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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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The objectives and achievements of the development program for space electrical power systems are discussed. Power requirements for various space projects and products of power development research are considered. Research on the radiation-resistant n-p solar cell, thin-film solar cells, and rechargeable batteries is outlined. The development of Snap-8 is also discussed.
Lithium-Ion (Li-Ion) batteries are fast becoming the battery chemistry of choice for aerospace applications requiring (rechargeable) power supplies. These batteries offer high-energy density and high-specific energy combined with excellent rate capability and cycle potential. The increased energy content and operational characteristics of this system require defined safety and handling procedures to ensure the safe implementation. Standardized approaches to defining, determining, and addressing safety, handling, and qualification for Li-Ion batteries have been developed and published as an NESC-sponsored Li-Ion Battery Guidelines Document. A data base was established cataloging cells and batteries that have been considered for aerospace applications.
The International Space Station (ISS) Electric Power System (EPS) currently uses Nickel-Hydrogen (Ni-H2) batteries to store electrical energy. The batteries are charged during insolation and discharged during eclipse. The Ni-H2 batteries are designed to operate at a 35 depth of discharge (DOD) maximum during normal operation in a Low Earth Orbit. Since the oldest of the 48 Ni-H2 battery Orbital Replacement Units (ORUs) has been cycling since September 2006, these batteries are now approaching their end of useful life. In 2010, the ISS Program began the development of Lithium-Ion (Li-ion) batteries to replace the Ni-H2 batteries and concurrently funded a Li-ion cell life testing project. This paper will include an overview of the ISS Li-Ion battery system architecture and the progress of the Li-ion battery design and development.
This work presents a multiscale modeling approach to predict the fracture strength of fibrous Thermal Protection System (TPS) materials. The model assumes that system failure is initiated at the joints between individual fibers. We investigated three distinct TPS compositions: amorphous silica, alumina and aluminosilicate fibers. Molecular dynamics (MD) simulations were employed to determine the fracture strength values of these fiber joints for both material systems. These fracture strength values were then integrated into simulations of 3D randomly populated fiber structures, where tensile load transfer occurs through the fiber joints. These microscale properties are upscaled through a renormalization approach [1] to predict macroscale tensile strength of 3D random fiber networks, accounting for joint-dominated failure and effective load-bearing area. The study concludes by demonstrating the resulting strength variation as a function of material composition, fiber density, and morphology. We also show validation of results by comparing them against explicit fiber finite element (FE) modeling [2] where fiber joint fracture is represented by cohesive elements.
The Crewed Space Vehicle Battery Safety Requirements document has been prepared for use by designers of battery-powered vehicles, portable equipment, and experiments intended for crewed spaceflight. The purpose of the requirements document is to provide battery designers with information on design provisions to be incorporated in and around the battery and on the verification to be undertaken to demonstrate a safe battery is provided. The term "safe battery" means that the battery is safe for ground personnel and crew members to handle and use; safe to be used in the enclosed environment of a crewed space vehicle; and safe to be mounted or used in unpressurized spaces adjacent to habitable areas. Battery design review, approval, and certification is required before the batteries can be used for ground operations and be certified for flight.
QuickSounder (QS) is the pathfinder space mission for the next generation of NOAA LEO environmental satellites in the NEON program, follow-on to the JPSS program. It is a collaborative initiative between NASA and NOAA to verify rapid and cost-effective delivery of small Earth observation satellites. QuickSounder is focusing on mission elements other than science performance. In this context, an existing sensor, the refurbished ATMS EDU (Advanced Technology Microwave Sounder, Engineering Development Unit) was chosen as the QuickSounder payload. This poster discusses the performances of QuickSounder ATMS during thermal vacuum (TVAC) calibration to ensure that QS ATMS is characterized and calibrated in the same manner as JPSS ATMS units, even though science performance attributes are not the priority of this mission.
A stable, high temperature strain gage based on reactively sputtered indium tin oxide (ITO) was demonstrated at temperatures up to 1050 C. These strain sensors exhibited relatively large, negative gage factors at room temperature and their piezoresistive response was both linear and reproducible when strained up to 700 micro-in/in. When cycled between compression and tension, these sensors also showed very little hysteresis, indicating excellent mechanical stability. Thin film strain gages based on selected ITO alloys withstood more than 50,000 strain cycles of +/- 500 micro-in/in during 180 hours of testing in air at 1000 C, with minimal drift at temperature. Drift rates as low as 0.0009%/hr at 1000 C were observed for ITO films that were annealed in nitrogen at 700 C prior to strain testing. These results compare favorably with state of the art 10 micro-m thick PdCr films deposited by NASA, where drift rates of 0.047%/hr at 1050 C were observed. Nitrogen annealing not only produced the lowest drift rates to date, but also produce the largest dynamic gage factors (G = 23.5). These wide bandgap, semiconductor strain sensors also exhibited moderately low temperature coefficients of resistance (TCR) at temperatures up to 1100 C, when tested in a nitrogen ambient. A TCR of +230 ppm/C over the temperature range 200 C < T < 500 C and a TCR of -469 ppm/C over the temperature range 600 C < T < 1100 C was observed for the films tested in nitrogen. However, the resistivity behavior changed considerably when the same films were tested in oxygen ambients. A TCR of -1560 ppm/C was obtained over the temperature range of 200 C < T < 1100 C. When similar films were protected with an overcoat or when ITO films were prepared with higher oxygen contents in the plasma, two distinct TCR's were observed. At T < 800 C, a linear TCR of -210 ppm/C was observed and at T > 800 C, a linear TCR of -2170 DDm/C was observed. The combination of a moderately low TCR and a relatively large gage factor make these semiconducting oxide films promising candidates for the active strain elements in high temperature thin film strain gages, particularly in applications where static strain measurement is desired.
The Biological and Physical Sciences (BPS) Division of NASA’s Science Mission Directorate (SMD), and its predecessors, has sponsored extensive flight and ground experiments yielding benchmark datasets in many materials science research areas including thermophysical properties and solidification microstructure formation and evolution. The subject study sought to motivate and focus BPS’s engagement within the broader Integrated ICME community to understand the phenomena underlying material processing, structure, and properties in the microgravity environment of space and to support future space exploration efforts.
Three batteries designed for the GPS system were evaluated. The batteries were wired together, and during the eclipse period were discharged through parallel diodes into a boost converter which then boosted the battery voltage up to the totally regulated bus voltage. Each battery, with a system life of approximately five years, had its own charger. During testing the battery was maintained or used on trickle charge. Data are presented for the battery capacity during the reconditioning. Raw data for each eclipse period and calculations for the average discharge voltage for each battery are given. Thermal cycling for one of the batteries and reconditioning cycles and regimes for all of the batteries are discussed. A reconditioning discharge curve is also given. The problem of temperature cycling in one of the batteries was resolved by redesigning the battery radiator system.
This document provides guidelines on probable climatic extremes and probabilities-of-occurrence of terrestrial environment data specifically applicable for NASA space vehicles and associated equipment development. The geographic areas encompassed are The Eastern Test Range (Cape Kennedy, Florida); Huntsville, Alabama; New Orleans, Louisiana; The Space and Missile Test Center (Vandenberg AFB California); Sacramento, California; Wallops Test Range (Wallops Island, Virginia); White Sands Missile Range, New Mexico; and intermediate transportation areas. In addition, sections have been included to provide information on the general distribution of natural environment extremes in the United States (excluding Alaska and Hawaii), cloud cover, and some worldwide climatic extremes. Although all these areas are covered, the major emphasis is given to the Kennedy Space Center launch area and Vandenburg Air Force Base due to importance in NASA's future large space vehicle programs. This document presents the latest available information on probable climatic extremes, and supersedes information presented in TM X-64589. The information in this document is recommended for employment in the development of space vehicles and associated equipment design and operational criteria, unless otherwise stated in contract work specifications.
Battery development and testing efforts at Phillips Laboratory fall into three main categories: nickel hydrogen, sodium sulfur, and solid state batteries. Nickel hydrogen work is broken down into a Low Earth Orbit (LEO) Life Test Program, a LEO Pulse Test Program, and a Hydrogen Embrittlement Investigation. Sodium sulfur work is broken down into a Geosynchronous Earth Orbit (GEO) Battery Flight Test and a Hot Launch Evaluation. Solid state polymer battery work consists of a GEO Battery Development Program, a Pulse Power Battery Small Business Innovation Research (SBIR), and an in-house evaluation of current generation laboratory cells. An overview of the program is presented.
Heat sterilizable battery program including development of Ag-Zn battery, electrochemistry, separators and case materials
Previous reports have shown how a battery model was developed using porous electrode theory. Since then the model has been upgraded and expanded. These upgrades include oxygen reation and positive electrode intercalation and proton diffusion. The effects of additional details of the solid state physics of the nickel electrode will be reported here.
Empirical formula represents performance of electrical storage batteries. Formula covers many battery types and includes numerous coefficients adjusted to fit peculiarities of each type. Battery and load parameters taken into account include power density in battery, discharge time, and electrolyte temperature. Applications include electric-vehicle "fuel" gages and powerline load leveling.
In this study, we apply the electromagnetic (EM) melt processing of thermoplastics on an innovative EM field-driven powder bed fusion additive manufacturing (AM) concept for high-performance functional parts: Selective Microwave Melting/Sintering (SMM/SMS). This technique leverages the EM susceptibility of carbon nanotube-coated polymer micro-pellets to achieve rapid, localized heating and powder fusion. Thus, selective microwave melting (SMM) was used to fabricate multilayer specimens made of recycled polyphenylene sulfide (rPPS) and carbon nanotubes (CNTs). The resulting SMM specimens exhibited very good interlayer integrity, localized fusion at pellet boundaries, and tolerable residual porosity, indicating effective fusion and acceptable consolidation. CNT-rich interphases were retained after irradiation, generating anisotropic electrically active network pathways and enabling conductivity enhancement at low filler content. At only 1.0 wt% CNT, the specimens exhibited electrical conductivity approximately three orders of magnitude higher than neat rPPS. Dynamic mechanical analysis showed improved viscoelastic response relative to neat rPPS, while tensile testing confirmed that the SMM-processed specimens retained practical mechanical integrity despite localized voids. These results demonstrate that SMM can effectively consolidate EM susceptible thermoplastic powder beds while preserving their segregated conductive networks. This may become a scalable route for producing multifunctional thermoplastic parts with low filler loadings, tunable anisotropy, and structured materials and parts. Overall, the findings suggest that EM field-based AM can help overcome key limitations of conventional thermoplastic processing by enabling scalable, energy-efficient fabrication of nanostructured composites and expanding AM to a broader range of resins, including high-performance thermoplastics with customized functional properties.
Topics covered include: Super NiCd(TradeMark) Energy Storage for Gravity Probe-B Relativity Mission; Hubble Space Telescope 2004 Battery Update; The Development of Hermetically Sealed Aerospace Nickel-Metal Hydride Cell; Serial Charging Test on High Capacity Li-Ion Cells for the Orbiter Advanced Hydraulic Power System; Cell Equalization of Lithium-Ion Cells; The Long-Term Performance of Small-Cell Batteries Without Cell-Balancing Electronics; Identification and Treatment of Lithium Battery Cell Imbalance under Flight Conditions; Battery Control Boards for Li-Ion Batteries on Mars Exploration Rovers; Cell Over Voltage Protection and Balancing Circuit of the Lithium-Ion Battery; Lithium-Ion Battery Electronics for Aerospace Applications; Lithium-Ion Cell Charge Control Unit; Lithium Ion Battery Cell Bypass Circuit Test Results at the U.S. Naval Research Laboratory; High Capacity Battery Cell By-Pass Switches: High Current Pulse Testing of Lithium-Ion; Battery By-Pass Switches to Verify Their Ability to Withstand Short-Circuits; Incorporation of Physics-Based, Spatially-Resolved Battery Models into System Simulations; A Monte Carlo Model for Li-Ion Battery Life Projections; Thermal Behavior of Large Lithium-Ion Cells; Thermal Imaging of Aerospace Battery Cells; High Rate Designed 50 Ah Li-Ion Cell for LEO Applications; Evaluation of Corrosion Behavior in Aerospace Lithium-Ion Cells; Performance of AEA 80 Ah Battery Under GEO Profile; LEO Li-Ion Battery Testing; A Review of the Feasibility Investigation of Commercial Laminated Lithium-Ion Polymer Cells for Space Applications; Lithium-Ion Verification Test Program; Panasonic Small Cell Testing for AHPS; Lithium-Ion Small Cell Battery Shorting Study; Low-Earth-Orbit and Geosynchronous-Earth-Orbit Testing of 80 Ah Batteries under Real-Time Profiles; Update on Development of Lithium-Ion Cells for Space Applications at JAXA; Foreign Comparative Technology: Launch Vehicle Battery Cell Testing; 20V, 40 Ah Lithium Ion Polymer Battery for the Spacesuit; Low Temperature Life-Cycle Testing of a Lithium-Ion Battery for Low-Earth-Orbiting Spacecraft; and Evaluation of the Effects of DoD and Charge Rate on a LEO Optimized 50 Ah Li-Ion Aerospace Cell.
Experimental and computational fluid dynamic activities in rocket propulsion were discussed. The workshop was an open meeting of government, industry, and academia. A broad number of topics were discussed including computational fluid dynamic methodology, liquid and solid rocket propulsion, turbomachinery, combustion, heat transfer, and grid generation.
This project implemented a digital-engineering approach to optimize the impact absorption performance of polymer aerogels and aerogel-based composites for Micrometeoroids and Orbital Debris (MMOD) containment. We developed a curated materials database and a machine-learning framework to derive composition-response relationships, enabling predictive design and targeted material selection. In support of experimental validation, a split Hopkinson pressure bar (SHPB) test rig, specifically adapted for low-density aerogel materials, was designed and built in-house. This project accelerates the development of new aerogel formulations, producing candidate materials tailored for enhanced impact-absorption behavior.