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NASA Aerospace Flight Battery Program: Recommendations for Technical Requirements for Inclusion in Aerospace Battery Procurements

This NASA Aerospace Flight Battery Systems Working Group was chartered within the NASA Engineering and Safety Center (NESC). The Battery Working Group was tasked to complete tasks and to propose proactive work to address battery related, agency-wide issues on an annual basis. In its first year of operation, this proactive program addressed various aspects of the validation and verification of aerospace battery systems for NASA missions. Studies were performed, issues were discussed and in many cases, test programs were executed to generate recommendations and guidelines to reduce risk associated with various aspects of implementing battery technology in the aerospace industry. This document contains Part 2 - Volume I: Recommendations for Technical Requirements for Inclusion in Aerospace Battery Procurements of the program's operations.

Jung, David S.

Compositional Homogeneity in Rapidly Solidified 316L stainless steel produced by laser powder-bed fusion processing

The segregation of alloying elements in rapidly solidified 316L stainless steel produced using additive manufacturing technologies is widely reported throughout literature. The microstructure of thin walls manufactured from 316L stainless steel using laser powder bed fusion are examined for the presence of alloy segregation, i.e. the rejection of solutes to grain boundaries. Metallographic methods including mechanical polishing and chemical etching are used to prepare samples for microanalysis m

Jankowski, Alan F. [Sandia National Laboratories (

Evolution of the Antarctic Ice Sheet from 2000–2300 and beyond: model sensitivity and uncertainty analysis using MPAS-Albany Land Ice

We present a description of the Antarctic Ice Sheet model configuration submitted to the ISMIP6-Antarctica-2300 experiment using the MPAS-Albany Land Ice model, along with three new sets of simulations: (1) a set of extended simulations to 2500 for three forced experiments and to 2775 for the control experiment; (2) a sensitivity analysis of our model configuration to parameters controlling basal sliding and sub-shelf melt, and to model structural choices including the choice of the energy and stress balances; and (3) a 72-member ensemble run on graphics processing units (GPUs) and analysis of variance to determine the primary sources of uncertainty in our ice-sheet model projections. Our extended simulations predict rapid retreat beginning after 2300 for SSP1-2.6 forcing and after 2500 for present-day (control) forcing, primarily in the Amundsen Sea Embayment. We find that varying the sub-shelf melt parameter between the 5th to 95th percentile values for a mean-Antarctic calibration target results in an up to ∼ ± 40 % change in sea-level contribution relative to our baseline simulations that used the median value. Using a linear basal sliding law reduces sea-level contribution by 51 %–73 % relative to our baseline nonlinear sliding law with an exponent of 1/5. When using basal sliding law exponents of 1/3 and 1/10, the overall difference from our baseline simulations at 2300 is on the order of 10 %. The Amundsen Sea Embayment region displays a strongly non-linear dependence of mass loss on the sliding law exponent, with no discernible relationship between the sliding law exponent and the mass loss by 2300, while the sectors feeding the Ross and Filchner-Ronne ice shelves exhibit more mass loss with a more-plastic sliding law. Our model fidelity sensitivity experiments reveal a 9 %–31 % increase in sea-level contribution when using a depth-integrated stress balance approximation relative to our three-dimensional solver, while using a fixed-in-time temperature field increases sea-level contribution by 14 %–88 % relative to two thermomechanically coupled configurations. Our 72-member ensemble and analysis of variance show that the uncertainty in long-term projections is dominated by the choice of Earth system model forcing and the presence or absence of hydrofracture forcing, rather than uncertainty in sliding and sub-shelf melt parameters.

58 GEOSCIENCES

Battery Cell-to-Pack Scaling Trends for Electric Aircraft

Battery pack gravimetric energy density is one of the most important, yet often miss- estimated design parameters for sizing all-electric aircraft. Proper accounting for thermal, structural, and operational safety margins are frequently lost when extrapolating performance from the cell level to the aircraft level. This paper summarizes the relevant engineering and certification details needed to better account for the penalties associated when assembling battery packs. The relationship between the cell and pack energy density is not linear, as is often assumed. Furthermore, the relationship varies depending on pack requirements, cell chemistry, and architecture. Parametric, high-fidelity models are used to determine optimal battery pack sizes over a range of conditions to better quantify technology scaling effects.

Battery Electric Aircraft

A Frank Discussion on Lessons Learned From Adopting and Applying NASA-STD-6030 for Spaceflight Systems

With the advancement and adoption of Additive Manufacturing (AM) for spaceflight systems, numerous lessons have been learned during the qualification and certification of AM components. The lessons learned covered in this presentation will provide an overview of the challenges faced by NASA centers and commercial partners working to design AM hardware that complies with NASA-STD-6030 Additive Manufacturing Requirements (AMR). Topics of interest include tailoring of requirements for specific projects, documentation requirements, and addressing conservative approaches towards mechanical property development and analysis. In addition to that, this presentation aims to impress that these lessons learned will influence the future revisions of the NASA technical standard to facilitate and advance AM technology adoption on NASA projects.

Additive Manufacturing

A Survey of Lunar Rock Types and Comparison of the Crusts of Earth and Moon

The principal known types of lunar rocks are briefly reviewed, and their chemical relationships discussed. In the suite of low-KREEP highland rocks, Fe/(Fe + Mg) in the normative mafic minerals increases and the albite content of normative plagioclase decreases as the total amount of normative plagioclase increases, the opposite of the trend predicted by the Bowen reaction principle. Lunar highland samples analyzed are uniformly distributed in this sequence, in which normative plagioclase contents range from ~ 40 percent to ~ 100 percent. The distribution of compositions of rocks from terrestrial layered mafic intrusives is substantially different: here the analyses fall in several discrete clusters (anorthositic rocks, norites, granophyres and ferrogabbros, ultramafics), and the chemical trends noted above are not reproduced. It is suggested that the observed trends in lunar highland rocks could be produced by crystal fractionation in a deep global surface magma system if (1) plagioclase tended to float, upon crystallization, and (2) the magma was kept agitated and well mixed (probably by thermal convection) until crystallization was far advanced and relatively little residual liquid was left. When such a system was finally immobilized, the Fe-, Na-rich residual liquid would produce Fe-rich mafic minerals in the upper levels of the system, but could not much alter the composition of abundant calcic plagioclase. Conversely, the same liquid would produce sodic plagioclase deep in the sequence, but could not much alter the composition of abundant magnesian mafic minerals. After the crustal system solidified, but before extensive cooling had developed a thick, strong lithosphere, mantle convection was able to draw portions of the lunar anorthositic crust down into the mantle in a manner analogous to the present-day behavior of the terrestrial mantle and crust. At depth, the crustal material was heated; KREEP-rich norite was extracted by partial melting and erupted at the surface as a lava, analogous to terrestrial andesite eruptions.

John A Wood

Interfacial Adhesion Mechanism of Anionic Polyelectrolyte Brushes Induced by Oppositely Charged Macromolecular Counterions

Abstract Polyelectrolyte brushes are widely used as model systems for investigating electrostatic interactions at soft interfaces and to achieve exceptional lubrication properties. Previous studies have primarily focused on their behavior in the presence of multivalent counterions, which induce brush collapse, ionic crosslinking, and pronounced changes in interfacial structures. However, interactions between polyelectrolyte brushes and oppositely charged macromolecular counterions, such as polycations, remain poorly understood. Here, we prepare well-defined polystyrene sulfonate (PSS) brushes fabricated via surface-initiated grafting and employ surface forces apparatus measurements to investigate their interactions with oppositely charged polycations. In contrast to multivalent ions, polycations do not induce noticeable brush collapse, but instead generate significant adhesion between symmetric PSS brush layers. This adhesion increases with both contact time and applied load, eventually reaching a steady plateau, indicating that the interaction is governed not simply by electrostatic screening but by the gradual formation of polycation-mediated bridging under confinement. Furthermore, the introduction of monovalent Na+ ions disrupts the adhesive interaction even at very low concentrations, suggesting that the bridging function of the adsorbed polycation is highly sensitive to competitive ionic screening. In comparison, measurements with trivalent counterions reveal the expected brush collapse behavior but minimal dependence of adhesion on contact time, highlighting a clear mechanistic distinction from the polymeric counterion case. Collectively, these results demonstrate that molecular size, configurational restriction, and confinement-induced rearrangement, rather than charge valency alone, govern the interaction behavior of macromolecular counterions at brush interfaces. This work provides new insight into the molecular origins of adhesion and the regulation of interfacial interactions in charged polymer brush systems.

Park, Jinwoo [Argonne National Laboratory , , , ,;

Cryogenic Spray Quenching of A Simulated Propellant Storage Tank Wall With Heat Transfer Enhancement By A Thin-Film Coating and Flow Pulsing in Microgravity

Human space exploration to the Moon, Mars, and possibly asteroids is NASA’s biggest challenge for the new millennium. One of the critical elements to this mission is the effective, sufficient, and reliable supply of cryogenic propellant fluids. Future lower-earth-orbiting (LEO) propellant fuel depots and human-carrying orbital transfer spacecraft flying to the moon and Mars will have to utilize the high thrust and high efficiency of liquid cryogenic chemical propulsion or nuclear thermal propulsion. Efficient in-space tank-to-tank propellant transfer (propellant fuel depot to orbital transfer spacecraft) of cryogenic propellants is an enabling technology for the planned Crewed Mars Surface Mission. The transfer of cryogenic propellants in space, however, has yet to be accomplished, solely due to the unavailability of cryogenic quenching heat transfer data during chilldown (quenching) and filling of the propellant receiver tank in reduced gravity and microgravity as liquid propellant cannot be stored in a required liquid state until the tank is quenched down to the liquid temperature. Therefore, highly energy efficient thermal-fluid management breakthrough concepts to conserve and minimize the cryogen consumption during propellant transfer have become the focus of research and engineering development, especially for the deep-space mission to Mars. In this paper, we introduce such concepts and demonstrate their feasibility for cryogenic storage tank chilldown in parabolic flights under a simulated space microgravity condition. In order to maximize the storage tank chilldown efficiency for the least amount of cryogen consumption, the technology adopted included cryogenic spray cooling, Teflon thin-film coating of the simulated tank surface, and spray flow pulsing. The completed flight experiments successfully demonstrated that spray cooling is the most efficient cooling method for the tank chilldown in microgravity. In microgravity, Teflon coating alone can improve the efficiency up to 72% and the efficiency can be improved up to 59% by flow pulsing alone. However, Teflon coating together with flow pulsing was found to substantially enhance the chilldown efficiency in microgravity for up to 113%.

spray

Unravelling ultralow thermal conductivity in perovskite Cs2AgBiBr6: dominant wave-like phonon tunnelling and strong anharmonicity

Abstract Understanding the lattice dynamics and heat transport physics in the lead-free halide double perovskites remains an outstanding challenge due to their lattice dynamical instability and strong anharmonicity. In this work, we investigate the microscopic mechanisms of anharmonic lattice dynamics and thermal transport in lead-free halide double perovskite Cs 2 AgBiBr 6 from first principles. We combine self-consistent phonon calculations with bubble diagram correction and a unified theory of lattice thermal transport that considers both the particle-like phonon propagation and wave-like tunnelling of phonons. An ultra-low thermal conductivity at room temperature (~0.21 Wm −1 K −1 ) is predicted with weak temperature dependence( ~ T −0.34 ), in sharp contrast to the conventional ~T −1 dependence. Particularly, the vibrational properties of Cs 2 AgBiBr 6 are featured by strong anharmonicity and wave-like tunnelling of phonons. Anharmonic phonon renormalization from both the cubic and quartic anharmonicities are found essential in precisely predicting the phase transition temperature in Cs 2 AgBiBr 6 while the negative phonon energy shifts induced by cubic anharmonicity has a significant influence on particle-like phonon propagation. Further, the contribution of the wave-like tunnelling to the total thermal conductivity surpasses that of the particle-like propagation above around 310 K, indicating the breakdown of the phonon gas picture conventionally used in the Peierls-Boltzmann Transport Equation. Importantly, further including four-phonon scatterings is required in achieving the dominance of wave-like tunnelling, as compared to the dominant particle-like propagation channel when considering only three-phonon scatterings. Our work highlights the importance of lattice anharmonicity and wave-like tunnelling of phonons in the thermal transport in lead-free halide double perovskites.

Chemistry

Terahertz‐Nanoscale Visualization of the Microscopic Spin‐Charge Architecture of Colossal Magnetoresistive Switching

Resolving sub-10 nm spin switching and the associated terahertz (THz) electrodynamics during the colossal magnetoresistance (CMR) transition is a definitive frontier in reaching the fundamental spatial, temporal, and energy-dissipation limits of spin-electronics. Yet, simultaneous control of high magnetic field, cryogenic environment, and nanometer resolution has remained an elusive benchmark for THz nanoscopy, leaving the local THz dynamics of these transitions largely unexplored. Here, we overcome these limitations by utilizing a custom-built cryogenic magneto-THz scattering-type scanning near-field optical microscopy (cm-THz-sSNOM) to resolve the near-field THz spectroscopic evolution of the magnetic field-driven CMR transition in a manganite single crystal. Our measurements provide a nanoscale visualization of the THz conductivity, capturing the moment that magnetic-field-induced spin switching triggers the transition from an antiferromagnetic insulator to a ferromagnetic metal. An ellipsoidal near-field model reveals a multi-scale transition initiated by 1–2 nm isolated spin-flip sites at low magnetic fields, which coalesce into ∼15 nm conducting regions as the threshold field is approached. These results provide an nano-THz view of CMR switching, establishing an analysis framework for mapping spin–charge–lattice–orbit–coupled dynamics at spatial scales that transcend the nominal sSNOM resolution.

Haeuser, Samuel [Iowa State University, Ames, IA (

Nuclear–Electronic Orbital General Rate Theory: Predicting Hydrogen Kinetic Isotope Effects in the Deep Tunneling Regime

Hydrogen transfer is a critical component of many chemical and biological processes. The ratio of rate constants for hydrogen and deuterium transfer defines the H/D kinetic isotope effect (KIE), which is a powerful tool for elucidating hydrogen transfer mechanisms. Interpretation of experimental H/D KIEs relies on accurate and affordable computational methods. However, due to their light mass, hydrogen and deuterium can undergo tunneling, which is challenging to describe in multidimensional molecular systems. Herein, we introduce the nuclear–electronic orbital general rate theory (NEO-GRT), which enables the efficient prediction of H/D KIEs based on full-dimensional molecular quantum chemistry calculations. The NEO-GRT approach describes the hydrogen transfer rate constant with a general expression that spans the vibrationally adiabatic and nonadiabatic hydrogen tunneling regimes. The input quantities are computed using NEO density functional theory, which treats the transferring hydrogen or deuterium nucleus quantum mechanically on the same level as the electrons. We investigate two intramolecular proton transfer reactions in organic molecules at temperatures down to 50 K to evaluate the performance of NEO-GRT by comparison to transition state theory and ring-polymer instanton theory. The KIEs computed with NEO-GRT agree with those calculated using ring-polymer instanton theory for the full-dimensional molecular systems at the same level of electronic structure theory. This agreement indicates that NEO-GRT captures the deep hydrogen tunneling effects, in contrast to transition state theory, which neglects such effects. Given its relatively low computational cost, NEO-GRT is a promising approach for predicting H/D KIEs in large organic and organometallic systems.

Hydrogen

Spectrograph stabilization using a single-delay interferometer on the Hale Telescope

We describe a technique for spectrograph stabilization useful when conventional mitigation techniques of vacuum tanks, thermal insulation, and laser frequency comb may be impractical, expensive, heavy, or bulky. This includes spectrographs on airborne platforms or mounted on telescopes where they suffer a changing gravity vector or other drifts. Placing a fixed-delay interferometer in series with a spectrograph forms an externally dispersed interferometer (EDI). This produces a uniform sinusoidal comb multiplying input spectrum, creating (through heterodyning) beats (moiré patterns). In Fourier space for low frequencies up to the comb frequency, the moiré generated signal counter-rotates to ordinary spectra under an unknown disperser wavenumber drift Δx. This generates a large negative feedback signal useful in a conceptual control loop, to converge rapidly to a stable spectrum and yield Δx. A modified EDI data analysis algorithm (“crossfading”) combines frequency-weighted moiré with conventional spectrum to cancel net output spectrum reaction to Δx. Needing only a single-delay, this is a practical improvement over prior crossfading analyses requiring multiple delays. We test crossfading on ThAr data near 4850 cm−1 taken on Hale telescope in an earlier project. In a single pass, we reduce drift 20 times. Using seven iterations, we reduce 0.5 cm−1 (31 km/s Doppler equivalent) drift to 4×10−7 cm−1 (2.5 cm/s). The interferometer delay can wander, because linearity of phase versus wavenumber interpolates science features between bracketing calibrating spectral references. Second, mathematically reversing the heterodyning effect doubles effective spectral resolution without changing disperser slit.

Erskine, David J [Lawrence Livermore National Labo

Revealing the Roles of CuF 2 /NiF 2 Incorporation in the Electrochemical Performance of FeF 3 Cathodes in Solid‐State Batteries

Mixed metal fluorides have been considered as a promising candidate to lower the voltage hysteresis of conversion-type iron fluoride cathodes, but their cycling stability is limited due to transition metal dissolution and interphase growth in liquid electrolyte batteries. Here, we study the role of incorporating CuF 2 and NiF 2 in the electrochemical performance of FeF 3 cathode in halide-based solid-state batteries to test whether we can transfer the kinetic benefit of low voltage hysteresis to solid-state batteries while using solid electrolyte to eliminate transition metal dissolution and stabilize the interphase. Synchrotron X-ray absorption spectroscopy results indicated the redox reactions are attributed to Cu 0 /Cu + and Fe 0 /Fe 2+ in 25CuF 2 -75FeF 3 and Ni 0 /Ni 2+ and Fe 0 /Fe 3+ in 10NiF 2 -90FeF 3 . While no apparent improvement in electrode kinetics can be observed, the incorporation of CuF 2 and NiF 2 can largely improve the cycling stability of FeF 3 cathodes. In conclusion, the results demonstrate the advantages of using solid-state concept to improve the cycling stability of conversion-type cathodes.

25 ENERGY STORAGE

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

Asynchronous Transfer Mode Link Performance Over Ground Networks

The results of an experiment to determine the feasibility of using asynchronous transfer mode (ATM) technology to support advanced spacecraft missions that require high-rate ground communications and, in particular, full-motion video are reported. Potential nodes in such a ground network include Deep Space Network (DSN) antenna stations, the Jet Propulsion Laboratory, and a set of national and international end users. The experiment simulated a lunar microrover, lunar lander, the DSN ground communications system, and distributed science users. The users were equipped with video-capable workstations. A key feature was an optical fiber link between two high-performance workstations equipped with ATM interfaces. Video was also transmitted through JPL's institutional network to a user 8 km from the experiment. Variations in video depending on the networks and computers were observed, the results are reported.

E T Chow

Patchy nanoparticles by atomic stencilling

Stencilling, in which patterns are created by painting over masks, has ubiquitous applications in art, architecture and manufacturing. Modern, top-down microfabrication methods have succeeded in reducing mask sizes to under 10 nm, enabling ever smaller microdevices as today’s fastest computer chips. Meanwhile, bottom-up masking using chemical bonds or physical interactions has remained largely unexplored, despite its advantages of low cost, solution-processability, scalability and high compatibility with complex, curved and three-dimensional (3D) surfaces. Here we report atomic stencilling to make patchy nanoparticles (NPs), using surface-adsorbed iodide submonolayers to create the mask and ligand-mediated grafted polymers onto unmasked regions as ‘paint’. We use this approach to synthesize more than 20 different types of NP coated with polymer patches in high yield. Polymer scaling theory and molecular dynamics (MD) simulation show that stencilling, along with the interplay of enthalpic and entropic effects of polymers, generates patchy particle morphologies not reported previously. These polymer-patched NPs self-assemble into extended crystals owing to highly uniform patches, including different non-closely packed superlattices. We propose that atomic stencilling opens new avenues in patterning NPs and other substrates at the nanometre length scale, leading to precise control of their chemistry, reactivity and interactions for a wide range of applications, such as targeted delivery, catalysis, microelectronics, integrated metamaterials and tissue engineering.

36 MATERIALS SCIENCE

Artificial Intelligence for Multi-Mission Planetary Operations

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

David J Atkinson

AutoSourceID-Classifier: Star-galaxy classification using a convolutional neural network with spatial information

Aims.Traditional star-galaxy classification techniques often rely on feature estimation from catalogs, a process susceptible to introducing inaccuracies, thereby potentially jeopardizing the classification’s reliability. Certain galaxies, especially those not manifesting as extended sources, can be misclassified when their shape parameters and flux solely drive the inference. We aim to create a robust and accurate classification network for identifying stars and galaxies directly from astronomical images. Methods.The AutoSourceID-Classifier (ASID-C) algorithm developed for this work uses 32x32 pixel single filter band source cutouts generated by the previously developed AutoSourceID-Light (ASID-L) code. By leveraging convolutional neural networks (CNN) and additional information about the source position within the full-field image, ASID-C aims to accurately classify all stars and galaxies within a survey. Subsequently, we employed a modified Platt scaling calibration for the output of the CNN, ensuring that the derived probabilities were effectively calibrated, delivering precise and reliable results. Results.We show that ASID-C, trained on MeerLICHT telescope images and using the Dark Energy Camera Legacy Survey (DECaLS) morphological classification, is a robust classifier and outperforms similar codes such as SourceExtractor. To facilitate a rigorous comparison, we also trained an eXtreme Gradient Boosting (XGBoost) model on tabular features extracted by SourceExtractor. While this XGBoost model approaches ASID-C in performance metrics, it does not offer the computational efficiency and reduced error propagation inherent in ASID-C’s direct image-based classification approach. ASID-C excels in low signal-to-noise ratio and crowded scenarios, potentially aiding in transient host identification and advancing deep-sky astronomy.

Astronomy & Astrophysics