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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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205 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Recent Developments in Safe Lithium Ion Battery Design for Human Space Flight

This presentation provides an overview of EVA batteries and introduces the concept of designing lithium ion batteries that resist the propagation of a single cell catastrophic failure. Thermal runaway initiation methods are briefly discussed, and the safe performance of the resulting designs is summarized. Approached in an incremental fashion, each subsequent battery design is introduced, ending with a current development for the Exploration EVA spacesuit. Challenges in achieving safe design performance with limited internal volume are briefly discussed and forward work is identified. Video examples of both propagating and non-propagating designs are included.

lithium ion↗
NASA NTRS1983

Battery charge control with temperature compensated voltage limit

Battery charge control for orbiting spacecraft with mission durations from three to ten years, is a critical design feature that is discussed. Starting in 1974, the General Electric Space Systems Division designed, manufactured and tested battery systems for six different space programs. Three of these are geosynchronous missions, two are medium altitude missions and one is a near-earth mission. All six power subsystems contain nickel cadmium batteries which are charged using a temperature compensated voltage limit. This charging method was found to be successful in extending the life of nickel cadmium batteries in all three types of earth orbits. Test data and flight data are presented for each type of orbit.

Thierfelder, H. E.↗
NASA NTRSDate not supplied

An Efficient Approach to Collect Inlet Characterization Data

This report considers a novel process to acquire performance data for supersonic mixed compression inlets that is faster, and therefore less costly, than the previous one. In the previous process, measurements were recorded in discrete increments. The backpressuring actuator was advanced, there was a pause to allow for airflow fluctuations to diminish, and then the measurements were recorded. While this process was methodical, reliable and accurate, it consumed significant wind-on time. In general, high-speed wind tunnels are expensive to operate considering maintenance, energy and human resource requirements. Furthermore, many facilities, such as blowdown wind tunnels, are limited in the duration that they can maintain the desired test condition. Consequently, a quick method to collect the measurements is desired. A favored approach has the actuator moving in a continuous fashion with measurements recorded as the actuator continuously progresses through the increment points. This approach, identified as the dynamic inlet characteristic data acquisition procedure, uses in situ dynamic high-speed pressure sensors to measure pressure signals. While faster, continuous movement adds dynamic effects to the data. To better understand these dynamic effects and other potential influences, a study was undertaken to compare wind tunnel measurements taken at discrete actuator position points with data gathered during continuous actuator movement. Specially, plots of inlet pressure recovery versus mass capture ratio, or total pressure characteristic curves, were examined. The data were measured during experiments in the NASA Glenn Research Center Abe Silverstein 10- by 10-Foot Supersonic Wind Tunnel (SWT) with an inlet propulsion test article. In this report, the wind tunnel experiment and the study objectives are described. The processes to reduce the data and for analysis are explained. A discussion of the results along with features noted in the data is given. Finally, conclusions from this study that may be used to guide future wind tunnel experiment planning are presented.

Inlet↗
NASA NTRSDate not supplied

An Efficient Approach to Collect Inlet Characterization Data

This report considers a novel process to acquire performance data for supersonic mixed compression inlets that is faster, and therefore less costly, than the previous one. In the previous process, measurements were recorded in discrete increments. The backpressuring actuator was advanced, there was a pause to allow for airflow fluctuations to diminish, and then the measurements were recorded. While this process was methodical, reliable and accurate, it consumed significant wind-on time. In general, high-speed wind tunnels are expensive to operate considering maintenance, energy and human resource requirements. Furthermore, many facilities, such as blowdown wind tunnels, are limited in the duration that they can maintain the desired test condition. Consequently, a quick method to collect the measurements is desired. A favored approach has the actuator moving in a continuous fashion with measurements recorded as the actuator continuously progresses through the increment points. This approach, identified as the dynamic inlet characteristic data acquisition procedure, uses in situ dynamic high-speed pressure sensors to measure pressure signals. While faster, continuous movement adds dynamic effects to the data. To better understand these dynamic effects and other potential influences, a study was undertaken to compare wind tunnel measurements taken at discrete actuator position points with data gathered during continuous actuator movement. Specially, plots of inlet pressure recovery versus mass capture ratio, or total pressure characteristic curves, were examined. The data were measured during experiments in the NASA Glenn Research Center Abe Silverstein 10- by 10-Foot Supersonic Wind Tunnel (SWT) with an inlet propulsion test article. In this report, the wind tunnel experiment and the study objectives are described. The processes to reduce the data and for analysis are explained. A discussion of the results along with features noted in the data is given. Finally, conclusions from this study that may be used to guide future wind tunnel experiment planning are presented.

Data Acquisition↗
NASA NTRS2021

Mathematical Characterization of Battery Models

The purpose of this document is to demonstrate the use of the Extended Kalman Filter as a tool for battery state estimation and the estimation of battery state of charge. The mathematical details based on the equivalent circuit model are presented followed by an electrochemical engineering model. A simplified first-order model is used to demonstrate the procedure followed by second and third-order models. Next a simplified electrochemistry model is presented along with observer development. State observability is calculated for the simpler equivalent circuit models and the simplified electrochemistry model. An outline of the battery model parameter identification method is presented, and model performance based on experimental and flight data is demonstrated.

Battery↗
NASA NTRS2026

Dynamic Regulation of Sub-Atmospheric Pressure for Constant and Cyclic Gas Loads During Testing of Spacesuit Components

New iterations of the various subsystems within the spacesuit will benefit from a new sorbent technology. For example, sorbents used in the Trace Contaminant Control (TCC) and the Rapid Cycle Amine (RCA) systems within the Exploration Portable Life Support System (xPLSS), part of the Extra-Vehicular Mobility Unit (xEMU). For proper validation, the sub-atmospheric pressure needs to be maintained within a simulated 2 ft 3 spacesuit volume. The traditional approach, which involves placing the entire vent loop within a hypobaric chamber, is not practical for the widespread testing of components and prototypes, as these specialized chambers are costly and not widely available. A two-stage regulator based sub-atmospheric pressure system is presented in this work. The method regulates the pressure based on pressure differentials between the pressure regulation pump, the test system, and the ambient environment. The performance of this system is demonstrated using data collected during a 150+ hour non-regenerative TCC sorbent evaluation, several 24-hour regenerative TCC sorbent evaluations with different regeneration cycles, and an 8-hour RCA sorbent evaluation, all under xEMU operating conditions. For regulation, the inlet regulator was set to propagate a small leak to increase the stability of the system as the gas load from the testing system changes. It was also found that controlling the input flow rate that replaces the material lost during regeneration is critical for ensuring the stability of the system. This system provided excellent pressure regulation, without adjustments, for constant loads during shorter time evaluations (hours), while longer time evaluations (days) are easily obtainable with periodic regulator adjustments. A second method is under development to address longer-term stability and to automate pressure regulation. It will incorporate flow and pressure measurements to dynamically control a set of electronically controlled proportional valves for adjusting the pumping speed and air bleed supply.

Nicholas F Materer↗
NASA NTRSDate not supplied

Dry Pressed, High Areal Loading Electrode Architectures Enabled by Holey Graphene

For future electric aviation, advanced battery cell chemistry beyond lithium ion batteries are required to meet mission requirements. High energy density battery concepts such as lithium-sulfur (Li-S) and lithiumoxygen (Li-O2) chemistries are being intensively investigated to realize their extraordinary theoretical promise in terms of energy density. Most fabrication methods of cathodes for these novel battery chemistries followed a conventional approach. In this approach, the active material is mixed with a polymer binder and a conductive carbon in a high-boiling organic solvent to form a slurry, followed by casting onto a current collector and solvent evaporation. The process is usually lengthy and poses environmental hazards due to the use of organic solvents.

Lin Yi↗
NASA NTRS2026

Pulsed Electroacoustic Analysis Capabilities at NASA Glenn Research Center

The High Voltage Testing Laboratory at NASA Glenn Research Center is equipped with a pulsed electroacoustic (PEA) analyzer to study space charge phenomena in dielectric materials. Dielectric materials such as those used in high voltage insulation systems are of great interest due to their crucial role in withstanding high voltages and avoiding electrical breakdown in electrified aircraft power systems. Current research is underway for the development of novel lightweight electrical insulation and the thorough evaluation of these materials is required. The PEA instrumentation at NASA GRC is a nondestructive method to evaluate the space charge phenomena which can give a unique insight on the feasibility and lifetime of material systems. The instrumentation capability and initial results are reported here.

pulsed electroacoustic↗
NASA NTRS2026

A Modular Conjugate Heat Transfer Optimization Framework for Thermal Management of Electric Aircraft

Conjugate heat transfer (CHT) analysis and optimization is a powerful method for improving thermal management, as it simultaneously resolves the temperature distribution in both fluid and solid domains. This paper presents a modular, discrete adjoint-based CHT optimization capability integrated within the OpenMDAO/MPhys framework. A unique feature of the proposed framework is its flexibility to extend to multidisciplinary optimization, including aero-structural-thermal applications. The fluid domain is modeled using a finite-volume Computational Fluid Dynamics (CFD) solver, and the solid domain with a conduction heat transfer solver. A mixed Neumann-Dirichlet boundary condition is developed to enable full submersion of the solid geometry within the fluid domain, while ensuring consistent temperature and heat flux coupling at the CHT interface. Gradient-based optimization is performed; the gradients are efficiently computed using the discrete adjoint solvers implemented in DAFoam. To demonstrate the method, this paper considers two cases related to electric aircraft thermal management: a U-bend heat exchanger and an actively cooled battery pack. The U-bend case aims to minimize pressure loss while maximizing heat flux by changing the pipe geometry. The optimized design reduces pressure loss by 52.7% and increases total heat flux by 2.3%. In the battery pack case, a 3-by-3 cell configuration is cooled by ambient airflow, with constant heat generation prescribed in the cells. The battery casing shape serves as the design variable, and the objective function is a weighted sum of pressure loss and pack weight, subject to a maximum temperature constraint. The optimized design achieves a 44.6% reduction in pressure loss and a 1.5% reduction in weight, while satisfying the thermal constraint. To ensure the reliability of the optimized designs, this study validates coarse-mesh, steady-state predictions against fine-mesh unsteady simulations, demonstrating consistency within acceptable errors. This work demonstrates the potential of the developed framework to enable rapid, high-fidelity design of thermal management systems for electric aircraft.

heat transfer↗
NASA NTRS1966

Spacecraft Antenna Pointing

In examining the characteristic inaccuracies of a pre-programmed high-gain antenna pointing system, the effects of spacecraft attitude errors, as embodied in pitch, yaw and roll limit cycle activity, are of major concern. If the pointing accuracy requirements for a particular mission allow the use of a single degree of freedom pointing system, it is doubtful whether a method of correcting antenna position for spacecraft attitude errors would be worthwhile. This is because the pointing error due to fitting a plane curve to a three-dimensional trajectory would probably be at least as large as the additional pointing errors due to attitude drift within the deadbands. Further, trying to correct pointing for pitch, yaw, and roll drifts by adjusting a single hinge angle is relatively ineffective.

ERROR SIGNAL↗
NASA NTRS2004

Energetics of Single Substitutional Impurities in NiTi

Shape-memory alloys are of considerable current interest, with applications ranging from stents to Mars rover components. In this work, we present results on the energetics of single substitutional impurities in B2 NiTi. Specifically, energies of Pd, Pt, Zr and Hf impurities at both Ni and Ti sites are computed. All energies are computed using the CASTEP ab initio code, and, for comparison, using the quantum approximate energy method of Bozzolo, Ferrante and Smith. Atomistic relaxation in the vicinity of the impurities is investigated via quantum approximate Monte Carlo simulation, and in cases where the relaxation is found to be important, the resulting relaxations are applied to the ab initio calculations. We compare our results with available experimental work.

Binary Alloys↗
NASA NTRSDate not supplied

OverFlight: Graphical Flight Operations Planning

OverFlight is an in-development graphical user interface (GUI) that implements a state-of-the-art rotorcraft maneuvering noise model using a source noise hemisphere approach coupled with the Aircraft NOise Prediction Program 2 (ANOPP2). This GUI stems from a demand for easy-to-use mission planning and community impact acoustic tools that can model the maneuvering flight of a rotary-wing vehicle. This paper covers the models used for the development of OverFlight and model validation efforts. Data from a joint NASA/Army flight test of an MD530F aircraft are used both for source noise hemispheres as well as maneuvering flight data. Analysis of the predicted maneuvering noise shows better agreement that traditional methods currently employed, while also demonstrating maneuvers where the underlying assumptions fail to hold.

rotorcraft↗
NASA NTRS1990

Artificial Intelligence for Multi-Mission Planetary Operations

A brief introduction is given to an automated system called the Spacecraft Health Automated Reasoning Prototype (SHARP). SHARP is designed to demonstrate automated health and status analysis for multi-mission spacecraft and ground data systems operations. The SHARP system combines conventional computer science methodologies with artificial intelligence techniques to produce an effective method for detecting and analyzing potential spacecraft and ground systems problems. The system performs real-time analysis of spacecraft and other related telemetry, and is also capable of examining data in historical context. Telecommunications link analysis of the Voyager II spacecraft is the initial focus for evaluation of the prototype in a real-time operations setting during the Voyager spacecraft encounter with Neptune in August, 1989. The preliminary results of the SHARP project and plans for future application of the technology are discussed.

David J Atkinson↗
NASA NTRS2003

Global Characterization of Polygonally Fractured Terrain on Venus and Implications for a Climate Change Origin

On Earth, polygonal fractures with spacings of 1-100 cm form in lava flows that cool slowly under isotropic stress conditions. On Venus, polygonal fractures are observed with typical fracture spacings of 1-2 km, covering regions 10s to 100s of km across. These features have been proposed to form via cooling of lava flows or above subsurface intrusions, or due to surface cooling caused by climate change. A watershed algorithm was modified to search the entire Magellan image database autonomously for terrains with polygonal fractures. Here we characterize the 204 polygon terrains found using this method (including over 170 newly identified regions) with respect to size, morphology, stratigraphy, and geologic setting. These results are used to examine different models of origin.

S. E. Smrekar↗
NASA NTRS2026

Smart Process Planning for Automated Fiber Placement

Many industries, including aerospace, automotive, wind energy, maritime, and sporting goods, rely on strong, lightweight materials called composites. These materials are made by layering fibers, which can come in the form of narrow strips or wider sheets, and setting them in a polymer matrix. One of the most advanced ways to make these parts is through automated fiber placement, where a machine lays down the fibers in precise patterns. This method can create very efficient and strong designs, but it is complex, expensive, and often depends heavily on the experience of skilled engineers. Today, the design, manufacturing, and inspection stages of composite production are usually handled separately. This separation means that important information, such as how a part will be built or what defects might occur, is not always shared between stages. As a result, parts may not be as lightweight, strong, or defect-free as possible, and the process can take longer and cost more. This research develops a smart process planning system that connects design, manufacturing, and inspection into one continuous process. Built as software that works with existing tools, the system can automatically plan how the fibers are placed, predicting and reducing defects while improving both manufacturability and strength. The system optimizes not only individual layers but also how defects are distributed across all layers, preventing them from stacking up in ways that weaken the final part. It also uses inspection results from completed parts to improve future designs, creating a feedback loop where each stage informs the others. The system was tested by designing a composite panel using this new approach and comparing it to a panel made with state-of-the-art manual planning methods. The results showed that the system could intentionally control where defects appeared and increase the efficiency of the planning process. By unifying design, manufacturing, and inspection, this research shows a way to make advanced composite manufacturing more efficient, consistent, and cost-effective. This approach lowers the barrier to using automated fiber placement and opens the door for its wider adoption not only in aerospace but also in industries such as automotive, wind energy, maritime, and sporting goods, where strong and lightweight structures are essential.

Computer-Aided Process Planning↗
NASA NTRSDate not supplied

Thin-Film Embedded Sensors for Battery Health Monitoring

Hybrid or all-electric aircraft are being developed as the next generation of aircraft to both allow new forms of aviation and decrease environmental impact. Since these types of aircraft are based on high-capacity battery technology, safe operation of these batteries becomes increasingly important. In particular, the potential for battery failure due to uncontrolled chemical reactions resulting in thermal runaway, catastrophic failure, and battery fires must be addressed in order for such battery technology to have the level of safety needed for standard aviation implementation. Efforts to ensure battery safety often involve engineering solutions that seek to contain rather than prevent such events by early detection. Such approaches increase the system weight and decrease the power per unit mass provided by the battery system. Existing methods for measuring battery parameters to determine the battery state-of-health are limited. These methods include electrical measurements of the cell current and/or voltage output as well as temperature measurements taken externally on the cell surface. Such external temperature measurements are limited in their ability to provide early warning of impending battery failure. In response, an effort to develop sensors operating internal to battery for health monitoring has been ongoing in the NASA Sensor-based Prognostics to Avoid Runaway Reactions & Catastrophic Ignition (SPARRCI) project. The basic approach associated with this sensor work is the deposition of thin film sensors on the battery separator located between the anode and cathode of the battery. These thin film sensors are then monitored to determine changes in battery parameters and health. Microfabrication techniques are employed to minimize the overall impact of the sensors on battery operation through the implementation of sensors with minimal size, weight, and power consumption. The thickness of the films, which are fabricated through physical vapor deposition (sputtering), are on the order of thousands of angstroms and can have minimal surface area. Thin film sensors for system health management have been implemented for a many decades on complex components for aerospace applications. However, the application of thin films of this type on a battery separator for internal battery monitoring applications has not previously been demonstrated to our knowledge. This paper describes the development of sensors for the internal battery monitoring through the use of thin film sensor technology. Thin metal films were successfully deposited on a battery separator polymer material with good adherence and electrical continuity. Multiple types of sensors have been deposited, as well as lead connections from the sensor to the edge of the separator material. The ability of these thin film sensors immersed in electrolyte to perform multiple types of battery parameter measurements has been demonstrated. For example, a multiparameter sensor system measured multiple properties simultaneously inside of a pouch cell over a wide temperature range. Further, real time measurement of interior temperature changes in a battery pouch cell with an integrated interior temperature sensor was demonstrated. These changes include detecting a fault in the battery (shorting) in situ with rapid response time (less than a minute) corresponding to a more limited response by a temperature sensor mounted externally. Other aspects of monitoring battery health were also explored, such as real-time measurement of simulated dendrite growth/metal deposition by sensor on separator material demonstrated. Future efforts will include improvements in the durability of the sensor structure to allow introduction of the approach into standard battery fabrication techniques. Overall, this work is a step forward in providing a method to prevent catastrophic battery failures and provide a foundation for safer, lighter, and higher energy batteries for the electric aircraft industry.

thin film battery health↗
NASA NTRS2025

Operational Correction for the Temperature Dependence of A Class of Hyperspectral Radiometers

The correction for temperature response of optical radiometers implies access to their working temperature (i.e., either the internal or ambient one with the radiometers in thermal equilibrium). With specific reference to a class of widely used hyperspectral radiometers lacking a thermistor to measure the internal temperature, this work investigated the potential for operational corrections relying on the ambient temperature derived from the radiometer dark digital counts. With the objective to keep within approximately 1% the uncertainty for radiometric corrections in the 400–800-nm spectral range, findings showed the applicability of the method for ambient temperatures higher than approximately 30°C. The alternative use of an ambient temperature proxy, determined from the air temperature incremented by a few degrees Celsius, was shown a valid solution to constrain the uncertainty of radiometric corrections to within 1% over the entire 0°–40°C interval.

Giuseppe Zibordi↗
NASA NTRS2026

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↗