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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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At least 109 records · Page 6

Rheological Properties of Quasi-2D Fluids in Microgravity

In recent years, research on complex fluids and fluids in restricted geometries has attracted much attention in the scientific community. This can be attributed not only to the development of novel materials based on complex fluids but also to a variety of important physical phenomena which have barely been explored. One example is the behavior of membranes and thin fluid films, which can be described by two-dimensional (2D) rheology behavior that is quite different from 3D fluids. In this study, we have investigated the rheological properties of freely suspended films of a thermotropic liquid crystal in microgravity experiments. This model system mimics isotropic and anisotropic quasi 2D fluids [46]. We use inkjet printing technology to dispense small droplets (inclusions) onto the film surface. The motion of these inclusions provides information on the rheological properties of the films and allows the study of a variety of flow instabilities. Flat films have been investigated on a sub-orbital rocket flight and curved films (bubbles) have been studied in the ISS project OASIS. Microgravity is essential when the films are curved in order to avoid sedimentation. The experiments yield the mobility of the droplets in the films as well as the mutual mobility of pairs of particles. Experimental results will be presented for 2D-isotropic (smectic-A) and 2D-nematic (smectic-C) phases.

microgravity↗

Community Extreme Tonnage User Service (CETUS): A 5000 Ton Open Research Facility in the United States

Large sample volume 5000 ton multi-anvil presses have contributed to the exploration of deep Earth and planetary interiors, synthesis of ultra-hard and other novel materials, and serve as a sample complement to pressure and temperature regimes already attainable by diamond anvil cell experiments. However, no such facility exists on the North American continent. We propose the establishment of an open user facility for COMPRES members and the entire research community, with the unique capability of a 5000 ton (or more) press, supported by a host of extant co-located experimental and analytical laboratories and research staff. We offer wide range of complementary and/or preparatory experimental options. Any required synthesis of materials or follow up experiments can be carried out controlled atmosphere furnaces, piston cylinders, multi-anvil, or experimental impact apparatus. Additionally, our division houses two machine shops that would facilitate any modification or custom work necessary for development of CETUS, one for general fabrication and one located specifically within our experimental facilities. We also have a general sample preparation laboratory, specifically for experimental samples, that allows users to quickly and easily prepare samples for ebeam analyses and more. A service we can offer to COMPRES community members in general, and CETUS visiting users specifically, is a multitude of analytical instrumentation literally steps away from the experimental laboratories. This year we will be pursuing site funding of our laboratories through NASA's Planetary Science Directorate, which should result in substantial cost savings to all visiting users, and supports our mission of interagency cooperation for the enhancement of science for all (see companion PSAMS abstract). The PI is in a unique position as an employee of Jacobs Technology to draw funding from multiple sources, including those from industry and commerce. We submitted a Planetary Major Equipment proposal to the NASA Emerging Worlds solicitation for the full cost of a press, with competitive bids submitted from Sumitomo, Rockland Research, and Voggenreiter. Additional funding is currently being sought from industry sources through the Strategic Partnerships Office at NASA JSC, External Pursuits Program Office on the JETS contract, and Jacobs corporate in the United States. Internal funding is available for JETS contract personnel to travel to large press locations worldwide to study set-up and operations. We also anticipate a fortuitous cost savings in installation of the large press because plans are already underway for major renovations to the entire experimental petrology suite within the next 2 years in order to accommodate our growing user base. Our focus as contract staff is on serving the scientific needs of our users and collaborators. We are seeking community expert input on multiple aspects of this proposed facility, such as the press type and design, access management, immediate projects, and future innovation initiatives.

Danielson, L.↗

Phase Change Processes for Thermal Management Systems and Science Investigations

This white paper focuses on the scientific rationale and motivation for deploying phase change processes-based spacecraft thermal management systems for space missions [1,2]. Phase change processes need to be implemented in the design of various life support systems, sub-critical cryogenic and thermal control systems, taking advantage of the latent heat of phase change so as to significantly increase the heat transfer rate per unit fluid mass. Experimental data are critical to understanding gravitational effects on complex phase change processes using novel materials and working fluids. Experimental data can be acquired by either designing new testing platforms or performing experiments with simulant fluids on existing microgravity platforms. With the acquired data, theoretical flow physics models and numerical simulations can then be validated for use under long-duration microgravity conditions. The acquired data and validated models will enable the deployment of game-changing thermal management systems with remarkably improved efficiency and stability in heat acquisition, transport, and rejection for long-duration space missions.

Fluid mechanics↗

Introduction to Additive Manufacturing for Propulsion Systems

Additive Manufacturing (AM) has become a prominent technology of interest for manufacturing propulsion components and gaining attention across the aerospace industry. AM is maturing at a rapid pace and providing new design opportunities, novel materials, new industries and supply chains resulting in programmatic and technical performance improvements. The successful use of AM requires a methodical and intentional approach to understanding the concept to utilization lifecycle for AM. This course will provide an overview of the various steps in AM process trades, design, build process, post-processing, certification and infusion of AM. This will provide various lessons learned and experiences that were captured in a recent AIAA textbook titled "Metal Additive Manufactuging for Propulsion Applications" by the session chairs and industry colleagues. This course will include specific liquid rocket engine component examples and that went through the AM lifecycle including hot-fire testing.

Paul R. Gradl↗

Solid-State Architecture Batteries for Enhanced Rechargeability and Safety (SABERS): Advanced Battery Technology for Sustainable Aviation

All-electric vertical take-off and landing vehicles (eVTOL) for urban air mobility (UAM) concepts face numerous challenging technical barriers before their introduction into the consumer marketplace. The primary barrier to overcome is developing an energy storage system capable of meeting the rigorous aerospace safety and performance criteria. The performance metrics for eVTOL vehicles are at least two times greater than those of electric ground vehicles. Furthermore, inherently non-flammable batteries are essential for safe operation of commercial electric aerovehicles. The SABERS concept proposes a battery that meets the key performance criteria through development of a solid-state architecture battery utilizing high-capacity sulfur-selenium cathode and lithium metal anode. The combination of sulfur and selenium offers a balanced energy-to-power density ratio, which can be tailored to the specific application by altering the stoichiometric ratios of sulfur to selenium. This hybrid cathode will be developed by implementing NASA patented holey graphene technology as a highly conductive, ultra-lightweight electrode scaffold. A solid-state electrolyte will be used as a safe, non-flammable replacement to the highly flammable liquid organic electrolytes currently used in SOA lithium-ion batteries. This solid-state lithium-sulfur/selenium cell will be designed into a serial stacking configuration to enable dense packaging of the battery cells. The serial stacking configuration is termed a bipolar stack, which has the advantages of reducing overall cell weight, simplifying the interfaced connections for the cell, and minimizing the cooling requirements. Lastly, optimization of battery components will occur through a robust and rigorous combination of various computational modeling techniques covering multiple length scales. The expected result will be a fully solid-state battery with operational temperatures up to 150 °C which provides the required energy density, discharge rates, and inherent safety to meet the strict aerospace mission performance criteria. This presentation will demonstrate a feasible path for solid-state cells that possess a specific energy of greater than 400 Wh/kg to enable electric aircraft. The presentation will also explore novel materials and computational models used to achieve all solid-state cells that operate safely at very high temperatures and specific energies. The cells can withstand damage while operating without an increase in temperature or spontaneous ignition.

Urban Air Mobility (UAM) Vehicles↗

Additive Manufacturing for Propulsion Systems

Additive Manufacturing (AM) has become a prominent technology of interest for manufacturing propulsion components and gaining attention across the aerospace industry. AM is maturing at a rapid pace and providing new design opportunities, novel materials, new industries and supply chains resulting in programmatic and technical performance improvements. The successful use of AM requires a methodical and intentional approach to understanding the concept to utilization lifecycle for AM. This course will provide an overview of the various steps in AM process trades, design, build process, post-processing, certification and infusion of AM. This will provide various lessons learned and experiences that were captured in a recent AIAA textbook titled "Metal Additive Manufacturing for Propulsion Applications" by the session chairs and industry colleagues. This course will include specific liquid rocket engine component examples and that went through the AM lifecycle including hot-fire testing.

Additive Manufacturing↗

Solid-State Architecture Batteries for Enhanced Rechargeability and Safety (SABERS) Beyond Li-Ion: Technology to Enable Next-Generation Sustainable Electric

All-electric vertical take-off and landing vehicles (eVTOL) for urban air mobility (UAM) concepts face numerous challenging technical barriers before their introduction into the consumer marketplace. The primary barrier to overcome is developing an energy storage system that meets rigorous aerospace safety and performance criteria. The performance metrics for eVTOL vehicles are at least two times greater than those of electric ground vehicles. Furthermore, inherently non-flammable batteries are essential for the safe operation of commercial electric aero vehicles. The SABERS concept proposes a battery that meets the critical performance criteria by developing a solid-state architecture battery utilizing a high-capacity sulfur-selenium cathode and lithium metal anode. The combination of sulfur and selenium offers a balanced energy-to-power density ratio, which can be tailored to the specific application by altering the stoichiometric ratios of sulfur to selenium. This hybrid cathode will be developed using NASA-patented holey graphene technology as a highly conductive, ultra-lightweight electrode scaffold. A solid-state electrolyte will be used as a safe, non-flammable replacement for the highly flammable liquid organic electrolytes currently in SOA lithium-ion batteries. This solid-state lithium-sulfur/selenium cell will be designed in a serial stacking configuration to enable the dense packaging of the battery cells. The serial stacking configuration is termed a bipolar stack, which has the advantages of reducing overall cell weight, simplifying the interfaced connections for the cell, and minimizing the cooling requirements. Lastly, the optimization of battery components will occur through a robust and rigorous combination of various computational modeling techniques covering multiple length scales. The expected result will be a fully solid-state battery with operational temperatures up to 150°C, providing the required energy density, discharge rates, and inherent safety to meet the strict aerospace mission performance criteria. The SABERS team employed novel materials development, computational modeling, and design-of-experiments (DOE) optimization studies in their research. This presentation will show the results of these studies and demonstrate a feasible path for solid-state cells with a specific energy greater than 400 Wh/kg to enable electric aircraft.

Computational Modeling↗

Introduction to Metal Additive Manufacturing for Propulsion Applications: Part I and II

Additive Manufacturing (AM) has become a prominent technology of interest for manufacturing propulsion components and gaining attention across the aerospace industry. AM is maturing at a rapid pace and providing new design opportunities, novel materials, new industries and supply chains resulting in programmatic and technical performance improvements. The successful use of AM requires a methodical and intentional approach to understanding the concept to utilization lifecycle for AM. This course will provide an overview of the various steps in AM process trades, design, build process, post-processing, certification and infusion of AM. This will provide various lessons learned and experiences that were captured in a recent AIAA textbook titled "Metal Additive Manufacturing for Propulsion Applications" by the session chairs and industry colleagues. This course will include propulsion examples and that went through the AM lifecycle including hot-fire testing.

Additive Manufacturing↗

Development and Testing of a Superconducting Ground Plane on Transition Edge Sensors

Much of the normal matter in the universe is thought to exist as diffuse hot gas near 1.0 × 10 6 K, which can be detected through its 0.1–0.5 keV line emission. Distinguishing among multiple temperature regions and emission mechanisms along a line of sight requires resolving individual spectral lines in this particularly crowded spectral range. This requires 1–2 eV spectral resolution, which is currently only possible using grating spectrometers, which are suitable only for point sources, but not for the diffuse sources we wish to observe. We aim to measure individual spectral lines in this energy band using transition edge sensors (TES) that have the required 1–2 eV non-dispersive spectral resolution on a sounding rocket. While TESs offer sufficient energy resolution, they are very sensitive to ambient magnetic fields, e.g. from earth’s field and stray fields from the adiabatic demagnetization refrigerator (ADR) that is used to cool TESs to their ∼70 mK transition temperature. Strict space and weight limitations on the sounding rocket payload will limit the use of conventional high permeability magnetic shielding. Further design challenges arise in designing shielding with at least a 45∘ field of view, which is required to maintain a large enough throughput to obtain a useful spectrum on a brief (∼300 s) sounding rocket flight. Here we explore adding a superconducting ground plane (SGP) to the backside of the TES to reduce its field sensitivity and minimize attenuation requirements for the external shielding, which is based on prior work from (de Wit et al. 2022). We tested the feasibility of SGPs with novel materials, geometries, and on larger TESs with different biasing conditions.

Astrophysics↗

PROTECT: Production and Reuse of Thermally Efficient Ceramic Thermal Protection Systems

PROTECT (Production and Reuse Of Thermally Efficient Ceramic TPS) is a NASA Early Career Initiative focused on developing the next generation of reusable ceramic thermal protection systems (TPS). This project addresses key challenges in TPS design, including temperature capability, thermal stability, and refurbishment time, by integrating novel material development with predictive modeling. Leveraging enhanced capabilities in NASA’s Porous Microstructure Analysis (PuMA) software, PROTECT introduces new modeling tools to predict the thermal and mechanical behavior of fibrous ceramic materials. These tools enable accurate prediction of performance metrics such as thermal conductivity and structural integrity, reducing reliance on costly physical testing. Preliminary advances in these areas will be presented. To support model validation, PROTECT is building a comprehensive database of raw material properties using advanced characterization techniques, including micro computed tomography (CT) scanning in collaboration with the University of Illinois Urbana-Champaign (UIUC). The presentation will detail the sampling workflows and analysis methods used to generate this detailed microstructural data and how it is used to develop improved models in PuMA. This multi-center collaboration, spanning NASA (JSC, ARC, KSC, GRC), Oak Ridge National Laboratory, UIUC, and SpaceX, is developing tailored TPS solutions for LEO, lunar, and Martian missions. By bridging heritage systems with the demands of modern spaceflight, PROTECT contributes to the advancement of reusable TPS technologies for future exploration missions.

Propulsion, Refractory, and Coating Materials↗

PROTECT: Production and Reuse of Thermally Efficient Ceramic Thermal Protection Systems

PROTECT (Production and Reuse Of Thermally Efficient Ceramic TPS) is a NASA Early Career Initiative focused on developing the next generation of reusable ceramic thermal protection systems (TPS). This project addresses key challenges in TPS design, including temperature capability, thermal stability, and refurbishment time, by integrating novel material development with predictive modeling. Leveraging enhanced capabilities in NASA’s Porous Microstructure Analysis (PuMA) software, PROTECT introduces new modeling tools to predict the thermal and mechanical behavior of fibrous ceramic materials. These tools enable accurate prediction of performance metrics such as thermal conductivity and structural integrity, reducing reliance on costly physical testing. Preliminary advances in these areas will be presented. To support model validation, PROTECT is building a comprehensive database of raw material properties using advanced characterization techniques, including micro computed tomography (CT) scanning in collaboration with the University of Illinois Urbana-Champaign (UIUC). The presentation will detail the sampling workflows and analysis methods used to generate this detailed microstructural data and how it is used to develop improved models in PuMA. This multi-center collaboration, spanning NASA (JSC, ARC, KSC, GRC), Oak Ridge National Laboratory, UIUC, and SpaceX, is developing tailored TPS solutions for LEO, lunar, and Martian missions. By bridging heritage systems with the demands of modern spaceflight, PROTECT contributes to the advancement of reusable TPS technologies for future exploration missions.

Propulsion, Refractory, and Coating Materials↗

A Novel, Real-Valued Genetic Algorithm for Optimizing Radar Absorbing Materials

A novel, real-valued Genetic Algorithm (GA) was designed and implemented to minimize the reflectivity and/or transmissivity of an arbitrary number of homogeneous, lossy dielectric or magnetic layers of arbitrary thickness positioned at either the center of an infinitely long rectangular waveguide, or adjacent to the perfectly conducting backplate of a semi-infinite, shorted-out rectangular waveguide. Evolutionary processes extract the optimal physioelectric constants falling within specified constraints which minimize reflection and/or transmission over the frequency band of interest. This GA extracted the unphysical dielectric and magnetic constants of three layers of fictitious material placed adjacent to the conducting backplate of a shorted-out waveguide such that the reflectivity of the configuration was 55 dB or less over the entire X-band. Examples of the optimization of realistic multi-layer absorbers are also presented. Although typical Genetic Algorithms require populations of many thousands in order to function properly and obtain correct results, verified correct results were obtained for all test cases using this GA with a population of only four.

Hall, John Michael↗

Development of a Generic Small-Satellite Payload for On-Orbit Characterization and Evaluation of Novel Radiation-Shielding Materials

There is a need for lightweight and novel radiation shielding for small satellites operating in LEO and beyond. Current state of the art shielding materials include aluminum and polyethylene, or no shielding due to weight and dimensional considerations. New materials are being developed which may offer advantages over current options. These materials include novel lightweight composites impregnated with metallic nanoparticles, chitin-derived bioplastics, and aerogel-family materials. A compact experiment platform that allows the simultaneous testing of a number of potential shielding materials will be useful in comparing and validating them. The effort now underway seeks to develop a miniaturized, modularized payload which will allow testing of materials using 1U CubeSat form factor modules with four scintillator radiation detectors arrayed behind four sample material windows exposed to space. The first proposed mission will utilize a 2U payload volume to host two test quartets enabling eight materials to be tested. Such a test platform can potentially be used as a hosted payload on a variety of spacecraft to test other materials in the future.

Avery D Brock↗

Mechanical Properties of Nanostructured Materials Determined Through Molecular Modeling Techniques

The potential for gains in material properties over conventional materials has motivated an effort to develop novel nanostructured materials for aerospace applications. These novel materials typically consist of a polymer matrix reinforced with particles on the nanometer length scale. In this study, molecular modeling is used to construct fully atomistic models of a carbon nanotube embedded in an epoxy polymer matrix. Functionalization of the nanotube which consists of the introduction of direct chemical bonding between the polymer matrix and the nanotube, hence providing a load transfer mechanism, is systematically varied. The relative effectiveness of functionalization in a nanostructured material may depend on a variety of factors related to the details of the chemical bonding and the polymer structure at the nanotube-polymer interface. The objective of this modeling is to determine what influence the details of functionalization of the carbon nanotube with the polymer matrix has on the resulting mechanical properties. By considering a range of degree of functionalization, the structure-property relationships of these materials is examined and mechanical properties of these models are calculated using standard techniques.

Clancy, Thomas C.↗

Measurement of Creep Properties of Ultra-High-Temperature Materials by a Novel Non-Contact Technique

A non-contact technique for measuring the creep properties of materials has been developed and validated as part of a collaboration among the University of Massachusetts, NASA Marshall Space Flight Center Electrostatic Levitation Facility (ESL), and the University of Tennessee. This novel method has several advantages over conventional creep testing. The sample is deformed by the centripetal acceleration from the rapid rotation, and the deformed shapes are analyzed to determine the strain. Since there is no contact with grips, there is no theoretical maximum temperature and no concern about chemical compatibility. Materials may be tested at the service temperature even for extreme environments such as rocket nozzles, or above the service temperature for accelerated testing of materials for applications such as jet engines or turbopumps for liquid-fueled engines. The creep measurements have been demonstrated to 2400 C with niobium, while the test facility, the NASA MSFC ESL, has processed materials up to 3400 C. Furthermore, the ESL creep method employs a distribution of stress to determine the stress exponent from a single test, versus the many tests required by conventional methods. Determination of the stress exponent from the ESL creep tests requires very precise measurement of the surface shape of the deformed sample for comparison to deformations predicted by finite element models for different stress exponents. An error analysis shows that the stress exponent can be determined to about 1% accuracy with the current methods and apparatus. The creep properties of single-crystal niobium at 1985 C showed excellent agreement with conventional tests performed according to ASTM Standard E-139. Tests on other metals, ceramics, and composites relevant to rocket propulsion and turbine engines are underway.

Hyers, Robert W.↗

Solution Growth of a Novel Nonlinear Optical Material: L-Histidine Tetrafluoroborate

Single crystals of L-Histidine tetrafluoroborate (L-HFB), a semiorganic nonlinear optical (NLO) material have been successfully grown by the temperature lowering and evaporation methods in our laboratory. Solubility curves of L-HFB have been determined in different solvents, such as water, ethanol and acetone. The solubility of L-HFB is very low in acetone, and ethanol, therefore, it is not feasible to grow L-HFB single crystals using these solvents. Good quality single crystals of a novel nonlinear optical material L-HFB have been grown from aqueous solution. Effects of seed orientation on morphologies of L-HFB crystals were studied. The advantages and disadvantage of both the evaporation and the temperature lowering techniques are compared. The single crystals in size 20 x 20 x 10 cubic mm were grown with deionized water as solvent in two weeks with an approximate growth rate of 1.4mm/day. The transmission range for these crystals has been found to be from 250 nm to 1500 nm.

Aggarwal, M. D.↗

Novel Cryogenic Insulation Materials: Aerogel Composites

New insulation materials are being developed to economically and reliably insulate future reusable spacecraft cryogenic tanks over a planned lifecycle of extreme thermal challenges. These insulation materials must prevent heat loss as well as moisture and oxygen condensation on the cryogenic tanks during extended groundhold, must withstand spacecraft launch conditions, and must protect a partly full or empty reusable cryogenic tank from significant reentry heating. To perform over such an extreme temperature range, novel composites were developed from aerogels and high-temperature matrix material such as Space Shuttle tile. These materials were fabricated and tested for use both as cryogenic insulation and as high-temperature insulation. The test results given in this paper were generated during spacecraft re-entry heating simulation tests using cryogenic cooling.

White, Susan↗

Nd: LuLF: A New Nd Laser Material

Nd:LuLF, a novel laser material isomorphic to YLF, has been grown and evaluated on both polarizations in a simple, wavelength selective resonator.

Barnes, Norman P.↗