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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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NASA NTRSDate not supplied

SuperHERO X-ray Telescope Balloon Mission

The SuperHERO hard X-ray telescope will observe extended sources at unprecedented imaging resolution, revealing the origins of non-thermal emission in extreme astrophysical environments. Employing NASA Marshall Space Flight Center’s replicated NiCo full-shell X-ray mirror technology to achieve better than 10-arcsecond half-power diameter (HPD) angular resolution on a balloon platform, SuperHERO consists of seven identical, co-aligned telescopes with a combined effective area of 45 cm² at 30 keV. SuperHERO was selected in the APRA 2023 call as a five-year mission, with an inaugural two-day flight scheduled from Fort Sumner, New Mexico, in the fall of 2028. For its initial target, SuperHERO will observe the Crab pulsar wind nebula, localizing hard X-ray emission. Mission development is currently underway, with updates and status to be provided in this presentation.

Nick Thomas↗
NASA NTRS2026

The Future of in-Situ Sequencing-Based Microbial Monitoring: Development of a Shelf-Stable Method for Artemis and Beyond

Microbial monitoring onboard the International Space Station (ISS) is essential for assessing the efficiency of the Environmental Control and Life Support Systems (ECLSS) and providing insight into potential risk to both crew and spacecraft. Historically, this monitoring required the need to culture organisms onboard, return these cultures to Earth, and then complete the identifications, a process that would take months. Over the past decade, and through numerous payloads, advances in molecular biology have enabled in-flight microbial identifications using nanopore sequencing. The swab-to-sequencer method resulting from these efforts was transitioned from research to operations for microbial monitoring under the Crew Health Care Systems (CHeCS) BioMole. Collectively, these accomplishments have propelled the swab-to-sequencer method to be selected as the Microbial Surface Monitor (MSM) for Gateway, as well as a payload on Artemis IV. However, the lack of cold stowage availability for Artemis requires modifications to the entire method due to the thermal instability of the reagents required for sample preparation. To achieve this, new development, optimization, and validations were undertaken. Key considerations included enzyme concentration, buffer compatibility, and equal or enhanced sensitivity and specificity. At each step, thorough side-by-side comparisons with the current ISS method were performed. The development of a robust shelf-stable method will ensure continued sequencing-based microbial monitoring for Artemis and beyond, providing data in near real-time, enhancing risk response time, and yielding clear insight into the microbiome of spacecraft.

Christian G Mena↗
NASA NTRS1996

Nickel-Cadmium Battery Operation Management Optimization Using Robust Design

In recent years following several spacecraft battery anomalies, it was determined that managing the operational factors of NASA flight NiCd rechargeable battery was very important in order to maintain space flight battery nominal performance. The optimization of existing flight battery operational performance was viewed as something new for a Taguchi Methods application.

NiCd rechargeable battery Taguchi Methods applicat↗
NASA NTRS2026

Computational Materials for Qualification and Certification (CM4QC) Strategy Document: Maturation of Computational Materials Methods for Aviation-Focused Qualification and Certification of Metal Additive Manufacturing (as an Example of Process-Intensive Materials)

Although considerable scientific and technological advances have been made in recent years in additive manufacturing (AM) processes, these advances have not translated into significant market penetration of AM parts within the aviation industry. It is broadly acknowledged that using traditional qualification and certification (Q&C) approaches for AM components is one of the most significant barriers to broader adoption of AM, resulting in high costs, long product development and certification timelines, and complex design iterations during the product development cycle. A new approach is urgently needed. This document lays out a vision for a new Q&C paradigm with increased use of computational materials (CM) methods aimed at decreasing the time and cost of Q&C of process-intensive material (PIM) approaches in the aviation industry, with AM as the immediate use case. This vision was developed with substantial input from industry, regulatory agencies, government research organizations, and academia.

Edward H Glaessgen↗
NASA NTRS2026

Uranus Orbiter and Probe: Mission Challenges and Concept Updates Since the Origins, Worlds, and Life Decadal Survey

Origins, Worlds, and Life: Planetary Science and Astrobiology in the Next Decade identified a Uranus Orbiter and Probe as the highest-priority strategic mission for the decade 2023–2032, as it enables broad cross-disciplinary science in the largely unexplored Uranian system. The mission architecture evaluated by the Decadal Survey was a singular proof of concept demonstrating that a moderately instrumented mission could deliver Decadal-priority science with a reduced cost and risk posture by leveraging existing technologies to the maximum extent possible. With revised assumptions since the Decadal, we have explored a large trade space including launch vehicles, propulsion options, cruise trajectories, available power sources, viable concept of operations, and science data return for later launch dates without a Jupiter gravity assist. The most repeatable trajectory solutions employ either a commercially derived solar electric propulsion (SEP) transfer stage or the availability of a more capable launch vehicle under development, such as the SpaceX Starship. Orbit insertion has been moved farther from Uranus to acknowledge the remaining uncertainty in Uranian ring structure. A streamlined, SEP-adaptable, orbiter design was developed using two Next Gen Radioisotope Thermoelectric Generators, and the probe design was matured, reducing the entry gravitational acceleration, and assuming the largest Decadal-recommended payload to provide margin for future instrument selections. With this updated design, we also constructed a detailed concept of operations for three representative science cases, returning 13–15 Gbit of science data and spacecraft telemetry per ∼34 day orbit.

Amy A Simon↗
NASA NTRSDate not supplied

Flammability Test Method for Materials Intended for Use as Fire Barriers in Crewed Habitats

In some crewed-spacecraft applications, onboard materials are intentionally selected to function as hazard control barriers to prevent powered hardware and/or ignited flammable items from igniting nearby flammable materials by acting as non-breaching, non-flammable containment (e.g., cargo transfer bags, zero gravity stowage racks, and jettison stowage bags on the International Space Station). Historically, flammability self-extinguishment testing of broad acreage or outermost layer materials alone was believed to be sufficient to verify overall flammability compliance. Though required, testing on design features such as threaded seams and zippers was not performed due to the incorrect assumption that flammability performance would not be impacted. However, recent coupon level testing of layups and configurations consisting of multiple materials have revealed that these features may be more susceptible to ignition and fire propagation than the bulk material. Additionally, configurational coupon ignition and propagation testing does not explicitly determine a material’s ability to provide protection to vulnerable flammable hardware. The need to evaluate this gap in assessing material or layup effectiveness as fire barriers between ignition sources and flammable materials led to the development of a new configuration-based fire barrier test. Test setup, relevant configurations, and test validation are discussed. The new barrier test method establishes a configuration for the test apparatus, identifies a conservative ignitor configuration, and defines pass/fail criteria. Test setup, relevant configurations, and test validation are discussed.

Susana Harper↗
NASA NTRS2026

Evaluating Energy Absorption Methods for Integrated Composite Seat Designs

Composite materials have become ubiquitous in the aerospace industry due to their exceptionally light weight and high strength characteristics, as well as their unique ability to be engineered and tailored to meet specific loading conditions and performance requirements. These advanced materials offer superior strength-to-weight ratios compared to traditional metallic materials, making them particularly valuable in weight-critical aerospace applications where every pound saved translates to improved efficiency and performance. In currently operating fleets of commercial and military aircraft, composite materials have been successfully applied to critical structural components, including primary load-bearing elements such as the fuselage sections and flooring structures, which must withstand significant in-flight loads and provide passenger safety. Additionally, these materials have been specifically tailored and optimized for aerodynamic components such as wings and tail assemblies, where their ability to be molded into complex shapes while maintaining structural integrity is particularly advantageous. The application of composite materials extends beyond primary structural elements into the realm of internal cabin components, most notably in innovative seat designs where weight reduction and structural integration are paramount concerns. Modern composite seat structures can be designed to integrate multiple functions, including structural support, comfort features, and safety systems, all while maintaining the lightweight characteristics essential for aircraft performance.

Digital image correlation↗
NASA NTRS1985

Passive Remote Sensing of Stratospheric and Mesospheric Winds

A passive infrared sensor is described for remote sounding of the wind field in the stratosphere and mesosphere from near Earth orbital spacecraft. The instrument uses gas correlation spectroscopy together with electro-optic phase modulation techniques to measure winds in the 20- to 120-km altitude range globally, both in the day and at night, and with a vertical resolution of better than the atmospheric scale height. Measurement of temperature and the amounts of key atmospheric species may also be made simultaneously and in coincident fields of view with the wind observations. The sensor is currently being developed at the Jet Propulsion Laboratory as a candidate for the upcoming NASA Earth Observation System.

Daniel J Mccleese↗
NASA NTRS1962

Mercury Corrosion Loop Testing Program

The Mercury Corrosion Loop Testing Program continued through the second quarter. Materials to be tested in the 10 forced-convection test loops were selected; the materials are: Haynes 25, 9 Cr-1Mo alloy clad with Type 316 stainless steel, AM 350 stainless steel, and columbium (niobium) clad with Type 316 stainless steel. The eight-test-cell facility was completed and all utilities were installed. Pneumatic and electronic instrumentation for all test cells was installed and calibrated. Fabrication was initiated on the first four Haynes 25 loops. The first loop was 85% assembled at the end of the quarter. A centrifugal pump made from Type 316 stainless steel was tested; bearing modifications were made to improve operation.

Corrosion↗
NASA NTRS2026

Measure sea level air pressure from space to improve knowledge and forecasting of the atmospheric state

Modern numerical weather prediction (NWP) and analysis models require globally-observed meteorological data including sea-level pressure (SLP) for accurate operations. Up until now, SLP has only been measured by in situ instruments from ships, buoys, and ocean platforms. These measurements are sparse with large gaps, leaving models starved of this critical information to constrain the atmospheric state. Recent advancements in differential absorption radar (DAR) provide a path to close this critical observation gap through spaceborne observations in the coming decade, improving the analysis models relied upon for atmospheric research and the weather forecasts depended upon daily for public safety and commerce.

Matthew L Walker McLinden↗
NASA NTRSDate not supplied

Pragmatic Stress Prediction on Additively Manufactured Coupons

Prediction of residual stresses from process parameters for additively manufactured large metal parts is computationally expensive. NASA is currently developing meter-scale parts with direct energy deposition. Practically, the predictive computational methods need to efficiently scale-up to meter-scale parts. Coupled thermal-mechanical multi-physics simulations have been developed with the pragmatic method using ABAQUS, COMSOL Multiphysics, ALE3D software. The residual stresses are a result of the manufacturing process which creates thermal cycling of the build layers. The pragmatic method uses lumped thermal layers for stress predictions to reduce computational costs. The stress predictions as well as deformations of the different codes are compared with each other and with ANSYS Additive using identical material models, boundary and initial conditions. The codes were used to simulate three different geometries: a thin wall, hollow cylinder and twin-cantilever part. The coupon parts were then manufactured with Inconel-625. The residual stresses in these parts were measured using X-ray diffraction as well as neutron beam diffraction at NIST. The stress measurements for the two technologies are compared. The pragmatic stress prediction method enabled predictions of the multi-centimeter scale parts using desktop computer workstations in only a few hours for each coupon. The results of the simulated stress predictions compared favorably with the measured stresses even though thermally lumped layers were employed. Finally, a two-meter scale nozzle was simulated using ANSYS Additive. The simulations were used to examine the build orientation trade-space with respect to resulting geometric deformation. The predicted deformations were compared to measurements of an actual subscale part manufactured with direct energy deposition.

pragmatic method↗
NASA NTRS1992

Flight Testing

It is considered by the Flight Mechanics Panel of AGARD as vitally important that the NATO flight test community meet regularly so that new techniques for flight test, instrumentation and data analysis and lessons learned from past and on-going programs be disseminated to ensure that safe efficient cost-effective and timely testing is accomplished. There are many new systems being tested or planned for testing in the near future. These include programmable signal processor radars, integrated flight, fire and propulsion control systems, thrust vectoring, low observable technologies, multifunction pilot displays and multisensor integration. Acquisition and processing of large quantities of avionics multiplex data are challenges that must be met. There is a need for greater use of simulators and other hardware-in-the-loop ground test facilities.

Source record↗
NASA NTRS1973

Implementation of A Self-Controlling Heater

Temperature control of radiation sensors, targets, and other critical components is a common requirement in modern scientific instruments. Conventional control systems use a heater and a temperature sensor mounted on the body to be controlled. For proportional control, the sensor provides feedback to circuitry which drives the heater with an amount of power proportional to the temperature error. It is impractical or undesirable to mount both a heater and a sensor on certain components such as ultra-small parts or thin filaments. In principle, a variable current through the element is used for heating, and the change in voltage drop due to the element's temperature coefficient is separated and used to monitor or control its own temperature. Since there are no thermal propagation delays between heater and sensor, such control systems are exceptionally stable.

Maxwell G Strange↗
NASA NTRS1993

Formal Functional Test Designs with a Test Representation Language

The application of the category-partition method to the test design phase of hardware, software, or system test development is discussed. The method provides a formal framework for reducing the total number of possible test cases to a minimum logical subset for effective testing. An automatic tool and a formal language were developed to implement the method and produce the specification of test cases.

J M Hops↗
NASA NTRSDate not supplied

Developmental and Cryogenic Thermal Vacuum (TVAC) Testing Lessons Learned

Developmental thermal vacuum (TVAC) testing is a critical step in maturing hardware designs and validating performance prior to flight qualification. Unlike qualification or acceptance testing, developmental testing provides flexibility to explore design margins, uncover integration challenges, and refine test approaches before formal verification activities begin. This presentation highlights the value of developmental testing while sharing common pitfalls encountered during developmental TVAC campaigns. Lessons learned from hands-on testing experience, including extensive developmental testing at cryogenic temperatures, will be shared in this presentation. Topics include test planning and preparation, instrumentation strategies, contamination control considerations, troubleshooting unexpected anomalies, and approaches for staying on schedule while meeting test objectives. The audience will gain practical insights and best practices that can improve test efficiency, reduce risk, and enhance the overall success of future developmental TVAC efforts.

Mackenzie Byrnes↗
NASA NTRSDate not supplied

Evaluation of Low-Energy Hydrogen Separation Method Using Metal-Organic Frameworks (MOFs) for Closed-Loop ECLSS Air Revitalization (CLEAR)

The State-of-the-Art (SOA) air revitalization architecture onboard the International Space Station (ISS) recovered approximately 50% of the oxygen (O 2 ) from metabolic carbon dioxide (CO 2 ) via the Sabatier process from 2011 to 2017. O 2 recovery is currently constrained by the limited availability of reactant hydrogen (H 2 ) preventing complete conversion of CO 2 to H 2 O. Increasing O 2 recovery within Closed-Loop ECLSS is essential to reducing resupply mass for long-duration manned missions; specifically focusing on water (H 2 O) which supplies H 2 for Sabatier via water electrolysis. Past ground test endeavors at Marshall Space Flight Center (MSFC) have attempted to recover H 2 from Sabatier-produced CH 4 using technologies such as carbon vapor deposition (CVD) and plasma pyrolysis. The byproducts of these technologies can act as a catalyst poison or reactor deadload to the Sabatier reactor. Hydrogen separation techniques must be utilized to maintain the Sabatier catalyst during gas recycling and must be scalable, non-energy intensive, and safe to operate in a habitation setting. Research indicated that metal-organic frameworks (MOFs) could meet these criteria and were tested for their capability to capture the various carbon-based gaseous products of CVD and plasma pyrolysis such as acetylene (C 2 H 2 ), ethylene (C 2 H 4 ), ethane (C 2 H 6 ), and carbon monoxide (CO) which would purify the hydrogen gas stream passing through the MOF. A sub-scale adsorption column was developed by Marshall Space Flight Center to test three MOF candidates against a synthetic gas mixture comprised of process-relevant carbonous gases and hydrogen to evaluate the separation capability of the MOFs. The results of the hydrogen separation capability, isothermal desorption capability, and demonstrated cyclic reuse of the MOF are presented in this paper.

Kagen Crawford↗
NASA NTRS2026

Performance Optimization for Lunar Extravehicular Activity Readiness (POLAR) Study: Methods Paper

To better understand which aspects of physical fitness may be most related to performance during Lunar surface operations and thereby help to inform the current NASA fitness standards, much can be learned from fields encompassing the “tactical athlete.” Other physically demanding professions such as law enforcement, military, or rescue professionals often require candidates to meet occupationally-relevant fitness standards. The determination of such standards is a multistep process, including both objective and subjective measures, to determine tasks essential to occupational performance and identify the minimal fitness profile needed to meet physical demands of the job. Notably, fitness is only one component which may contribute to the demands of astronaut selection, flight assignment, and occupational performance. Utilizing a framework to systematically determine which domains of fitness most contribute to relevant job tasks can aid in the refinement of current NASA-STD-3001 fitness standards. Therefore, NASA’s Exercise Physiology & Countermeasures Laboratory conducted the Performance Optimization for Lunar Extravehicular Activity Readiness (POLAR) study to identify and examine a comprehensive list of fitness tests (including NASA-STD-3001 assessments: 1-Repetition Maximum [1-RM] bench press and deadlift) and determine preliminary relationships between identified fitness parameters and novel Artemis-relevant tasks to help inform future investigations for the continued development of aerobic and muscular fitness standards for surface EVAs. This was accomplished through 1) a review of the literature relating fitness assessments to simulated or real EVA performance to identify fitness tests that are most correlated with simulated EVA task performance; 2) a task analysis following a modified framework for physical employment standards development to down select mission critical tasks; and 3) development and pilot testing of a novel, portable Artemis-relevant EVA task circuit to relate to a battery of fitness assessments. The current report describes the methodology used to complete the task analysis, EVA task circuit development, and the pilot study.

Nicole C Strock↗
NASA NTRS1991

A Space Servicing Telerobotics Technology Demonstration

Supervised telerobotic controls provide the key to successful remote servicing, as demonstrated in the telerobot testbed of the jet propulsion laboratory. Such advanced techniques and systems are specially applicable to ground-remote operations for servicing tasks, which are to be performed remotely in space and to be operated under human supervision from the ground. Laboratory demonstrations have successfully proven the utility of such techniques and systems. Instrumental to the success of supervised robotic operations are the techniques called object designate and relative target. In addition, a technique called universal camera calibration was also applied in the telerobot testbed. Generalized compliant control techniques were used in the robotic removal and insertion operations. These techniques were proven successful in task situations where preprogrammed automation cannot be adequately exercised due to errors, changes, or omission in the worksite data base.

Edwin P Kan↗