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The 1998 NASA Aerospace Battery Workshop

This document contains the proceedings of the 31st annual NASA Aerospace Battery Workshop, hosted by the Marshall Space Flight Center on October 27-29, 1998. The workshop was attended by scientists and engineers from various agencies of the U.S. Government, aerospace contractors, and battery manufacturers, as well as international participation in like kind from a number of countries around the world. The subjects covered included nickel-hydrogen, silver-hydrogen, nickel-metal hydride, and lithium-based technologies, as well as results from destructive physical analyses on various cell chemistries.

Brewer, Jeffrey C.

Optimal Battery Charging for Damage Mitigation

Our control philosophy is to charge the NiH2 cell in such a way that the damage incurred during the charging period is minimized, thus extending its cycle life. This requires nonlinear dynamic model of NiH2 cell and a damage rate model. We must do this first. This control philosophy is generally considered damage mitigating control or life-extending control. This presentation covers how NiH2 cells function, electrode behavior, an essentialized model, damage mechanisms for NiH2 batteries, battery continuum damage modeling, and battery life models. The presentation includes graphs and a chart illustrating how charging a NiH2 battery with different voltages and currents affects damages the battery and affects its life. The presentation concludes with diagrams of control system architectures for tracking battery recharging.

Hartley, Tom T.

Emergence of Complex Modes in Lightly Damped Structural Systems

In this short presentation format, we will provide a set of useful equations, relationships, and physical interpretations direct from the damped two-mode interaction problem. We will demonstrate that the results from the two-mode interaction problem are in direct agreement with observed test data. Practical methods for estimating the parameters driving the relations direct from modal test data are provided. We finalize with two examples demonstrating weak and strong interactions.

spaceflight hardware

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

Enabling Interoperability in Earth System Digital Twins (ESDT): Integrating Observations, Models, and AI for Actionable Insights Through NASA'S Intelligent Systems Technology Program

NASA’s Intelligent Systems Technology Program (IST) is driving a paradigm shift in Earth science through the development of Earth System Digital Twins (ESDT). These integrated information systems create a dynamic "digital replica" of the Earth by harmonizing continuous, multi-source observations with high-fidelity models and state-of-the-art artificial intelligence (AI) that enable “What now?”, “What next?”, and “What if?” scenario building. These scenarios are reflected in NASA IST’s series of ESDTs, from the Coastal Zone Digital Twin that integrates complex data on the current state of the Chesapeake Bay to the Terrestrial Environmental Rapid-Replication and Assimilation Hydrometeorological (TerraHydro) AI-based ESDT that forecasts water movement across Earth’s surface, to the Agriculture Land Information System (AgLIS) which can be used to assess optimal planting dates and crop yield estimates. By bridging the gap between vast data archives and actionable insights, these projects enable a system-of-systems approach to understanding complex, interacting Earth processes. This poster will highlight recent innovations and future directions from NASA’s ESDT initiatives: Continuous Data Assimilation & Multi-Source Fusion. A core requirement of the ESDT work is the transition from static models to dynamic "living" replicas. This involves creating frameworks for the continual assimilation of near-real-time data from uncoordinated, heterogeneous sources, including satellite observations and airborne assets, and ground-based Internet of Things (IoT) sensors. These systems link design, operational status, and environmental data, ensuring the digital twin accurately reflects the current state of the physical Earth system. High-Fidelity Hybrid Modeling & Computational Acceleration to enable interactive "what-if" explorations, programs are moving beyond traditional, slow physical solvers by developing fast surrogate machine learning models and Deep Generative Models (DGMs). These hybrid approaches use neural networks to emulate complex physics, such as cloud feedback or ocean dynamics, at a fraction of the original computing cost, often leveraging advanced hardware like Graphics Processing Units (GPUs) to achieve the necessary scale. Federated Ecosystems & Interoperable Frameworks rather than building isolated tools, NASA IST is moving toward federated ESDTs and reusable analytic collaborative frameworks. This theme focuses on interoperability standards and common ontologies that allow specialized digital twins to interact and share data. This system-of-systems architecture supports multi-discipline investigations, such as analyzing how upstream watershed changes impact downstream urban flooding or how wildfire emissions affect regional air quality. By leveraging these advancements, ESDTs empower researchers and decision-makers to conduct real-time analysis and run complex hypothetical scenarios, ultimately improving our understanding of Earth’s evolving systems and informing critical real-world applications.

Earth System

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

Analysis of Impact Induced Damage and its Effect on Structural Integrity of Space Flight Composite Overwrapped Pressure Vessels

The objective of this research work has been to provide analytical background and support to the ongoing experimental program at NASA, White Sands Test Facility, involving testing composite overwrapped pressure vessels (COPV) for impact damage and cyclic pressurization. Preliminary theoretical basis, including the governing equations for a shallow shell subjected to internal pressure, has been established. Effects of the Griffith type cracks on the structural integrity of the cylindrical vessel were evaluated by methods of Fracture Mechanics. The results indicate that the effective mass of the pressure vessel is an important factor influencing the response to impact events. We also have found that the material properties of the target, contained in the constitutive equations of the composite attached to the Aluminum liner, dominate the impact event in the low velocity range, the material properties become less important, while the target mass distribution and the impactor mass become more significant as the velocity of the impactor increases. Therefore, at high-velocity impact it is not only the kinetic energy of the impactor but also its mass which has a significant effect on the dynamics of the event, and consequently on the induced damage. This work also suggests a methodology for an assessment of the rate of loading effects on the degradation of the material toughness associated with a high-velocity impact where the rate effects become significant. To model the rate dependence of the material response a viscoelastic-plastic constitutive equations were assumed, and on this basis predictions are made regarding the rate dependent material resistance curve. Other dynamic phenomena associated with the impact event have been treated in the framework of the Computational Mechanics using the courtesy of Prof. P. Guebelle and his graduate student at University of Illinois at Urbana-Champaign who have an access to a super-fast computer located on their campus. Finally, the guidelines for a follow-up research program are provided in the body of this report. They address three major areas: theoretical research, numerical studies, and further experimental work.

Michael P Wnuk

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

The Utilization of Advanced Composites in Military Aircraft

The purpose of this workshop was to identify the current state of the art in key issues related to compression loading and fluid effects in composite materials. In the area of compression loading, there was considerable concern over the different results obtained from various test methods. It was agreed that failure modes produced by the various test methods along with a better fundamental understanding of compression failure were key issues in the development of compression test methods. In the area of fluid effects, a lack of a comprehensive data base hampers identification of key mechanisms leading to fluid degradation. This is further complicated by the fact that interactions depend on the fluid and composite under consideration.

Advisory Group for Aerospace Research and Developm

Bipolar nickel-hydrogen battery design

The initial design for the NASA-Lewis advanced nickel-hydrogen battery is discussed. Fabrication of two 10-cell boilerplate battery stacks will soon begin. The test batteries will undergo characterization testing and low Earth orbit life cycling. The design effectively deals with waste heat generated in the cell stack. Stack temperatures and temperature gradients are maintained to acceptable limits by utilizing the bipolar conduction plate as a heat path to the active cooling fluid panel external to the edge of the cell stack. The thermal design and mechanical design of the battery stack together maintain a materials balance within the cell. An electrolyte seal on each cell frame prohibits electrolyte bridging. An oxygen recombination site and electrolyte reservoir/separator design does not allow oxygen to leave the cell in which it was generated.

Koehler, C. W.

In-Space Laser Forming Simulated Under Thermal Vacuum (TVAC) Conditions

NASA Marshall Space Flight Center is investigating laser forming under thermal vacuum conditions representative of the space environment through a partnership with the DARPA NOM4D program. The thermal gradient mechanism (TGM) is used to bend a metal sheet towards the laser optics. Laser equipment and process parameters are being optimized for thermal vacuum conditions. Such conditions are representative of the extreme cold and hot temperatures and high vacuum that exist on orbit or on the lunar surface. in situ photogrammetry and thermography assess the bend/counterbend and elucidate the TGM in thermal vacuum. Structured light scanning and metallography after bending reveal the macroscopic and microscopic structure after TGM.

thermal vacuum

Laser Welding Dissimilar Reflective Alloys

This project, jointly sponsored by Rocketdyne and CSTAR, involves the development of laser joining of materials which have heretofore been impractical to bond. Of particular interest are joints between stainless steel and copper and also aluminum 6061 to aluminum 2219. CSTAR has a unique opportunity in this area since both the process and development and diagnostics are of interest to industry. Initial results using the pulse tailored laser welding technique developed in CLA for joining crack sensitive materials have proven promising for the aluminum joints based upon metallurgical and electronic microprobe analysis. A declaration of success requires additional mechanical testing. A CW technique has been applied to the stainless-copper joining with some preliminary success. These joints are of significant interest for aeronautics and rocket propulsion applications and the project is expected to continue.

M H Mccay

Advanced Non-Intrusive Instrumentation for Propulsion Engines

Changes in engine technology such as higher temperatures, higher tip speeds, new metal/composite/ceramic materials together with radical changes in design philosophy will require amongst other prerequisites the ability to measure and to monitor key internal gas and structural characteristics. The symposium papers presented non-intrusive measurement and analysis technologies in the following categories: Laser Point Measurements (11); Absorption and Infrared Techniques (4); Paints - Surface Sensors (6); Laser Induced Fluorescence (6); Mechanical (7); Films (5); Laser Planar Measurement (9); and a Keynote Address.

Propulsion

The Effects of Lunar Dust on EVA Systems During the Apollo Missions

Mission documents from the six Apollo missions that landed on the lunar surface have been studied in order to catalog the effects of lunar dust on Extra-Vehicular Activity (EVA) systems, primarily the Apollo surface space suit. It was found that the effects could be sorted into nine categories: vision obscuration, false instrument readings, dust coating and contamination, loss of traction, clogging of mechanisms, abrasion, thermal control problems, seal failures, and inhalation and irritation. Although simple dust mitigation measures were sufficient to mitigate some of the problems (i.e., loss of traction) it was found that these measures were ineffective to mitigate many of the more serious problems (i.e., clogging, abrasion, diminished heat rejection). The severity of the dust problems were consistently underestimated by ground tests, indicating a need to develop better simulation facilities and procedures.

James R Gaier

The Effects of Lunar Dust on EVA Systems During the Apollo Missions

Mission documents from the six Apollo missions that landed on the lunar surface have been studied in order to catalog the effects of lunar dust on Extra-Vehicular Activity (EVA) systems, primarily the Apollo surface space suit. It was found that the effects could be sorted into nine categories: vision obscuration, false instrument readings, dust coating and contamination, loss of traction, clogging of mechanisms, abrasion, thermal control problems, seal failures, and inhalation and irritation. Although simple dust mitigation measures were sufficient to mitigate some of the problems (i.e., loss of traction) it was found that these measures were ineffective to mitigate many of the more serious problems (i.e., clogging, abrasion, diminished heat rejection). The severity of the dust problems were consistently underestimated by ground tests, indicating a need to develop better simulation facilities and procedures.

James R Gaier

The Thermal and Kinematic Sunyaev–Zeldovich Effect in Galaxy Clusters and Filaments Using Multifrequency Temperature Maps of the Cosmic Microwave Background A399–A401 Cluster Pair Case Study

We present a multifrequency and multi-instrument methodology to study the physical properties of galaxy clusters and cosmic filaments using cosmic microwave background observations. Our approach enables simultaneous measurement of both the thermal (tSZ) and kinematic Sunyaev–Zeldovich (kSZ) effects, incorporates relativistic corrections, and models astrophysical foregrounds such as thermal dust emission. We do this by jointly fitting a single physical model across multiple maps from multiple instruments at different frequencies, rather than fitting a model to a single Compton-y map. We demonstrate the success of this method by fitting the A399–A401 galaxy cluster pair and filament system using archival data from the Planck satellite and new, targeted deep data from the Atacama Cosmology Telescope, covering 11 different frequencies over 14 maps from 30 GHz to 545 GHz. Our tSZ results are consistent with previous work using Compton-y maps. We measure the line-of-sight peculiar velocities of the cluster–filament system using the kSZ effect and find statistical uncertainties on individual cluster peculiar velocities of ≲600 km s −1 , which are competitive with current state-of-the-art measurements. Additionally, we measure the optical depth of the filament component with a signal-to-noise of 8.5σ and reveal hints of its morphology. This modular approach is well-suited for application to future instruments across a wide range of millimeter and submillimeter wavebands.

Ajay S Gill

Evaluations of Additively Manufactured Superalloy Lattice Blocks

Cast lattice block structures made up of high-temperature superalloys were previously shown to offer advantages in density, efficiency, and tailored properties. However, inconsistencies in casting die-fill, composition, and microstructure were identified as persistent issues with the casting process path. Three candidate lattice designs were screened through additive manufacturing of a superalloy. Laser powder bed fusion was applied with superalloy powder to produce lattice blocks for three-dimensional octahedral unit-cell designs of three heights. Properties of the structural designs versus additively manufactured lattices were compared, including structural dimensions, densities, defects, grain structures, crystallographic texture, and surface residual stresses. Findings indicate this concept could produce useful superalloy structures for high-temperature-capable static components requiring tailored density, and thermophysical and mechanical properties.

superalloy

Engineering and Abuse Testing of Panasonic Lithium-Ion Battery and Cells

This viewgraph presentation reviews the performance testing of Lithium Ion batteries and cells under different conditions of charge and discharge. The tests show that the 0.5 C rate of charge and discharge might be the ideal condition for long term cycling. It reviews the issues of overcharge and overdischarge of the cells. The cells and the battery have adequate protection under both conditions to prevent any catastrophic occurrences. Temperatures above 150 C are required to vent the cells or cause a thermal runaway, Since this situation is non-credible in the cabin of the Space Shuffle or ISS this should not pose a problem. The presentation includes graphs and charts showing the charge and discharge capacities of the battery and also the current and voltage profiles. A view of a circuit board which contains the controlling mechanism for the battery is also shown.

Jeevarajan, Judith A.