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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

AUTOIGNITION DELAY TIMES FOR REFORMATE GAS MIXTURES FROM METHANE GAS ENGINES

Methane slip is a prominent issue in natural gas reciprocating engines that are used in transportation and marine applications. The incomplete combustion that results in methane slip can be resolved with the introduction of hydrogen within the combustion mixture to improve methane oxidation and further enable combustion within the engine crevices where methane has previously remained unreacted. Steam methane reforming (SMR) is a common method used to produce hydrogen and can be used to design an onboard device to reduce methane slip from reciprocating engines. The development of this reformer device requires the validation of high-fidelity chemical kinetic models at the low temperatures of the crevice volumes of these engines. In this work, auto-ignition data is obtained using a shock tube at lean (φ—0.714 or λ—1.4) and stoichiometric (φ, λ = 1) equivalence ratios spanning a temperature range of 1042–1234 K at the 80-bar operating pressure of the test engine. Blends of methane, hydrogen, and reformate products from the SMR reaction are shock-heated in synthetic air, with the ignition delay time measured using an OH* chemiluminescence detector at 310 nm and a CH* detector at 430 nm. The experimental results are compared to several state-of-the-art chemical kinetic mechanisms from the literature. In general, most of the mechanisms show very good agreement with experiments at higher temperatures, with simulation results showing little deviation from experiments at lower temperatures. A sensitivity analysis was conducted, and the results reveal that the reaction H2 + CH3O2 = H + CH3O2H has a very significant role in determining low-temperature ignition delay times (IDTs) of SMR mixtures. These findings provide valuable insights into the chemical kinetics governing methane reformate combustion and contribute to the optimization of onboard reformer designs aimed at mitigating methane slip in natural gas-fueled engines.

Fraze, Matthew↗
NASA NTRSDate not supplied

On-Orbit Calibration Assessment of NOAA-21 VIIRS Thermal Emissive Bands and Implications for JPSS-4 VIIRS

The Visible Infrared Imaging Radiometer Suite (VIIRS) instrument onboard the NOAA-21 (N21) satellite has been successfully operating for over three years collecting valuable scientific measurements. A large suite of weather forecasting models and scientific research applications are supported with the VIIRS measurements from N21 combined with those acquired from the VIIRS instrument onboard the S-NPP and NOAA-20 spacecraft. Among the 22 VIIRS spectral bands, there are seven thermal emissive bands (TEB) covering the 3.7 to 12.2 µm spectral range at two different spatial resolutions. The VIIRS TEB detectors are calibrated onboard using a blackbody at a controlled temperature and a space view for background signal measurement. In this paper, we discuss the on-orbit performance of the N21 VIIRS TEB using various parameters such as the detector gain, noise, and offset. This on-orbit assessment provides critical insights into instrument behavior and calibration performance that will inform pre-launch testing and post-launch validation strategies for the upcoming JPSS-4 VIIRS mission scheduled for launch in 2027. The methodologies and lessons learned from characterizing the N21 TEB performance will enable more efficient and comprehensive radiometric assessment of the next VIIRS instrument. Specific focus is placed on identifying performance trends and anomaly signatures observed during the N21 commissioning phase that can enhance the JPSS4 instrument checkout procedures and accelerate the transition to routine on-orbit operations. The established performance baselines and uncertainty estimates will serve as an acceptance criterion for the JPSS-4 commissioning activities, ensuring mission readiness and data continuity for operational users.

Amit Angal↗
DOE OSTI1961

Laboratory Development of a Pot Calcination Process for Converting Liquid Wastes to Solids

Simulated Darex, Purex, Thorex, and TBP-25 wastes were batch-evaporated and calcined to solids. The weight of residue was decreased to ~ 8% of the original waste for Darex, to ~ 4% for Purex, to ~ 2% for Thorex, and ~ 7% for TBP-25 by calcination to 1200°C. Semicontinuous evaporation and calcination to solids at 900°C of Darex and Purex wastes gave volume reduction factors of ~ 8 and 7 to 10, respectively. The nitrate contents of the residues from batch calcination to 800°C were from ~ 0.07 to 0.5 wt % while the nitrate contents of the residues from semicontinuous calcination to 900°C were from ~ 0.1 to 0.7 wt %. Sodium, calcium, and magnesium additives to Purex waste decreased the percent of sulfate volatilized into the condensate from ~ 30% to <0.5%. Replacement of the atmosphere above the waste with nitric oxide decreased ruthenium volatility from 50 to 60% of that originally present in Purex waste to 0.5 to 3.5%. The thermal conductivities for the calcined wastes, measured in situ, were all >0.1 Btu/hr ft °F at ~ 400°F and increased almost linearly with increasing temperature to >0.3 Btu/hr ft °F at ~ 1600°F in all cases studied.

052001* -- Nuclear Fuels-- Waste Processing↗
NASA NTRSDate not supplied

A Radiometric Consistent Spectral Fingerprinting Algorithm for Continuity Products of Hyperspectral Sounders

A radiometric consistent climate fingerprinting methodology has been developed to derive long-term temperature, water vapor, cloud, trace gases, and surface skin temperature anomaly time series from the hyper-spectral sounder measurements of multiple platforms. The spectral fingerprinting methodology requires the use of radiative kernels that are radiometrically consistent with observations. Radiative kernels are built using space-time averaged Jacobians that are physically retrieved from observations under all sky conditions. The physical retrieval algorithm uses the Principal Component based Radiative Transfer Model (PCRTM) for the forward simulation. The incorporation of multiple scattering simulation in PCRTM allows the direct radiative relationship between single field-of-view (FOV) radiance observations and corresponding thermal dynamic variables including cloud properties to be established. Therefore, radiance ?closure? can be achieved under all-sky conditions by the fingerprinting scheme. This methodology has been used to derive climate anomalies from the space-time averaged spectra of AIRS/AMSU and CrIS/ATMS. The use of a consistent fingerprinting scheme provides an effective mean of generating continuity product by merging observations from different platforms and therefore facilitating the long-term climate trend study.

Wan Wu↗
NASA NTRSDate not supplied

Thermal Cycle and Capacitance Testing of Mezzo Industries Phase Change Material Heat Capacitor

A phase change material heat capacitor prototype, designed and built under a NASA Small Business Innovation Research grant by Mezzo Technologies, was tested through coolant thermal cycling within the expected flow rates and temperature range of the Orion spacecraft’s propylene glycol-water mixture coolant system. Testing was performed with the phase change material contained under sealed conditions after a degassing procedure and exposed to atmosphere without prior degassing. The useful heat storage capacitance was measured and compared to Orion spacecraft requirements and theoretical N-Pentadecane storage capacity.

Propylene Glycol Water↗
NASA NTRS2023

Cryogenic Flow Boiling in Microgravity: Effects of Reduced Gravity on Two-Phase Fluid Physics and Heat Transfer

With the growing interest in space exploration, cryogenic technologies involving two-phase flow and heat transfer are in high demand to successfully procure advanced space applications such as fuel depots and nuclear thermal propulsion (NTP) systems for deep space missions. However, the unique and extreme thermal properties of cryogenic fluids introduce distinct flow boiling fluid physics and energy transport phenomena, which differ significantly from those observed with conventional fluids. Understanding the unique two-phase physics in cryogenic flow boiling remains an ongoing challenge. Furthermore, the lack of readily available microgravity cryogenic steady-state heat transfer data hinders the assessment of gravitational effects on cryogenic flow boiling. This study aims to elucidate the gravitational effects on two-phase fluid physics and heat transfer by conducting the first-ever experimental measurement of cryogenic flow boiling performance using a steady-state heated method in a reduced gravity environment. Parabolic flight experiments were performed to acquire both heat transfer measurements and high-speed video of interfacial behaviors, under varying gravity levels (microgravity, hypergravity, Lunar gravity, and Martian gravity). The experiments involved flow boiling of liquid nitrogen (LN 2 ) with a near-saturated inlet along a circular heated tube of dimensions 8.5-mm inner diameter and 680-mm heated length. The operating parameters varied are mass velocity of 398.3 - 1342.8 kg/m2s, inlet quality of -0.08 to -0.01, and inlet pressure of 413.68 - 689.48 kPa. Captured microgravity flow patterns range from bubbly to annular, all having vapor structures that are larger than those under higher gravity levels. Under microgravity, absence of buoyancy yields symmetrical vapor structures without flow stratification, laying a physical foundation for the distinct two-phase heat transfer trends during LN 2 flow boiling in microgravity. Transient data collected during the flight parabolas exhibited decreasing heated wall temperature as the aircraft transitioned from hypergravity to microgravity phases. The temperature variation indicated an enhancement in flow boiling heat transfer with decreasing gravity levels and a reduction with increasing gravity levels. The effect of reduced gravity on cryogenic flow boiling heat transfer coefficient (HTC) is discussed based on steady state heat transfer analysis. Seminal HTC correlations are evaluated against the measured microgravity HTC data, of which one is identified for superior accuracy in predicting microgravity data. Finally, a new HTC correlation is proposed to improve accuracy of microgravity predictions, yet there still exists room for further improvement with future terrestrial flow boiling experiments at different flow orientations relative to Earth gravity.

Microgravity↗
NASA NTRSDate not supplied

In Situ Synchrotron Micro-CT of Microballoon-Filled RTV Silicone During Thermal Decomposition

This work investigates the thermal decomposition of microballoon-filled room-temperature-vulcanizing (RTV) silicone using time-resolved synchrotron micro-CT at the Advanced Light Source. In situ imaging of constrained and unconstrained samples captures the evolution of the internal microstructure during heating, including material expansion, microballoon and void growth, tearing, pyrolysis, shrinkage, and increasing porosity. The measurements provide new insight into the mechanisms governing RTV degradation and generate three-dimensional data for future quantitative analysis and material-response model development.

TPS↗
NASA NTRS1977

Riddles About the Origin and Thermal History of the Moon

Analyses of lunar rocks have confirmed that the interior of the Moon has been subjected to magmatic differentiation, as has been determined by calculation of the thermal history of the Moon. However, it appears that differentiation occurred so early that it could not have been related to heating by long-lived radioactive elements, but rather indicates a high initial temperature of the Moon. The reasons for the high initial temperature remain unknown. The presence of a central, partially melted area revealed by seismic observations forces us to reject convective models of the Moon, while the dimensions of this area, together with the measured heat fluxes from the interior, serve as "boundary conditions" for any new calculations of the thermal history for a two-layered differentiated model of the Moon operative over the past 3.5 billion years. If we start with the early differentiation of the Moon and the high content of long-lived radioactive elements in it, explanation of its current thermal properties represents no difficulty. But these prerequisites themselves remain unexplained. Due to the continuing controversy concerning the true nature of the process of magmatic differentiation of the Moon, estimation of the composition of the entire Moon on the basis of analyses of surface rock remains unreliable, and use of these estimates to clarify the origin of the Moon is premature. Existing hypotheses concerning the origin of the Moon encounter dynamic difficulties, as well as difficulties with explanation of the high initial temperature, to say nothing of the difficulty involved in explaining the proposed differences in the composition of the Earth and Moon.

B Yu Levin↗
DOE OSTI2025

Field Validation of Thermoelectric Generation System at Holcim Cement Plant in Alpena, Michigan

Executive Summary Project Background The Industrial Technology Validation (ITV) program aims to identify and demonstrate the performance of new, emerging, and underutilized energy-saving technologies in the industrial sector to help inform decisions to help accelerate their commercialization and deployment, as well as to help make industries more competitive. This ITV demonstration evaluated a thermoelectric generation (TEG) technology at a cement plant, aiming to reduce energy demand in the cement industry. A median cement plant consumes 5.73 million British thermal units per ton of clinker production (resulting in 0.838 metric tons of carbon dioxide [CO₂] emissions per ton of clinker) (Boyd and Zhang 2011, EPA 2021), equivalent to approximately 6.9 trillion British thermal units (TBtu) per year in energy consumption at a cement plant producing 3,300 tons of clinker per day.¹ Collaborating with Holcim, Advanced Thermovoltaic Systems (ATS) developed and deployed a pilot-scale thermoelectric power system to efficiently capture and convert waste heat to electricity. The system leverages the Seebeck effect to convert temperature differences on two sides of semiconductor cartridges into electrical power (ScienceDirect, n.d.). This generation is realized with minimal moving parts compared to existing waste-heat-to-generation solutions and allows capture from heat sources with temperatures as low as 150°C. This project aimed to validate a scalable solution applicable for capturing medium-temperature waste heat, including ambient losses from other high-temperature processes, and high-temperature sources less suitable for other waste-heat-to-power solutions. By recovering this otherwise wasted heat, this project intends to validate improvements to overall process efficiency through reduction in purchased electricity, thereby reducing operational costs while enhancing resiliency and competitiveness. Description and Scope This study evaluated the performance of a TEG system from ATS as a solution to convert waste heat into useful power at a Holcim cement plant in Alpena, Michigan. This plant is a fully integrated cement plant that has been operating since 1907. The facility operates continuously (24/7/365) with approximately 250 employees and five long dry kilns, yielding a total production capacity of 7,852 tons of cement per day (EPA 2023). Currently, the Alpena plant uses waste heat boilers to convert waste heat from the exhaust of each kiln into steam, which drives steam turbine generators. The ATS TEG is being evaluated for its potential to supplement the steam turbines by capturing the remaining lower grade heat. This technology is also being considered for other Holcim plants where steam turbines are not a viable option. ATS installed a pilot-scale TEG unit with an array of 582 individual thermoelectric semiconductor cartridges, of which 573 were operational. The cartridges are sandwiched between 48 hot plates and 49 cold plates. Each cartridge is designed to generate 20 watts (W) of gross power at a hot-side temperature of 240°C and cold-side temperature of 20°C. As such, the total gross generation capacity of the installed system is 11.5 kilowatts (kW) at design conditions. The system configuration for the evaluation was designed to prioritize convenience of installation and minimize disruption to production at the site, while ensuring that the heat required can be obtained for evaluating the TEG system at various operational conditions. To accomplish this, a portion of the steam supplied to Alpena’s steam turbine generation system was diverted to be used as the heat source for the TEG system, while water was supplied to the cold side of the system from nearby Lake Huron. This configuration was designed for the evaluation of the pilot-scale system to assess the performance at different conditions. A commercial-scale system will likely vary from the pilot system depending on typical configurations, including both scale and application. Future commercial applications of the ATS system would involve integrating the system into the exhaust from kiln preheaters, clinker coolers, or radiant heat capture from kiln shells for the heat source. For the cold source, a range of cooling solutions can be considered, including a mechanical cooling system, depending on the location and the application. To increase the generation capacity for commercial applications, the technology provider is working toward developing a commercial-scale TEG system, which would combine multiple TEG units (each similar in design to the pilot system) together. The scope of this evaluation includes the pilot-scale TEG system and all impacted equipment including pumps, controllers, and power handling equipment. Study Objectives The evaluation's goal was to assess the potential of the ATS TEG system to generate useful electrical power by capturing waste heat from cement production kilns. The objectives of this study are to evaluate and verify the following claims made by ATS regarding the pilot-scale system installed at the Holcim Alpena plant. The following design parameters and claims are also outlined in Table ES- 1 and Table ES- 2: • Gross Power: The thermoelectric system converts heat into power to create gross power, the total measured power generated by the system. The 573 active cartridge pilot-scale system is expected to generate 11.5 kW of gross power at the designed hot-side temperature of 240°C and cold-side temperature of 20°C. Power production is dependent on the temperature difference between the heat source (ultimately from the waste heat) and cold temperature supply source. • Net Power: The net power is the total usable power provided to the site by the TEG system after deducting parasitic power loads from the gross generated power. Supplementary equipment is required to operate the TEG system including pumps, controllers, and, in certain anticipated applications, mechanical cooling, which introduce parasitic loads to system operation. After deducting the parasitic loads from the gross power generation, ATS anticipates achieving a net power generation of 7.5 kW from the pilot-scale system. • Thermal Efficiency: The thermal efficiency is the percent of the total heat transferred to the TEG system that is converted to gross power. Historically, TEGs have a thermal efficiency of 2%–5% (DOE 2008). Prior industrial-scale TEG systems, such as the E1 TEG offered by Alphabet Energy, operated at an efficiency of 2.5% (Lamonica, 2014). ATS anticipates achieving an average efficiency of 4.8% or higher in converting heat energy to usable electricity. • Cartridge Performance: The TEG system comprises 573 active individual semiconductor cartridges, each of which generates a portion of the total power. Cartridge optimization and selection is an important design consideration for potential future TEG system design performance. Therefore, understanding the distribution of gross power and efficiency within the pilot system is vital to understanding what is achievable. At a design hot-side temperature of 240°C and cold-side temperature of 20°C, ATS anticipates a cartridge performance of 20 W of gross power per cartridge at an efficiency of 4.8% per cartridge. In addition to evaluating the claimed performance of the TEG pilot-scale unit, the study estimated the potential annual impacts of a scaled-up commercial system used to capture kiln waste heat over annual operations. The evaluation estimated the gross and net annual electric generation achievable by capturing heat from the two proposed tap-in points: the kiln exhaust and the clinker cooler exhaust; see Section 2.1 for details. Two use cases were examined: • Holcim Alpena: The Holcim Alpena site consists of long dry kilns with superheater boilers, which differs from the rest of Holcim’s cement plant portfolio and results in lower waste heat temperatures. The study estimates gross and net annual generation using the superheater boiler exhaust and clinker cooler exhaust, based on 2023 operational data. • Typical Installation: Common cement plants have preheater kilns with higher exhaust temperatures than Holcim Alpena across a range of production rates. The study estimates gross and net annual generation using the preheater exhaust and clinker cooler exhaust, with a sensitivity analysis to account for the typical range of preheater exhaust temperatures, clinker cooler exhaust temperatures, and clinker production rates. Methodology The evaluation methodology followed a measurement and verification (M&V) strategy based on the International Performance Measurement and Verification Protocol Option B through comprehensive measurements and analyses of the affected systems. Evaluation data was collected from March 9 to March 11, 2024, the test period of the pilot TEG system. During the test period, in coordination with the ITV team, the ATS team adjusted system operations to capture the range of variability expected for each of the variables pertinent to performance of the system. The methodology consisted of two parts: evaluating the performance of the pilot unit's TEG system and estimating the annual TEG impact in terms of gross and net power based on a given waste heat profile. First, the evaluation of the thermoelectric generation performance of the pilot unit relative to the claims was performed by analyzing the collected test data. Gross power of the pilot TEG system was directly measured. Net power was determined by deducting the measured parasitic power from the gross power. The gross power generation was compared to heat transferred to the system by the working fluid (which was heated by steam generated from the kiln waste heat) to calculate the thermal efficiency achieved by the system. Performance of individual semiconductor cartridges within the pilot array was also assessed in terms of measured gross cartridge power and calculated cartridge thermal efficiency. The second part of the evaluation estimated the annual TEG impacts in terms of gross power and net power (calculated from the difference between gross power and parasitic power). This analysis comprised development of mathematical regression models for gross power and parasitic power, with assessment of each model’s goodness-of-fit characteristics to ensure satisfaction of statistical requirements. The models predicted the gross power generation, the parasitic load based on the temperature difference between the hot working fluid and the cold-side fluid (cold water from Lake Huron) entering the system, the volumetric flow rate of the cold-side fluid at the inlet, and the volumetric flow rate of the hot working fluid at the inlet. The annual impact analysis considered a theoretical commercial-scale system sized to capture the available waste heat at a cement plant, consisting of linked pilot-scale units that receive heat from a theoretical gas-to-working-fluid heat exchanger. To estimate annual impacts at the Alpena plant, the gross power and parasitic power regression models were applied to the arrays in the theoretical commercial-scale system. The heat supplied to the unit was calculated based on the kiln run time, annual production, kiln exhaust waste heat, and clinker cooler waste heat derived from 2023 Holcim Alpena kiln operational data. Net power impacts were calculated by deducting the resulting parasitic power from the estimated gross power. Inputs for the model were generated from a combination of hourly data, assumed design considerations for TEG system scale-up from the pilot-scale unit, and assumptions regarding TEG system operations. This analysis was then used as the basis for estimating annual impacts of typical TEG installation at cement plants, by applying sensitivity analyses to key kiln operational characteristics including kiln preheater exhaust temperatures, cooler clinker exhaust temperatures, and plant daily production rates across a range of expected values. Project Results/Findings Table ES- 2 and Table ES- 2 provide a summary of the operating conditions and evaluation results compared to the stated claims from the technology provider. Key takeaways include: • Gross Power: The peak gross power achieved during the testing period was 10.0 kW, compared to the 11.5 kW expected for 573 active cartridges. The claimed gross power was associated with a target hot side of 240°C; however, the system only received a maximum hot-side mean plate temperature of 212°C during the testing period. • Net Power: The pilot-scale unit exceeded the claims for net power, achieving a peak of 7.7 kW net compared to a claim of 7.5 kW. One factor contributing to the higher achieved net power is the relatively high water pressure available through Lake Huron. The pilot TEG system did not require cold-side pumps during the test, whereas most installations would. This reduced the parasitic loads on the system, ultimately contributing to higher net power relative to the gross power. • Thermal Efficiency: The pilot-scale unit outperformed the claimed efficiency, achieving a peak system efficiency of 5.0% thermal efficiency compared to the stated 4.8%. • Cartridge Performance: To compare cartridge performance against claims, the study focused on the third day of testing, which aimed for conditions closest to the design specifications, with a hot side of 240°C and cold-side exit temperature of 6.4°–30°C. On this day, the mean gross power observed in the cartridges within the TEG array was 18.1 W/cartridge, and the peak performance was 34.7 W/cartridge. The estimated mean cartridge efficiency was 5.2%, and the estimated efficiency at peak gross cartridge power was 10%. The regression models developed for gross power generation and parasitic loads were used to estimate the generation impact for given heat input to the TEG from the working fluid (captured from the waste heat) and from the cold loop (Lake Huron) on an hourly basis for a year of operation. Based on this analysis, installation of a commercial-scale TEG system at the Holcim cement plant in Alpena, Michigan, with a waste heat exchanger of 0.85 effectiveness, would generate up to 391 kW of net power, translating to between 920,000 and 1,800,000 kilowatt-hours (kWh) in net electricity per year. Based on typical grid emissions for Alpena, this would avoid estimated net emissions by 752 metric tons of CO₂ annually.² The sensitivity analysis estimated that typical TEG system installations at cement plants could generate an average of 56–1,040 kW of net power, or between 488,000 and 9,110,000 kWh of net energy. This generation potential is most significantly affected by plant production rates and also influenced by preheater and clinker cooler exhaust temperatures. Applying the national average emission rate, typical commercial-scale installations at Holcim plants are projected to avoid between 182 and 3,401 metric tons of CO₂ annually per site. Table ES- 3 shows a summary of the estimated annual impacts.³ While parasitic loads are significant and vary by application, this analysis assumed the use of heating loop pumps and access to Lake Huron as a cold sink. This setup assumed no need for cooling loop pumps due to the available water pressure at the test site. Applications that require cooling towers or additional equipment are likely to experience higher parasitic loads. Therefore, the study’s estimates are most applicable to scenarios with similar parasitic load configurations—namely, access to a high-pressure cold sink. Applicability to other locations may be limited, as differing conditions could necessitate additional pumps and cooling systems, potentially impacting performance significantly.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Flash Heating of a Hollow Rod to Determine Thermal Properties

In a nuclear reactor, prolonged exposure to high neutron flux levels can change material properties of reactor components. Due to the danger posed to personnel by highly radioactive components such as spent fuel, noncontact methods must be used to determine these properties. The objective of the current research is to test the viability of using a flash-heating method to determine the thermal diffusivity of a silicon carbide (SiC) tube, which could be used as cladding for a nuclear fuel rod. The flash-heating experiment was conducted at Oak Ridge National Laboratory and temperature results were analyzed as a two-Dimensional cross section which assumed axial symmetry. The model was fitted iteratively to the temperature measurements using nonlinear regression which required values for thermal diffusivity, Biot number and a term to determine the magnitude of the heat absorbed by the flash. The method could be expanded in the future to estimate the thermal diffusivity of spent nuclear fuel rods in an effort to increase the certainty of new reactor designs using precise thermal properties throughout the core life. A statistical analysis of the results of this work is provided as part of the analysis.

McMasters, Robert L [Virginia Military Institute, ↗
NASA NTRS1999

DS-2 Mars Microprobe Battery

In January of 1999 the NM DS-2 Mars microprobe will be launched to impact on Mars in December. The technical objectives of the missions are to demonstrate: key technologies, a passive atmospheric entry, highly integrated microelectronics which can withstand both low temperatures and high decelerations, and the capability to conduct in-situ, surface and subsurface science data acquisition. The scientific objectives are to determine if ice is present below the Martian surface, measure the local atmospheric pressure, characterize the thermal properties of the martian subsurface soil, and to estimate the vertical temperature gradient of the Martian soil. The battery requirements are 2-4 cell batteries, with voltage of 6-14 volts, capacity of 550 mAh at 80C, and 2Ah at 25C, shelf life of 2.5 years, an operating temperature of 60C and below, and the ability to withstand shock impact of 80,000 g's. The technical challenges and the approach is reviewed. The Li-SOCL2 system is reviewed, and graphs showing the current and voltage is displayed, along with the voltage over discharge time. The problems encountered during the testing were: (1) impact sensitivity, (2) cracking of the seals, and (3) delay in voltage. A new design resulted in no problems in the impact testing phase. The corrective actions for the seal problems involved: (1) pre weld fill tube, (2) an improved heat sink during case to cover weld and (3) change the seal dimensions to reduce stress. To correct the voltage delay problem the solutions involved: (1) drying the electrodes to reduce contamination by water, (2) assemblage of the cells within a week of electrode manufacture, (3) ensure electrolyte purity, and (4) provide second depassivation pulse after landing. The conclusions on further testing were that the battery can: (1) withstand anticipated shock of up to 80,000 g, (2) meet the discharge profile post shock at Mars temperatures, (3) meet the required self discharge rate and (4) meet environmental requirements.

Frank, H.↗
NASA NTRSDate not supplied

Fluid-Thermal-Structural Interactions Induced by an Asymmetric Shock-Wave/Boundary-Layer Interaction in a Mach-6 Compression Corner

An experimental study is conducted of the fluid-thermal-structural interaction of a clamped compliant panel exposed to a three dimensional shock-wave/boundary-layer interaction (SWBLI) induced by a Mach-6 compression ramp with a spanwise nonuniform incoming boundary layer. The nonuniform boundary layer was produced by placing trips on one side of the upstream flat plate, resulting in largely turbulent flow on the tripped side and transitional flow on the untripped side. Measurements of the flowfield confirmed that the tripped boundary layer contained elevated levels of unsteadiness, and the SWBLI was observed to vary from attached to fully separated as the ramp angle was increased from 10◦ to 38◦; the separation region on the tripped side of the panel was noticeably smaller, showing the elevated turbulence levels of the tripped-side flow to remain relatively localized rather than diffusing across the whole model. Full-field, time-resolved panel deformations were measured using high-speed photogrammetry and the vibrational response at each compression angle was characterized. Although the measured modes conformed largely to those from classical clamped-plate theory, some skewing of the mode shapes was observed. IR thermography highlighted regions of the compliant region where elevated temperatures were likely to promote thermal softening effects to the transient panel response. The quasi-static deformation and stress field was used to characterize the internal stress factor of each mode and showed a meaningful relationship between transient panel response and stress contained within each mode: modes with antinodes lying in high-stress areas of the plate tended to exhibit increases in vibrational frequency and decreases in vibrational power, whereas the opposite was true for modes with antinodes in low-stress areas.

Spectral Proper Orthogonal Decomposition↗
DOE OSTI2026

Laser-heated diamond anvil cell synthesis and recovery of metastable MnSb 2 and YbZn 2 for post-synthesis transport studies

The creation and exploration of new materials under extreme pressure–temperature conditions has become increasingly reliant on laser-heated diamond anvil cell (LHDAC) techniques, which provide direct access to previously unexplored regions of multinary phase diagrams. Whereas numerous high-pressure phases have been identified in situ, systematic recovery and post-synthesis physical property characterization of these materials remain significant challenges. In this work, we describe the setup and implementation of an LHDAC-based synthesis and recovery workflow and demonstrate its application to metastable MnSb 2 and YbZn 2 phases. Synchrotron x-ray diffraction and spatial mapping confirm dominant formation of the targeted phases, whereas laboratory-based refinement quantifies phase fractions despite intrinsic microstrain and minor secondary phases. High-pressure transport measurements on recovered samples reveal pressure-tunable electronic instabilities in both systems. In MnSb 2 , pressure suppresses two high-temperature magnetic ordering anomalies, observed in transport, by ∼5 GPa and, for higher pressures, induces a new low-temperature feature that increases with further pressure increase. In hexagonal high-pressure YbZn 2 , an electronic reconstruction emerges at ∼11 GPa, characterized by semiconducting-like behavior from ∼30 to 300 K and a broad low-temperature coherence crossover near 30 K. Our results establish LHDAC synthesis not only as a structural discovery tool but also as an experimental platform for investigating correlated quantum states stabilized far from equilibrium thermodynamic conditions.

Huyan, S. [Iowa State University, Ames, IA (United↗
NASA NTRS2025

Improving Adhesive Bondline Time of Flight Predictions During Autoclave Cure Utilizing Machine Learning

Composite materials are increasingly being used in aerospace applications due to their superior strength-to-weight ratio compared to commonly used metals. A current limitation to widespread adoption is the certification of adhesively bonded joints. One approach to improving adhesive bonding in composites is accurately measuring the thickness of adhesive bondlines in composite laminates. Precise bondline thickness control is essential for aerospace applications where adhesive layer thickness directly affects joint fracture properties and structural performance. This study focused on implementing machine learning techniques to determine the ultrasonic time of flight (directly correlated to thickness) in adhesive bondlines throughout autoclave cure cycles. A high-temperature (use up to 180°C) ultrasonic scanning system was deployed in an autoclave to provide time of flight data through composite panels. Three experiments were conducted on the curing of 305 mm × 305 mm unidirectional composite panels. In the first experiment, a piecewise function was fit for the temperature correction factor to account for changing autoclave temperatures. Due to deficiencies in the first calibration experiment, a second experiment was run, and the results were used to train a machine learning model. The revised experiment, in combination with the machine learning model, significantly increased the accuracy of the bondline time of flight predictions (~14% error reduced to <1%). Data was processed using the Regression Learner Application in MATLAB®, with a Support Vector Machine selected for the model. The result was a machine learning algorithm capable of reliably quantifying ultrasonic time of flight through adhesive bondlines. The third experiment provided independent test data for the machine learning model, demonstrating that the model produces accurate predictions from data beyond its training set.

Machine Learning↗
DOE OSTI2026

The MuFusE large-volume diamond anvil cell for exploring muon-catalyzed fusion at higher pressures and temperatures

A new large-volume diamond anvil cell (DAC) has been developed for the Muon-catalyzed Fusion (μCF) Experiment (MuFusE), enabling the compression and heating of deuterium–tritium (d–t) mixtures to pressures and temperatures needed to advance μCF research. The MuFusE DAC achieves the large sample volumes necessary for high-precision fusion measurements while integrating cryogenic loading, all-metal sealing, and flexible bellows to maintain a secure environment during cell compression. Combined with remote pneumatic actuation and secondary containment, the DAC safely managed a 25 Ci tritium inventory while providing a clear optical path for in situ measurements of sample pressure and composition via laser spectroscopy. Utilizing 5 mm diameter diamond anvils oriented in the path of a high-intensity muon beam, the apparatus achieved a stable sample volume of 19.2 mm 3 at liquid density, pressures up to 933 MPa and temperatures up to 400 K—benchmarks that significantly exceed previously reported limits for static d–t targets.

Kalow, J. D. [Acceleron Fusion, Inc., Cambridge, M↗
NASA NTRS2026

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

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

Colin Campbell↗
NASA NTRS2026

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

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

Colin Campbell↗
NASA NTRS2026

Thermal Cycle and Capacitance Testing of Mezzo Industries Phase Changer Material Heat Capacitor

Effective Thermal management is essential for the safety and performance of human spacecraft, especially during long-duration missions with fluctuating heat loads. Phase Change Material (PCM) heat exchangers offer a compact, efficient solution by storing and releasing thermal energy through latent heat during phase transitions. This allows PCM systems to buffer transient thermal loads without immediate heat rejection, reducing the need for oversized radiators – particularly critical during ascent and re-entry when radiators are stowed. By maintaining stable temperatures in crew cabins and equipment bays, PCM technology enhances crew comfort, protects sensitive systems, and supports long-term mission sustainability with minimal mass and volume impact. A phase change material heat capacitor prototype, designed and built under a NASA Small Business Innovation Research grant by Mezzo Technologies, utilizes a laser welding microtube manufacturing process that promises increased reliability and performance over current manufacturing methods like brazing. This heat exchanger was tested through coolant thermal cycling within the expected flow rates and temperature range of the Orion spacecraft, the crewed spacecraft taking NASA astronauts to the moon under the Artemis Program. The useful heat storage capacitance was measured and compared to Orion spacecraft requirements.

Active Thermal Control Systems↗