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NASA NTRS2007

STS-114 Micrometeoroid/Orbital Debris (MMOD) Post-Flight Assessment

NASA Johnson Space Center (JSC) personnel assisted Kennedy Space Center (KSC) inspection teams in the identification of 41 micrometeoroid/orbital debris (MMOD) impact sites on the OV-103 vehicle (Discovery) during STS-114 postflight inspections. There were 14 MMOD impacts reported on the crew module windows (Figure 1). The largest impact feature, a 6.6 mm x 5.8 mm crater on window #4, was caused by a particle with an estimated diameter of 0.22 mm (Figure 2). This impact was among the largest ever recorded on a crew module window. The window was removed and replaced. Scanning Electron Microscope/Energy Dispersive X-ray (SEM/EDX) analysis of dental mold samples from the impact site to determine particle origin was inconclusive, possibly due to contamination picked up on the ferry flight from Edwards Air Force Base to KSC. The radiators on the inside of the payload bay doors sustained 19 impacts (Figure 3) with one of the impacts causing a face sheet perforation. The 0.61 mm diameter hole was produced by a particle with an estimated diameter of 0.4 mm, which approaches the 0.5-mm critical particle diameter of the wing leading edge reinforced carbon-carbon (RCC) panel high-temperature regions (Zone 3, Figure 4) that was established during Return to Flight testing of the RCC panels. An inspection of the payload bay door exterior insulation (FRSI) revealed a 5.8 mm x 4.5 mm defect that was caused by an MMOD particle with unknown composition, as the sample obtained was contaminated. Figure 5 provides a summary of the exterior surface survey that was conducted following the STS-114 mission. Two windows were removed and replaced due to hypervelocity impact. Nineteen impacts were recorded on the payload bay door radiators, with one face sheet penetration. Three impact sites were identified on the FRSI. There were four hypervelocity impact sites detected on the wing leading edge RCC panels. One impact was detected on the top cover of the TPS sample box (TSB) payload that was mounted on a carrier in the aft portion of the payload bay.

Hyde, J.↗

NASA NTRS2009

Hydrogen Fuel System Design Trades for High-Altitude Long-Endurance Remotely- Operated Aircraft

Preliminary design trades are presented for liquid hydrogen fuel systems for remotely-operated, high-altitude aircraft that accommodate three different propulsion options: internal combustion engines, and electric motors powered by either polymer electrolyte membrane fuel cells or solid oxide fuel cells. Mission goal is sustained cruise at 60,000 ft altitude, with duration-aloft a key parameter. The subject aircraft specifies an engine power of 143 to 148 hp, gross liftoff weight of 9270 to 9450 lb, payload of 440 lb, and a hydrogen fuel capacity of 2650 to 2755 lb stored in two spherical tanks (8.5 ft inside diameter), each with a dry mass goal of 316 lb. Hydrogen schematics for all three propulsion options are provided. Each employs vacuum-jacketed tanks with multilayer insulation, augmented with a helium pressurant system, and using electric motor driven hydrogen pumps. The most significant schematic differences involve the heat exchangers and hydrogen reclamation equipment. Heat balances indicate that mission durations of 10 to 16 days appear achievable. The dry mass for the hydrogen system is estimated to be 1900 lb, including 645 lb for each tank. This tank mass is roughly twice that of the advanced tanks assumed in the initial conceptual vehicle. Control strategies are not addressed, nor are procedures for filling and draining the tanks.

Millis, Marc G.↗

DOE OSTI2020

Editorial for Special Issue: Grid-Interactive Efficient Buildings—Part 2

This issue of the ASME Journal of Engineering for Sustainable Buildings and Cities (JESBC) is fully dedicated to peer-reviewed papers specific to technologies and applications of Grid-interactive Efficient Buildings (GEBs). As defined by a series of publications by the U.S. Department of Energy (DOE) and outlined in Part 1 of the editorial of JESBC August 2020 issue, GEBs are efficient, connected, smart, and flexible buildings. This GEB special issue covers some technologies and applications for grid-connected buildings and communities. Some of technologies included in the special issue are dynamic insulation systems for building envelopes, building integrated fuel cells, and rooftop PV systems. Furthermore, the issue outlines the designs and cost-benefits of net-zero energy (NZE) buildings and carbon neutral communities in the United States.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Strategies for conformal REBCO windings

A high-field winding can be fabricated from a cable of non-insulated REBCO tapes stacked face-to-face without twisting. If the cable is oriented within each turn of a winding so that the tape face is closely parallel to the magnetic field at its location, the supercurrent capacity of that cable is enhanced ~3x greater than in a transverse or twisting orientation. This concept for a conformal winding was presented in a previous paper pertinent to the body winding of a REBCO based high-field dipole. Strategies are presented and simulated for how the same orientation can be sustained in the flared ends of a high-field hybrid dipole.

43 PARTICLE ACCELERATORS↗

NASA NTRS1979

Lightning protection design external tank /Space Shuttle/

The possibility of lightning striking the Space Shuttle during liftoff is considered and the lightning protection system designed by the Martin Marietta Corporation for the external tank (ET) portion of the Shuttle is discussed. The protection system is based on diverting and/or directing a lightning strike to an area of the spacecraft which can sustain the strike. The ET lightning protection theory and some test analyses of the system's design are reviewed including studies of conductivity and thermal/stress properties in materials, belly band feasibility, and burn-through plug grounding and puncture voltage. The ET lightning protection system design is shown to be comprised of the following: (1) a lightning rod on the forward most point of the ET, (2) a continually grounded, one inch wide conductive strip applied circumferentially at station 371 (belly band), (3) a three inch wide conductive belly band applied over the TPS (i.e. the insulating surface of the ET) and grounded to a structure with eight conductive plugs at station 536, and (4) a two inch thick TPS between the belly bands which are located over the weld lands.

Anderson, A.↗

DOE OSTI2023

Hierarchical thermal-conductive polymer nanocomposites for thermal management

Managing heat in electrical conductors is a major challenge to meet the demands for sustainable energy use and electrical reliability, most notably power electronics and energy-critical electrical machines. Achieving such disparate functionalities, such as high temperature thermal and electrical reliability, require rational design and manufacturing of thermal conductor material and its hierarchical structures. Here we present hierarchical thermal-conductive nanocomposites, consisting of nanostructured ceramic conformal coating and aligned ultrahigh molecular weight polyethylene fiber, to tailor heat dissipation in electric conductors. The hybrid aligned thermal interface exhibits a highly desirable temperature dependent anisotropic high thermal conductivity with 0.98W m –1 K –1 and dielectric strength with 3.4. In addition, electrically insulating thermal interfaces demonstrate high-performing and reliable electrical systems under the dynamic load conditions. The surface temperature of heterogeneous ceramic-polymer encapsulated conductor is 17.8 °C lower than that of polymer-encapsulated conductor at the same electrical load. Consequently, the findings shown here hold great promises for directing heat extraction in electrical machine systems, advancing thermal management for emerging electronic applications.

36 MATERIALS SCIENCE↗

DOE OSTI2022

South Texas Industrial Assessment Center (Final Report)

The South Texas Industrial Assessment Center (ST-IAC) provides small to mid-size manufacturing companies and water treatment plants in the Rio Grande Valley of Texas, free energy assessments to help them reduce costs and stay competitive for sustainable development. The ST-IAC operates within the University of Texas Rio Grande Valley (UTRGV), and is the largest Hispanic-serving IAC in the U.S. Created in 2016, the ST-IAC, situated in the most economically disadvantaged region in the country, has been successful in training students and assessing local industries served by a predominantly Hispanic population. UTRGV, now the second largest Hispanic Serving Institution (HSI) of higher education in the U.S., has a student population of 32,000, of which 90% is Hispanic. While Covid-19 had a negative impact to our program during Budget Periods (BP) 4 and 5, the center still managed to provide opportunities for individuals, manufacturing and water industries in the local region. The program developed an energy engineering program in the region and further advanced national priorities. Those include resilience and sustainability of operations by implementing energy efficiency processes, renewable energy sources, decarbonization, battery storage, and cybersecurity in south Texas.

14 SOLAR ENERGY↗

NASA NTRS2017

Environmental Testbed Development to Evaluate Power Distribution Materials in Electrified Aircraft (EA)

NASA is pursuing the development of electrified propulsion (EP) technologies to improve air transportation in terms of efficiency, affordability, and sustainability. The power requirements are expected to reach 20 megawatts for large EP commercial airliners. A key challenge is transmission and distribution of the high voltage (20 kilovolts) needed for some EP systems. This is a challenge because the risk of electrical failure in aircraft at high altitude (low pressure) due to corona discharge and other forms of partial discharge increases significantly when voltages exceed 327 V. Corona discharge is a form of partial discharge in which gaseous molecules are ionized by strong electric fields. Corona discharge leads to aging in power transmission lines. Aging is a leading cause of electrical failure in electrical insulation materials. In particular, aging from electrical, vibrational, and thermal stresses decrease the performance life of insulation materials. There are currently no test standards or equipment that can effectively age materials under high altitude, voltage and frequency conditions. This poster proposes a design for a test system including an environmental chamber that can simulate the environment of future EP systems for material and component aging tests.

Materials Test chamber Design↗

NASA NTRSDate not supplied

Scaling Electric Machines to a Megawatt and Material Options

Megawatt (MW) electric aircraft propulsion (EAP) is seen as a significant contributor toward achieving the goals set forth by the Sustainable Flight National Partnership. A large part of enabling MW EAP is developing specific-power-dense electric machines. As specific-power-dense electric machines are scaled up from kW to MW power levels, the thermal stresses on the machines increase in both magnitude and performance-affecting characteristics. This is particularly true for the stators of these machines. Analysis via thermal resistance network modeling and multiscale modeling reveals that increasing amounts of heat will be trapped in the stator windings as the power levels increase. The challenges this presents can be addressed through material advancements whereby materials gain multifunctionality. Specifically, the electrical insulation and potting materials, along with the electrical conductor, that compose the stator slot must work together (gain multifunctionality) to relieve the increased thermal stress. Materials research at the NASA Glenn Research Center points to some useful solutions in this trade space.

Electric Machine↗

NASA NTRS2023

Scaling Electric Machines to a Megawatt and Material Options

Electric Machine↗

DOE OSTI2026

Relaxor Ferroelectric-Like Spatiotemporal Memory in Field-Driven Lipid Bilayers

Lipid membranes are often regarded as passive barriers, yet their nonlinear dielectric response remains poorly understood. Using all-atom molecular dynamics, we show that fully hydrated dipalmitoylphosphatidylcholine bilayers exhibit relaxor ferroelectric-like behavior under time-dependent electric fields. Unlike crystalline relaxors, which are bipolar and display little remanent polarization, lipid bilayers exhibit a unipolar polarization response: even an alternating current field produces persistent, asymmetric polarization. Furthermore, the underlying free-energy landscape contains two distinct minima, a nonpolarized state and a unipolarly polarized state, between which stochastic thermally activated transitions occur. Directionally resolved Van Hove analysis reveals pronounced anisotropy arising from out-of-plane electric dipole alignment, interleaflet coupling, and lateral polarization domains. Each field cycle nucleates polarization at distinct sites and monitors their relaxation, marking a crossover from thermal fluctuations to field-sustained polarization. Remarkably, these polarized domains persist after field removal, generating long-lived, spatially coherent dipolar patterns that encode nanoscale polarization memory. Potassium chloride amplifies these effects via dielectric screening and a modified hydration structure, enhancing electric dipole flexibility and cooperativity. Together, these results establish protein-free bilayers as nonlinear, history-dependent dielectrics capable of sustaining field-tunable electromechanical coupling, providing an emergent physical foundation for nanoscale information storage and memory phenomena reminiscent of short- and long-term plasticity in soft neuromorphic systems.

Insulators↗

NASA NTRS1996

Adjustment of Sensor Locations During Thermal Property Parameter Estimation

The temperature dependent thermal properties of a material may be evaluated from transient temperature histories using nonlinear parameter estimation techniques. The usual approach is to minimize the sum of the squared errors between measured and calculated temperatures at specific locations in the body. Temperature measurements are usually made with thermocouples and it is customary to take thermocouple locations as known and fixed during parameter estimation computations. In fact, thermocouple locations are never known exactly. Location errors on the order of the thermocouple wire diameter are intrinsic to most common instrumentation procedures (e.g., inserting a thermocouple into a drilled hole) and additional errors can be expected for delicate materials, difficult installations, large thermocouple beads, etc.. Thermocouple location errors are especially significant when estimating thermal properties of low diffusively materials which can sustain large temperature gradients during testing. In the present work, a parameter estimation formulation is presented which allows for the direct inclusion of thermocouple positions into the primary parameter estimation procedure. It is straightforward to set bounds on thermocouple locations which exclude non-physical locations and are consistent with installation tolerances. Furthermore, bounds may be tightened to an extent consistent with any independent verification of thermocouple location, such as x-raying, and so the procedure is entirely consonant with experimental information. A mathematical outline of the procedure is given and its implementation is illustrated through numerical examples characteristic of light-weight, high-temperature ceramic insulation during transient heating. The efficacy and the errors associated with the procedure are discussed.

Milos, Frank S.↗

DOE OSTI2026

Toward durable stacks: glass-ceramic sealants for intermediate-temperature protonic ceramic electrochemical systems

Protonic ceramic electrochemical cells (PCECs) are emerging as promising technologies for efficient energy conversion and hydrogen production because they operate at intermediate temperatures with improved efficiency and durability compared with conventional solid oxide electrochemical cells. However, the long-term reliability and commercialization of PCEC stacks remain strongly limited by the performance of sealants, which are required to maintain gas tightness, electrical insulation, and mechanical integrity under harsh thermal and chemical environments. Among various sealing approaches, glass-ceramic sealants are considered the most practical and scalable due to their excellent wettability, chemical tunability, and strong interfacial adhesion. This review provides a comprehensive overview of recent advances in glass-ceramic sealants for intermediate-temperature protonic ceramic electrochemical systems. The fundamental design principles of sealant compositions are first discussed, followed by recent developments in deposition methods, sintering strategies, surface treatments, and degradation monitoring techniques. Particular attention is given to the unique challenges associated with PCEC operating conditions, including hydrothermal degradation, interfacial reactions with barium-containing electrolytes, and thermal mismatch. Finally, future opportunities involving sustainable materials, multiscale modeling, additive manufacturing, and artificial intelligence-assisted sealant optimization are highlighted.

glass–ceramic sealants↗

NASA NTRS2012

Amplitude-Stabilized Oscillator for a Capacitance-Probe Electrometer

A multichannel electrometer voltmeter that employs a mechanical resonator maintained in sustained amplitude-stabilized oscillation has been developed for the space-based measurement of an Internal Electrostatic Discharge Monitor (IESDM) sensor. The IESDM is new sensor technology targeted for integration into a Space Environmental Monitor (SEM) subsystem used for the characterization and monitoring of deep dielectric charging on spacecraft. Creating a stable oscillator from the mechanical resonator was achieved by employing magnetic induction for sensing the resonator s velocity, and forcing a current through a coil embedded in the resonator to produce a Lorentz actuation force that overcomes the resonator s dissipative losses. Control electronics employing an AGC loop provide conditions for stabilized, constant amplitude harmonic oscillation. The prototype resonator was composed of insulating FR4 printed-wireboard (PWB) material containing a flat, embedded, rectangular coil connected through flexure springs to a base PWB, and immersed in a magnetic field having two regions of opposite field direction generated by four neodymium block magnets. In addition to maintaining the mechanical movement needed for the electrometer s capacitor-probe transducer, this oscillator provides a reference signal for synchronous detection of the capacitor probe s output signal current so drift of oscillation frequency due to environmental effects is inconsequential.

Blaes, Brent R.↗

DOE OSTI2025

Backbone editing and deconstruction of polyethylene by Beckmann rearrangement and hydrogenolysis

Polyethylene is the most widely produced commodity plastic and is used in many applications, including packaging, insulation, and medical devices. However, the inertness of polyethylene makes chemical recycling inefficient and challenging. We report the conversion of oxidized high-density and low-density polyethylene, formed by direct, catalytic oxidation, to polyamides by Beckmann rearrangement of the corresponding oximes. These polyamides have enhanced surface properties over those of unmodified polyethylene, while maintaining the same, favorable mechanical profiles. The amide sites were reductively cleaved by hydrogenolysis with ruthenium-based catalysts to furnish alcohol- and amine-terminated fragments, which were used for the synthesis of polyurea-urethanes with poly(tetrahydrofuran) and methylene diphenyl diisocyanate. These experiments show how to install cleavable moieties into the backbone of polyethylene to facilitate deconstruction and the generation of new materials to affect greater sustainability in polyolefins.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Laboratory Instrument Software Controlled Spread Spectrum Time Domain Reflectometry for Electrical Cable Testing

This research discusses development of a software-controlled laboratory instrument based spread spectrum time domain reflectometry system (SSTDR). This constitutes one task within PNNL’s Light Water Sustainability Program (LWRS) whose mission includes advancing nondestructive examination (NDE) techniques for off-line and on-line in-situ cable condition monitoring. In 2022, PNNL evaluated SSTDR for detection and characterization of a number of cable anomalies (Glass et al. 2022). The review included comparison of SSTDR to Frequency Domain Reflectometry (FDR) techniques which have enjoyed encouraging feedback and are starting to be used in nuclear power plants for periodic cable condition monitoring of cable systems as part of the plant’s overall cable aging management program. The FDR test introduces a broad-band chirp onto the cable at the cable end then listens for any reflection from a change of impedance along the cable caused by a damaged conductor or insulation, splices, contact with moisture, or other cable anomalies. The signal is captured in the frequency domain then transformed back to the time domain using an inverse Fourier transform (IFT). Based on the velocity of propagation, the impedance response signal is plotted against distance along the cable. Peak locations along the X-axis indicate the distance along the cable where a portion of the signal has been reflected back to the instrument as a result of a cable anomaly. The FDR test is considered the gold standard of reflectometry however it does require the cable to be de-energized to perform the test. The LIVEWIRE commercial SSTDR produces a similar plot to the FDR however all processing is in the time domain. A pseudo-random noise code (PN code) is input onto the cable conductor and the instrument listens for any reflected response from cable anomalies. The SSTDR processes the signal as an autocorrelation comparing the input PN code to any reflected signal detected. The autocorrelation analysis for thermal aging, water and water ingress detection, ground fault and phase-to-phase fault detection at various locations along the cable and with the cable attached and detached from a motor load, and on both energized and un-energized conditions were performed. These results were contrasted to Frequency Domain Reflectometry (FDR) measurements of the un-energized cable. Results were encouraging but indicated more work was warranted – particularly with the SSTDR, it seemed that the insulation damage would likely be better evaluated with multiple bandwidth cable tests particularly including larger bandwidths than were possible with the current commercial instrument. The commercial instrument’s bandwidth was set at 6, 12, 24, and 48MHz but note that SSTDR and FDR definitions of bandwidth trend similarly but are not the same. The FDR response could be more broadly adjusted, and the bandwidth of 100 to 500 MHz produced the best responses. FDR responses to anomalies were clearer than SSTDR responses and indications were that a broader bandwidth SSTDR may lead to improved SSTDR detection capability. This project used a laboratory instrument based SSTDR (primarily using an Arbitrary Waveform Generator (AWG) and a digital oscilloscope plus Python in-house software) that allowed software adjustment of the SSTDR bandwidth, window functions applied to the exciting Pseudo-random Noise (PN) code plus and other aspects of the SSTDR signal processing. Hereafter, this will be referred to as the PNNL SSTDR. Evaluating specific performance of the PNNL SSTDR is left to a separate report. This report documents hardware and software development to produce the SSTDR cable test system.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2025

Assessing hydrogen supply chains: An integrated review of leakage and energy efficiency studies

This paper examines hydrogen leakage and efficiency across the supply chain for liquid, gaseous, and mixed hydrogen systems. These factors are crucial for assessing hydrogen's role in mitigating emissions and facilitating a clean energy transition. Drawing on a comprehensive review of existing literature and model-based analysis, the study compiles leakage rates and efficiency metrics at each stage of the supply chain: production, storage, transmission, distribution, and end-use. These data inform system scenarios that estimate the impact of leakage on overall performance and climate benefits. The analysis also identifies persistent data gaps, particularly for liquid and mixed system configurations, and outlines priorities for future research. A comparison of hydrogen system types shows that gaseous pathways generally achieve the highest efficiencies (28 %–39 %) and the lowest leakage rates (∼4.5 %) across the supply chain. Liquid hydrogen systems, while favorable for long-distance and high-volume transport due to their higher energy density, exhibit lower efficiency (∼28 %) and a greater leakage potential (∼12 %). Mixed systems, which combine gaseous and liquid elements (e.g., pipeline transmission followed by liquefaction and truck distribution), show compounded energy losses and moderate-to-high leakage rates (6.8 %–9.4 %), highlighting trade-offs associated with added system complexity. The study highlights opportunities for technological advancements, including optimizing liquefaction, enhancing insulation for storage and transportation, and refining refueling equipment. These improvements are crucial for maximizing the climate benefits of hydrogen. The results offer actionable insights for researchers, industry, and policymakers working to develop low-leakage, high-efficiency hydrogen infrastructure.

08 HYDROGEN↗

NASA NTRS2017

The Benefits of Incorporating Shipping Containers into the Climate Change Adaption Plans at NASA Wallops Flight Facility

The National Aeronautics and Space Administration has several centers and facilities located near the coast that are undoubtedly susceptible to climate change. One of those facilities is Wallops Flight Facility on the Eastern Shore of Virginia which is separated into three areas: Main Base, Mainland, and the Island. Wallops Island has numerous buildings and assets that are vulnerable to flood inundation, intense storms, and storm surge. The shoreline of Wallops Island is prone to beach erosion and is slated for another beach replenishment project in 2019. In addition, current climate projections for NASAs centers and facilities, conducted by the Climate Adaptation Science Investigators, warn of inevitable increases in annual temperature, precipitation, sea level rise, and extreme events such as heat waves. The aforementioned vulnerabilities Wallops Island faces in addition to the projections of future climate change reveal an urgency for NASA to adjust how new buildings at its centers and facilities near the coast are built to adapt to the inevitable effects of climate change. Although the agency has made strides to mitigate the effects of climate change by incorporating L.E.E.D. into new buildings that produce less greenhouse gas, the strides for the agency to institute clear climate adaptation policies for the buildings at its centers and facilities near the coast seem to lag behind. As NASA continues to formulate formidable climate change adaptation plans for its centers and facilities, an architectural trend that should be examined for its potential to replace several old buildings at Wallops Island is shipping containers buildings. Shipping containers or Intermodal Steel Building Units offer an array of benefits such as strength, durability, versatility, modular, and since they can be upcycled, they are also eco-friendly. Some disadvantages of shipping containers are they contain harmful chemicals, insulation must be added, fossil fuels must be used to transport them to the site, and multiple ISBUs are needed. However, the benefits of shipping container buildings could be utilized at NASA centers or facilities near the coast such as Wallops Island on new buildings that are designed to adapt to the impending effects of climate change. Thus, this Masters Research Project will explore how those benefits can be incorporated into the climate change adaptation plans at Wallops Island and make recommendations for policy guidelines and shipping container buildings specific to Wallops Island.

Sustainable Design↗