is the National Aeronautics and Space Administration (NASA) Johnson Space Center’s only human-rated thermal vacuum (TVAC) chamber. Historically it was used in Gemini, Apollo, Skylab, Shuttle, and the International Space Station (ISS) suit tests. Recently, the chamber has been returned to service with new capabilities for suit testing. In 2023, The Exploration Extravehicular Mobility Unit (xEMU) underwent a 5-day, extensive thermal vacuum test that included both a full-bodied Exploration Pressure Garment Suit (xPGS) as well as a high fidelity Short xEMU. SpaceX has also used the chamber for human-in-the-loop (HITL) qualification and acceptance testing on their flight Polaris Dawn suits for the first-ever commercial extravehicular activity (EVA). Current chamber Manlock B2 upgrades include the support of two test subjects at the same time with updated chamber interface and support systems for the next generation of suits. This paper will discuss the history of spacesuit testing in the chamber, the recent testing for commercial and NASA suits, and upgrades to accommodate new test requirements.

Polaris Dawn

Overview of Past and Future EVA Suit Testing and Training in Chamber B at NASA JSC

The Crew and Thermal System Division’s Chamber B has received an increase in demand for next generation suit testing. Chamber B is the National Aeronautics and Space Administration (NASA) Johnson Space Center’s only human-rated thermal vacuum (TVAC) chamber. Historically it was used in Gemini, Apollo, Skylab, Shuttle, and the International Space Station (ISS) suit tests. Recently, the chamber has been returned to service with new capabilities for suit testing. In 2023, The Exploration Extravehicular Mobility Unit (xEMU) underwent a 5-day, extensive thermal vacuum test that included both a full-bodied Exploration Pressure Garment Suit (xPGS) as well as a high fidelity Short xEMU. SpaceX has also used the chamber for human-in-the-loop (HITL) qualification and acceptance testing on their flight Polaris Dawn suits for the first-ever commercial extravehicular activity (EVA). Current chamber Manlock B2 upgrades include the support of two test subjects at the same time with updated chamber interface and support systems for the next generation of suits. This paper will discuss the history of spacesuit testing in the chamber, the recent testing for commercial and NASA suits, and upgrades to accommodate new test requirements.

Human-in-the-loop

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

Spacecraft thermal margins depend on the temperature penalty of installed interfaces, yet catalog conductivity omits bondline thickness, mating surfaces, preload, and environment. The Testbed for Advanced Interface Materials in Vacuum (TAIMV) addresses this engineering-data gap by converting ambient/vacuum temperature fields from a four-coupon stack into quantities usable in spacecraft thermal models. Its 17-node steady-state model resolves axial conduction, parasitic fixture paths, grease-filled contact, radiation, and ambient convection. Four monolithic checks gave axial heat-rate ratios of 0.90–1.02, and Braycote calibration self-recovery gave 2.20% casewise mean absolute percentage error (MAPE) and 2.85% maximum difference. With transferable fixture terms frozen, Krytox LVP tested cross-material transfer against a manufacturer-derived external relation. The six Krytox cases gave 2.28% MAPE, 5.10% maximum difference, and full-field residual root-mean-square values of 0.553 °C ambient and 1.306 °C vacuum. Installed-joint resistance spanned 6.39–7.15 × 10⁻⁴ m²·K/W for Braycote and 4.09–4.49 × 10⁻⁴ m²·K/W for Krytox, corresponding to 2.33–6.66 K per modeled interface over the tested heat-flux range. TAIMV therefore supplies directly usable installed-joint resistance and conductance, plus apparent installed conductivity and explicitly model-conditioned grease conductivity/contact terms.

heat transfer

Assembly and Integration Status of a High Fidelity Ground Test Bed for the Water Processor Assembly

The Water Recovery System (WRS) is a critical component of life support aboard the International Space Station (ISS) and will play an essential role in future missions beyond Low Earth Orbit (LEO). Its primary functional units – the Urine Processor Assembly (UPA), Brine Processor Assembly (BPA), and Water Processor Assembly (WPA) – must be evaluated for extended operation, dormancy resilience, material obsolescence, and reliability under exploration-driven constraints. Ground testing is vital for developing these technologies and generating statistically relevant reliability assessments, which requires extended runtime under integrated, Flight-like conditions. Currently, no high-fidelity, fully integrated WPA ground test bed exists to support these objectives. To address this gap, NASA is developing a WPA test bed at Marshall Space Flight Center (MSFC) that combines downgraded ISS flight hardware with functionally flight-like components in a cost-effective configuration while maintaining priority hardware investigations. This paper describes the current status of hardware assembly and integration, outlines key challenges such as simulating microgravity effects and mitigating obsolescence, and presents future test objectives including software development, reliability assessments, dormancy studies, and exploration-oriented upgrades.

Water Processor Assembly

Fuel injector design for high temperature aircraft engine

The objective of the Innovative High Temperature Aircraft Engine Fuel Nozzle Program was to design and evaluate a nozzle capable of operating at a combustor inlet air temperature of 1600 F (1144 K) and a fuel temperature of 350 F (450 K). The nozzle was designed to meet the same performance requirements and fit within the size envelope of a current production dual orifice fuel nozzle. The design approach was to use improved thermal protection and fuel passage geometry in combination with fuel passage surface treatment to minimize coking at these extreme fuel and air temperatures. Heat transfer models of several fuel injector concepts were used to optimize the thermal protection, while sample tube coking tests were run to evaluate the effect of surface finish, coatings and tube material on the coking rate. Based on heat transfer analysis, additional air gaps, reduced fuel passage flow area and use of ceramic tip components reduced local fuel wetted wall temperatures by more than 200 F (100 K) when compared to a current production fuel nozzle. Sample tube coking test results showed the importance of surface finish on the fuel coking rate. Therefore, a one micro-inch (0.025 micron) roughness was specified for all fuel passage surfaces. A novel flow divider valve in the tip was also employed to reduce weight, allow room for additional thermal protection, and provide back pressure to reduce the risk of fuel vaporization. The fuel nozzle was fabricated and evaluated in a series of high temperature coking tests. Initial results of these tests indicate that thermal protection and surface treatments were partially successful in preventing nozzle fouling, but additional refinement of the internal flowpath is needed to prevent buildup of coke particles that partially blocked the spin slots which meter the nozzle fuel flow.

R. W. Stickles

Resistance of Silicon Nitride Turbine Components to Erosion and Hot Corrosion/Oxidation Attack

Silicon nitride turbine components are under intensive development by AlliedSignal to enable a new generation of higher power density auxiliary power systems. In order to be viable in the intended applications, silicon nitride turbine airfoils must be designed for survival in aggressive oxidizing combustion gas environments. Erosive and corrosive damage to ceramic airfoils from ingested sand and sea salt must be avoided. Recent engine test experience demonstrated that NT154 silicon nitride turbine vanes have exceptional resistance to sand erosion, relative to superalloys used in production engines. Similarly, NT154 silicon nitride has excellent resistance to oxidation in the temperature range of interest - up to 1400 C. Hot corrosion attack of superalloy gas turbine components is well documented. While hot corrosion from ingested sea salt will attack silicon nitride substantially less than the superalloys being replaced in initial engine applications, this degradation has the potential to limit component lives in advanced engine applications. Hot corrosion adversely affects the strength of silicon nitride in the 850 to 1300 C range. Since unacceptable reductions in strength must be rapidly identified and avoided, AlliedSignal and the NASA Lewis Research Center have pioneered the development of an environmental life prediction model for silicon nitride turbine components. Strength retention in flexure specimens following 1 to 3300 hour exposures to high temperature oxidation and hot corrosion has been measured and used to calibrate the life prediction model. Predicted component life is dependent upon engine design (stress, temperature, pressure, fuel/air ratio, gas velocity, and inlet air filtration), mission usage (fuel sulfur content, location (salt in air), and times at duty cycle power points), and material parameters. Preliminary analyses indicate that the hot corrosion resistance of NT154 silicon nitride is adequate for AlliedSignal's initial engine applications. Protective coatings and/or inlet air filtration may be required to achieve required ceramic component lives in more aggressive environments.

Nitride

Manned Lunar Landing Via Rendezvous

In any mission description, the vehicles, the flight profiles, and the astrionics hardware to im- plement the mission are all tightly interwoven things. A final result evolves only after many iterations to the solution are made. This paper will describe one of these iterations in the Saturn C-5 Earth Orbit Rendezvous approach to the Manned Lunar Landing Program. Since the iter- ation to be described in an nthone, there exists some basis for the hope that the perturbation from the final solution is small. This paper is not concerned with the landing itself, but only with those operations leading to injection of the space craft into the lunar trans- fer trajectory. However, as is to be expected, it is the target conditions which set the pace for the overall operation. The entire operation must be sized to culminate at a time and place which places the lunar target in an attainable position. The procedure would call for a burst of activity lasting over a relatively short time as compared to the long and extensive preparations leading up to it. The activity must be aimed at the opening of the lunar "launch window". Figure 1 illustrates the variation in the velocity increment required to launch a vehicle into a lunar transfer trajectory from a 485 kilometer earth orbit. The minima are at irregularly spaced intervals and are a func- tion of the inclination of the lunar and the earth satellite planes and of the position of the moon in its orbit around the earth (i. e. , the day of the month). In an operations analysis these spacings will influence the number of vehicles on the launch pad (primary and back-up) , their state of readi- ness, the firing rate, and also the flight profile to be chosen. Whether it is decided to go by "con- necting" or by "tanking" mode, the objective must be to get the spacecraft in the launch ready state at the opening of one of these launch windows. It may be desired that the first vehicle be capable of remaining in a functionally capable state even after bridging one or more of the gaps between the windows. This consideration will influence the design of the vehicles as well as the operational modes to be designed into the flight control hard- ware. For example, a sleep switch may be de- sirable from the standpoint of savings in battery we ight.

LUNAR LANDING

User Interface Issues in Supporting Human-Computer Integrated Scheduling

A major problem in designing user interfaces for scheduling systems is one of allowing the human to become an integral part of the system. The human role in scheduling extends beyond the simple tasks of providing the input and accepting the output. Because of the inherent intractability of most real-world scheduling problems, intelligence must be incorporated into the scheduling process in order to reach an acceptable solution in a reasonable amount of time. Artificial Intelligence research has concentrated on identifying algorithms and heuristics for this purpose. However, interfaces which allow the scheduler to take advantage of human intelligence and allow the user insight into and influence over the planning process are also needed.

Lynne P Cooper

In-suit CO2 Washout Test System (ICWTS) for CO2 Washout Verification in Spacesuits

Since the time of Mercury, Gemini, and Apollo, NASA has been performing CO 2 washout verification of spacesuits with Human in the Loop (HITL) test methods. Classically, the only instrumentation both with the accuracy and response time necessary was that of external mass spectrometers or medical gas analyzers fed by a long capillary line from the oro-nasal region within the suit. The helmet CO 2 washout configuration including the challenges posed by variation of a suited human subject frequently created difficulty in capturing adequate breath by breath data. For example, a nasal cannula could be worn with reasonable comfort however it posed the following challenges: (1) impeded the test subject’s ability to do a proper Valsalva maneuver; (2) frequently provided a corrupted waveform with relative movement; (3) precluded the ability to evaluate the Flow Weighted Average (FWA) at subject interface. A mouthpiece could be used in lieu of a cannula but posed challenges as well: (1) created potential disturbances of the flow field; (2) precluded the test subject from speaking during usage; and (3) presented comfort issues limiting the duration of test points. These challenges made it impractical to use a mouthpiece for anything other than short lab ambient environment tests. Technology development and NASA investment have afforded new capabilities to address some of these measurements providing improved data collection and are implemented in the In-suit CO 2 Washout Test System (ICWTS) which provides suit inlet/outlet pressure, temperature, relative humidity, partial pressure of oxygen, partial pressure of CO 2 , and flow measurement coupled with the acquisition of the inspired PPCO 2 including the ability for FWA measurement. This test system, coupled with use of the In-suit Respiration Mannequin Assembly (IRMA) and Computational Fluid Dynamics (CFD) combine to provide a full picture of the in-suit oro-nasal flow field and effectiveness of CO 2 washout in a spacesuit design.

Colin Campbell

Advanced Materials for the Lunar Surface: Multiscale Computational Design of Refractory Alloys and Carbides

Emerging operational environments, such as the lunar surface, present novel challenges for NASA and drive the need for advanced materials in applications like fission surface power systems. To address these demands, computational materials science is rapidly evolving to augment or replace costly and hazardous empirical testing. Although materials selection at NASA remains predominantly experimentally driven, advanced simulation methodologies are being steadily integrated into the engineering lifecycle. This work details the application of multiscale simulation techniques—including first-principles calculations, CALPHAD, dislocation dynamics, and molecular dynamics—at NASA's Ames Research Center to evaluate advanced materials for extreme environments. First, we present contributions to the Space Nuclear Propulsion Project. Be-cause propellant channel coatings in nuclear thermal rockets must withstand high-pressure, high-temperature hydro-gen, optimizing these materials is critical. First-principles calculations were employed to establish a rigorous quantitative and qualitative understanding of the behavior of the refractory carbides ZrC, NbC, and their mixtures in high-enthalpy hydrogen environments. This necessitated the generation of high-fidelity thermodynamic models for both stoichiometric and carbon-depleted carbides, both with and without the presence of hydrogen. Furthermore, we highlight efforts under the Refractory Alloy Additive Manufacturing Build Optimization (RAAMBO) project, where existing and novel alloy compositions were assessed for additive manufacturing printability and subsequent performance in applications such as heat pipes and rocket nozzle extensions. This was accomplished through a comprehensive multiscale simulation framework that bridged the gap from the nanometer to the millimeter scale. Across both initiatives, rigorous validation against empirical data was prioritized. By systematically employing a verified and validated computational frame-work, we demonstrate how simulation effectively supports multidisciplinary engineering efforts, builds project-wide confidence, and drives critical materials development.

computational materials

Barium Fluoride as a Standard Reference Material for Infrared Refractometry

This work proposes a standard reference material (SRM) for measurements of refractive index in the infrared spectral region (1–12 μm). The purpose of this material is to enable cross-method comparison of refractive index data obtained through minimum deviation, ellipsometry, interferometry, and prism coupling techniques. This will allow vendors and metrology laboratories, regardless of which technique they employ, to certify that their measurements meet required levels of accuracy, precision, and repeatability. Drawing on foundational work by Tilton at the National Bureau of Standards, a figure of merit for candidate SRM materials is outlined, and three materials are selected for further evaluation. Ultimately, barium fluoride is proposed as the most suitable SRM for the infrared spectral region, based on its broad transmission range, chemical and mechanical stability, low temperature dependence of refractive index, and well-characterized dispersion behavior.

Andrew Howe

In-suit CO 2 Washout Test System (ICWTS) for CO 2 Washout Verification in Spacesuits

Since the time of Mercury, Gemini, and Apollo, NASA has been performing CO 2 washout verification of spacesuits with Human in the Loop (HITL) test methods. Classically, the only instrumentation both with the accuracy and response time necessary was that of external mass spectrometers or medical gas analyzers fed by a long capillary line from the oro-nasal region within the suit. The helmet CO 2 washout configuration including the challenges posed by variation of a suited human subject frequently created difficulty in capturing adequate breath by breath data. For example, a nasal cannula could be worn with reasonable comfort however it posed the following challenges: (1) impeded the test subject’s ability to do a proper Valsalva maneuver; (2) frequently provided a corrupted waveform with relative movement; (3) precluded the ability to evaluate the Flow Weighted Average (FWA) at subject interface. A mouthpiece could be used in lieu of a cannula but posed challenges as well: (1) created potential disturbances of the flow field; (2) precluded the test subject from speaking during usage; and (3) presented comfort issues limiting the duration of test points. These challenges made it impractical to use a mouthpiece for anything other than short lab ambient environment tests. Technology development and NASA investment have afforded new capabilities to address some of these measurements providing improved data collection and are implemented in the In-suit CO 2 Washout Test System (ICWTS) which provides suit inlet/outlet pressure, temperature, relative humidity, partial pressure of oxygen, partial pressure of CO 2 , and flow measurement coupled with the acquisition of the inspired PPCO 2 including the ability for FWA measurement. This test system, coupled with use of the In-suit Respiration Mannequin Assembly (IRMA) and Computational Fluid Dynamics (CFD) combine to provide a full picture of the in-suit oro-nasal flow field and effectiveness of CO 2 washout in a spacesuit design.

Colin Campbell

A review of nickel hydrogen battery technology

This paper on nickel hydrogen batteries is an overview of the various nickel hydrogen battery design options, technical accomplishments, validation test results and trends. There is more than one nickel hydrogen battery design, each having its advantage for specific applications. The major battery designs are individual pressure vessel (IPV), common pressure vessel (CPV), bipolar and low pressure metal hydride. State-of-the-art (SOA) nickel hydrogen batteries are replacing nickel cadmium batteries in almost all geosynchronous orbit (GEO) applications requiring power above 1 kW. However, for the more severe low earth orbit (LEO) applications (greater than 30,000 cycles), the current cycle life of 4000 to 10,000 cycles at 60 percent DOD should be improved. A NASA Lewis Research Center innovative advanced design IPV nickel hydrogen cell led to a breakthrough in cycle life enabling LEO applications at deep depths of discharge (DOD). A trend for some future satellites is to increase the power level to greater than 6 kW. Another trend is to decrease the power to less than 1 kW for small low cost satellites. Hence, the challenge is to reduce battery mass, volume and cost. A key is to develop a light weight nickel electrode and alternate battery designs. A common pressure vessel (CPV) nickel hydrogen battery is emerging as a viable alternative to the IPV design. It has the advantage of reduced mass, volume and manufacturing costs. A 10 Ah CPV battery has successfully provided power on the relatively short lived Clementine Spacecraft. A bipolar nickel hydrogen battery design has been demonstrated (15,000 LEO cycles, 40 percent DOD). The advantage is also a significant reduction in volume, a modest reduction in mass, and like most bipolar designs, features a high pulse power capability. A low pressure aerospace nickel metal hydride battery cell has been developed and is on the market. It is a prismatic design which has the advantage of a significant reduction in volume and a reduction in manufacturing cost.

Smithrick, John J.

Modular Battery Controller

Some embodiments of the present invention describe a battery including a plurality of master-less controllers. Each controller is operatively connected to a corresponding cell in a string of cells, and each controller is configured to bypass a fraction of current around the corresponding cell when the corresponding cell has a greater charge than one or more other cells in the string of cells.

Button, Robert M