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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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Usage-based Lifing of Lithium-Ion Battery with HybridPhysics-Informed Neural Networks

Lithium-ion batteries are commonly used to power unmanned aircraft vehicles (UAVs).The ability to model and forecast the remaining useful life of these batteries enables UAV reliability assurance. Building accurate models for battery state of charge and state of health based on first principles is challenging due to the complex electrochemistry that governs battery operations and computational complexity required to solve them. Therefore, reduced order models are often used due to their ability to capture the overall battery discharge. Un-fortunately, these simplifications lead to residual discrepancy between model predictions and observed data. In this paper, we present a hybrid modeling approach merging reduced-order models and neural networks. In this approach, while most of the input-output relationship is captured by Nernst and Butler-Volmer equations, data-driven kernels reduce the gap between predictions and observations. We validate our approach using data publicly available through the NASA Prognostics Center of Excellence repository. Results showed that our hybrid battery prognosis model can be successfully calibrated, even with a limited number of observations.

Lithium-ion Battery

Planets and Satellites of the Outer Solar System, Asteroids, and Comets

The cosmogenic significance of outer solar system objects is evaluated with emphasis on planets and larger satellites of greatest biological interest; comets, asteroids, and the smaller satellites are also discussed. Principal physical and rudimentary photometric data for the five outer planets are presented in tables. Sufficient information on planetary motions is included for most calculations in physical planetology.

Ray L Newburn, Jr

Modeling a Li/SOCl2 battery for design purposes

A generalized code applicable to many different electrochemical systems and geometric designs is discussed. The code is to be set up so that physical property data such as thermal conductivity, viscosity, density, and configuration (e.g. physical dimensions) are the input data. Thus, by changing these parameters many different battery configurations can be handled. The outputs, as a function of time and space, are voltage, current, temperature, pressure, velocity, and species concentration.

Ernst, D. W.

Trajectory Engineering with Modular Patched Conics for Entry Systems and TPS (TEMPEST)

Brief Presenter Biography (35 word limit): Bohdan Wesely is an Aerospace Engineer in the Entry Systems and Technology Division at Ames. He has worked on a variety of projects for NASA including integrated TPS (thermal protection system) flight hardware deliveries and testing services for commercial partners. Introduction: TEMPEST is a new trajectory analysis framework that is designed to fill the gap between dedicated flight mechanics tools and aerothermal and TPS sizing tools. The project started as an SJSU master’s thesis and has since evolved into a general conceptual design tool capable of studying a wide variety of entry problems. Development is ongoing in the Entry Systems and Technology Division at NASA ARC. Why TEMPEST: Space missions involving entry into a planetary atmosphere involve a series of unique requirements across multiple disciplines. Whether it is traditional entry descent and landing (EDL), or aerocapture, the vehicle must navigate to its target landing location or orbit state, and the TPS must protect the payload during entry. The design process typically involves iterative handoffs between various flight mechanics, flow solver, and material response level tools. During the early conceptual phase, a wide variety of feasible trajectories are simulated in a Monte Carlo scenario which broadly satisfy the mission or landing requirements. Next, computational fluid dynamics (CFD), direct simulation Monte Carlo (DSMC), and other flow solver analyses are performed at various key trajectory points to generate an aero-database, heating and TPS design requirements also emerge at this stage. At this point, with updated aerodynamics from the various flow solvers, trajectories can be re-run, this in turn can change the required freestream conditions for the CFD tools, and as a project progresses, these analyses converge, and uncertainty is reduced. However, there is always a “hand-off” occurring between two inherently coupled phenomena. Analysis Description: One of the goals with TEMPEST is to use a variety of first principles estimation methods coupled with an atmosphere model to predict vehicle aerothermodynamics across the entire flight regime while propagating a 3 or 6 degree of freedom (DoF) trajectory. Aerodynamics methods include modified Newtonian, Maxwell and Cercignani- Lampis-Lord (CLL) for continuum, transitional, and free molecular flow regimes. Aerothermodynamics include boundary layer and reference enthalpy methods, and Mutation++ for non-equilibrium chemistry modeling. TEMPEST is also capable of stitching multiple trajectory segments together to study mission scenarios like multi-pass aerocapture and aero-gravity assists. Most of the program is implemented in MATLAB using modern system objects, it relies on several C++ shared libraries for supporting tools like Gmsh, the Global Reference Atmospheric Model (GRAM), and Mutation++. The various first principles aerothermal estimation methods are discretized across either a structured axisymmetric panel mesh or an unstructured tri-mesh generated from an open-source tool such as Gmsh, this allows solutions on the same mesh to be compared across tools such as CB-Aero. CFD Coupling. A physics-aware, gaussian process CFD anchoring scheme is proposed to adjust the various first principles methods as a CFD database is populated. One goal for this anchoring module is to inform the project where CFD should be run. Full knowledge of the entire trajectory, atmosphere, and aerothermodynamics allows for easier identification of high sensitivity areas and uncertainty quantification. While the first principles effects are well known and proven accurate in existing tools such as CB- Aero and Cart3D, a physics aware CFD anchoring scheme increases tool credibility across a project lifecycle. Material Response Modeling. Correct TPS sizing is critical for optimizing mass for science payloads and ensuring mission success. The process typically involves a thermal analysis along the trajectory with surface heating environments as a boundary condition. Several design constraints are maximum bondline temperature and maximum recession with various margining techniques. The material response tool FIAT, developed out of NASA Ames, is currently being integrated into the TEMPEST environment. TPS recession, shape change, mass loss, and mass property alteration are all factors that can perturb an entry trajectory. For missions like Mars 2020, recession was minimal and was safely handled separately as a post process. For missions such as Jupiter Galileo with a high TPS mass fraction or asteroid entries, recession plays a major role. The proposed fully coupled scheme is to use an epoch-based approach where the trajectory integration is halted after a recession threshold, the energy balance and FIAT are solved at each panel, the mesh, aerodynamics, and mass properties are updated, and the trajectory continues. Several computational tradeoffs have been made during the development of TEMPEST to limit the cost of a single trajectory and preserve its utility as a conceptual, rapid iteration tool. Conclusion: Development of TEMPEST is ongoing and the project is still in its infancy. This talk aims to showcase its unique capabilities to support future NASA entry systems missions.

Bohdan O Wesely

Toward Large Field-of-view X-ray Spectrometers with Magnetic Microcalorimeters

A future X-ray telescope mission like Lynx, a X-ray flagship mission concept, requires a large field of view, high energy resolution, and high spatial resolution. The Magnetic Microcalorimeter (MMC) detectors we are developing for such a mission feature a 5-arcminute field of view, approximately 100,000 pixels, each spanning 0.5–1 arcsecond. These detectors require the readout of 8,000 sensors. Three different array types have been designed to meet scientific goals, two of which utilize thermal multiplexing to reduce the number of readout channels in a scheme called “Hydra.” We are currently fabricating detectors on a recently completed buried wiring wafer with connections to every sensor. The sensors are read out using a microwave multiplexer (μMUX) with flux ramp modulation. A single μMUX can read out approximately 1,000 sensors with only two feed lines. We will report on the test of the first two-dimensional μMUX chip, consisting of 78 resonators. μMUX chips that pass screening will be directly bonded to MMC array chips using indium bump bonding. In parallel, we have tested a kinetic inductance traveling wave parametric amplifier (KI-TWPA) to amplify signals at low temperatures. The KI-TWPA exhibits extremely low internal noise, approaching the standard quantum limit. Since the energy resolution of an MMC is primarily limited by the readout system, the KI-TWPA is an ideal amplifier for MMCs with μMUX readout. We recently measured the readout noise of a μMUX with a KI-TWPA, demonstrating its capability for reading out MMC arrays. We present the design and fabrication of the latest MMC detectors, along with its readout performance.

Magntic Microcalorimeters

Battery case shear

Hand operated shear removes a battery case without disturbing the internal components which are to be tested. It consists of three tool-steel elements, the cutter blade, and a hand lever that provides the mechanical advantage required to cut steel.

Patro, S.

Dynamic Analysis of Reynolds Number Effects on Trailing Edge Transonic Vortex Shedding and Its Impact on Turbine Blade Aerodynamic Performance

In this work, we will discuss observations from images acquired from a time-resolved, high-speed self-aligned focusing Schlieren campaign that was performed at the CW-22 facility at NASA Glenn Research Center to understand the dynamic behavior of thick trailing-edge high-pressure turbine blades simulating a ceramic matrix composite (CMC) construction at high inlet turbulence conditions. For the CMC-9 blade, which has a trailing edge thickness of 9% of the axial chord, we identified a regime where an excessive total pressure loss (loss anomaly) is observed only for a narrow range of Reynolds numbers at a fixed exit Mach number of 0.74. The loss anomaly is qualitatively explained by our images, which were taken at 10 distinct blade Reynolds numbers spanning a factor of 6. The images show a significant increase in energy related to the oscillations due to transonic vortex shedding at the Reynolds numbers related to the high loss conditions. This increased energy leads to the formation of strong acoustic waves that turn into shock waves at the highest loss conditions. From our observations stemming from Spectral POD analysis of the high-speed images, we see the acoustic waves produced by the trailing edge vortex shedding exist in all conditions tested; but the shedding frequency has a very slight trend upwards as the Reynolds number is increased, varying about 6% in the range tested. Considering this variation of shedding frequency as a function of Reynolds number, which is well-established for other bluff-body flows, we stipulate there may be a potential feedback mechanism involving an acoustic information transfer path across neighboring blades that may explain why only a narrow range of Reynolds numbers displays strong, shock-forming vortex shedding. We consider a few feedback paths and examine the timing based on the mean flow field from a high-resolution LES simulation. It appears that all feedback mechanisms are viable, presenting an integer number of delay cycles with respect to disturbances generated at the trailing edge. Most noteworthy, however, is the acoustic/shock-boundary layer interaction mechanism at the blade geometric throat. Based on our analysis, this mechanism likely plays an important role in realistic, curved turbine blade passages.

Aerodynamics

Optimization of X-ray Absorbers for High-Resolution TES Detectors in NewATHENA X-IFU

NewATHENA’s X-ray Integral Field Unit (X-IFU) uses a large-format array of Transition Edge Sensor (TES) microcalorimeters coupled with absorbers made of gold and bismuth providing 4 eV FWHM resolution up to 7 keV in the 0.2- 12 keV band. X-ray absorbers must be thick enough for photon absorption, maintain low heat capacity for energy resolution, and have good thermalization properties. The X-IFU requires total Quantum Efficiency (QE) of 96%, 87%, and 63% at 1, 7, and 9.5 keV, respectively. Optimal thicknesses are 1.05 µm gold and 5.5 µm bismuth to achieve 0.731 pJ/K at 90 mK and 87% QE at 7 keV. While typical TES absorbers are 3-4 µm thick, producing the required 5.5 µm Bi absorbers via standard electroplating creates enlarged grains and surface roughness. The increased roughness and grain size variability produced with our standard recipe have resulted in instances of 1) low energy spectral tails 2) spectral broadening of the energy resolution and 3) thermal shorts between pixels when a large grain bridges the gap between absorbers. In this study, we have introduced a new fabrication process and altered the morphology of the thick Bi through changes in the electroplating process. The process changes are intended to address all three issues as well as reduce particulate contamination observed on the finished detector arrays.

Absorber

Material Properties and Modeling of Room Temperature Vulcanizing Silicone

Room Temperature Vulcanizing silicone (RTV) is a high-temperature adhesive that has successfully been used as a gap-filler between Thermal Protection System (TPS) tiles for heatshields on numerous missions. It is also used to bond instrumentation plugs such as temperature and pressure sensors into the heatshields. While RTV has been traditionally assumed to be a non-porous and non-ablating material, numerous experiments have shown that RTV pyrolyzes and becomes highly porous as it is heated. Heating RTV has also shown swelling, or intumescence, which can pose unique problems that lead to roughness induced boundary-layer transition, surface oxide formation and contamination of heat shield sensors. Therefore, it is crucial to understand and model the intumescence phenomenon of RTV. As data for RTV material properties is limited, the first step in modeling RTV is to collect material properties such as pyrolysis mass-loss, microstructure change, virgin and char porosity, etc. which was performed in our initial study. Additionally, thermomechanical properties such as Young’s modulus and Poisson ratio are required for modeling the intumescence of RTV, which were taken from literature and the coefficient of thermal expansion was collected using in-situ heating and Micro Computed Tomography (µ-CT) in previous studies. Finally, numerous other properties such as pyrolysis gas properties, virgin and char thermal conductivity and specific heat were compiled from previous experiments and literature into a material database that can be used for simulations. In Porous Material Analysis Toolbox based on OpenFOAM (PATO) [4], structural mechanics coupled with material response was used for simulating the intumescence of RTV as it is heated. However, since the permeability of the material is very low, the pyrolysis gas creates an internal pressure build-up as the material is being heated, significantly contributing to the deformation of the material. To correctly characterize this phenomenon, additional physics models were implemented into PATO's stress analysis solver, and results were compared with RTV dilatometry test data as a preliminary verification case. Future work will include experiments of RTV at the Plasmatron X facility and the in-situ heating cell with µ-CT, and improvement of simulation tools to more accurately model RTV intumescence.

PATO

COBE battery overview: History, handling, and performance

The following topics are presented in viewgraph format: Cosmic Background Explorer (COBE) mission background; battery background and specifications; cell history; battery mechanical/structural design; battery test data; and flowcharts of the various battery approval procedures.

Yi, Thomas

"Long Life" Dc Brush Motor for Use on the Mars Surveyor Program

DC brush motors have several qualities which make them very attractive for space flight applications. Their mechanical commutation is simple and lightweight, requiring no external sensing and control in order to function properly. They are extremely efficient in converting electrical energy into mechanical energy. Efficiencies over 80% are not uncommon, resulting in high power throughput to weight ratios. However, the inherent unreliability and short life of sliding electrical contacts, especially in vacuum, have driven previous programs to utilize complex brushless DC or the less efficient stepper motors. The Mars Surveyor Program (MSP'98) and the Shuttle Radar Topography Mission (SRTM) have developed a reliable "long life" brush type DC motor for operation in low temperature, low pressure CO2 and N2, utilizing silver-graphite brushes. The original intent was to utilize this same motor for SRTM's space operation, but the results thus far have been unsatisfactory in vacuum. This paper describes the design, test, and results of this development.

David Braun

NASA JSC’s Simulant Development Lab Capabilities and Artemis Testing

The Simulant Development Lab (SDL) is a multifunctional collaborative workspace that supports the development, curation, analysis, testing, and distribution of planetary regolith simulants – including lunar, Martian, asteroidal, and other granular materials. The lab provides a multidisciplinary setting for scientific characterization of simulant physical properties and for engineering evaluations conducted with simulant test beds. To enable this work, the SDL curates and maintains a stock of more than 35 metric tons of simulant material. To evaluate these materials and support testing goals, the lab is equipped with a comprehensive suite of processing tools and analytical instruments. These capabilities enable the SDL’s mission at NASA’s Johnson Space Center to distribute, develop, process, characterize, and test regolith simulants for mission relevant applications. Through controlled and repeatable testing environments that replicate the physical and compositional properties of lunar regolith, the SDL supports Artemis hardware maturation, providing safe, Earth‑based analogs for evaluating systems that must withstand regolith dust interactions, physical wear and abrasion, and operational loads. The facility’s extensive simulant inventory and integrated geological and engineering test infrastructure accelerate technology readiness for Artemis and future exploration campaigns (e.g., future crewed or robotic missions to Mars).

Simulant Development Lab

Performance Optimization for Lunar Extravehicular Activity Readiness (POLAR) Study: Methods Paper

To better understand which aspects of physical fitness may be most related to performance during Lunar surface operations and thereby help to inform the current NASA fitness standards, much can be learned from fields encompassing the “tactical athlete.” Other physically demanding professions such as law enforcement, military, or rescue professionals often require candidates to meet occupationally-relevant fitness standards. The determination of such standards is a multistep process, including both objective and subjective measures, to determine tasks essential to occupational performance and identify the minimal fitness profile needed to meet physical demands of the job. Notably, fitness is only one component which may contribute to the demands of astronaut selection, flight assignment, and occupational performance. Utilizing a framework to systematically determine which domains of fitness most contribute to relevant job tasks can aid in the refinement of current NASA-STD-3001 fitness standards. Therefore, NASA’s Exercise Physiology & Countermeasures Laboratory conducted the Performance Optimization for Lunar Extravehicular Activity Readiness (POLAR) study to identify and examine a comprehensive list of fitness tests (including NASA-STD-3001 assessments: 1-Repetition Maximum [1-RM] bench press and deadlift) and determine preliminary relationships between identified fitness parameters and novel Artemis-relevant tasks to help inform future investigations for the continued development of aerobic and muscular fitness standards for surface EVAs. This was accomplished through 1) a review of the literature relating fitness assessments to simulated or real EVA performance to identify fitness tests that are most correlated with simulated EVA task performance; 2) a task analysis following a modified framework for physical employment standards development to down select mission critical tasks; and 3) development and pilot testing of a novel, portable Artemis-relevant EVA task circuit to relate to a battery of fitness assessments. The current report describes the methodology used to complete the task analysis, EVA task circuit development, and the pilot study.

Nicole C Strock

Fatigue Behavior of Laser Powder Bed Fused HAYNES 214: Effects of Different Surface Treatments

In this study, under NASA’s Rapid and Analysis Manufacturing Propulsion Technology (RAMPT) project, effects of different surface post-treatments on surface texture and fatigue behavior of L-PBF Alloy 214 were investigated. Various subtractive SPTs including abrasive flow machining (AFM), machining (M), shot peening (SP), vapormatt (VM), dry electropolishing (DE), chemical milling (CM), chemical-mechanical polishing (CMP), electro chemical (ECP) were applied to study the variations of the surface texture, microstructure and uniaxial fatigue behavior under fully reversed strain-controlled condition at four different strain amplitudes of 0.005, 0.004, 0.003, and 0.0025 mm/mm. The insights gained regarding the relationship between structural and mechanical properties for different SPTs can help establish guidelines for selecting the most effective process to enhance the performance of Laser Powder Bed Fusion (L-PBF) Alloy 214, especially for critical aerospace applications.

Post-Processing

Hubble Space Telescope 2004 Battery Update

Battery cell wear out mechanisms and signatures are examined and compared to orbital data from the six on-orbit Hubble Space Telescope (HST) batteries, and the Flight Spare Battery (FSB) Test Bed at Marshall Space Fiight Center (MSFC), which is instrumented with individual cell voltage monitoring.

Hollandsworth, Roger

FAST Spacecraft Battery Design and Performance

The Fast Auroral Snapshot (FAST) Explorer spacecraft is to study the physical processes that produce the aurora borealis and aurora australis. It is a unique plasma physics experiment that will take fundamental measurements of the magnetic and electrical fields. This investigation will add significantly to our understanding of the near-earth space environments and its effect. The FAST has a 1 year requirement and 3-year goal for its mission life in low earth orbit. The FAST power power system topology is a Direct Energy Transfer (DET) system based on the SAMPEX design. The FAST flight battery supplies power to the satellite during pre-launch operations, the launch phase, the eclipse periods for all mission phases, and when the load is about 50 watts.

Jung, David S.