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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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Extending mARC II Arc-Jet Test Duration via Design and Implementation of Model System Cooling Sleeve

The mARC II is a 30 kW arc-jet facility at NASA Ames Research Center used to generate high-enthalpy flows for low-cost thermal protection system (TPS) technology development. Sustained operation of downstream instrumentation and material samples is constrained by thermal loading transmitted through the arc-jet test environment, limiting achievable run times and experimental throughput. This work presents the design, integration, and validation of a cooling sleeve implemented on the sweep arm drive motor feedthrough to mitigate thermal accumulation during testing. The addition of the cooling sleeve is a simple, robust upgrade that translates directly into enhanced facility capability by supporting longer run durations, reduced turnaround time, and higher throughput.

numerical simulations

Impact Testing of 410 Stainless Steel for Material Impact Model Development

A project is underway to develop a consistent set of material properties, impact test data, and failure analysis for a variety of metallic aircraft materials that can be used to develop improved impact failure and deformation models. This project is jointly funded by the NASA Glenn Research Center and the Federal Aviation Administration William J. Hughes Technical Center. Particular features of this set of data are that all material property and impact test data are obtained using traceable material, the test methods and procedures are extensively documented, and all the raw data are available. Four parallel efforts are currently underway: measurement of material deformation and failure response over a wide range of strain rates and temperatures, failure analysis of material property specimens and impact test articles, development of improved numerical modeling techniques for deformation and failure, and impact testing of flat panels and substructures for model validation. This report describes impact testing performed on 410 stainless steel sheet and plate samples of different thicknesses with two different types of projectiles, one a regular cylinder and one with a more complex geometry incorporating features representative of a jet engine fan blade. Data from this testing will be used in validating material models developed under this program. The material tests and the material models developed in this program will be published in separate reports.

410 Stainless Steel

Development, Characterization, and Validation of Elevated-Temperature Constitutive Models: Deformation and Damage

This report provides a brief review of experimentally observed hereditary and nonhereditary material behavior along with background information on standard as well as advanced internal state variable constitutive modeling at elevated temperature. A description of exploratory, characterization, and validation testing is presented along with a detailed outline of what constitutes “sufficient” data content (i.e., quality and quantity) for developing or enhancing, characterizing, and validating a particular sophisticated nonlinear time- and history-dependent (hereditary) class of constitutive models known as GVIPS (generalized viscoplasticity with potential structure). The tests described are necessary to reveal a material’s behavior in the reversible (or viscoelastic) and irreversible (or viscoplastic) regimes, for the identification of both deformation and damage model parameters. Results presented are primarily for metallic materials. In all cases, both uniaxial and multiaxial tests are described, and the linkage between the specific tests and the parameters within the model that can be characterized from the results of these tests are also discussed. Discussion is also provided relative to the role information management must play relative to material data collection, analysis, maintenance, and dissemination. The need for such an information system is particularly important as both analyst and designer move toward utilizations of sophisticated, nonlinear time- and history dependent (hereditary) constitutive models. Lastly, the concept of state space and its utility in understanding and establishing constitutive models is addressed throughout. The intent behind this document is to help both the modeler and experimentalist understand each other’s specific points of view and provide guidance for both model development and characterization. Emphasis has been placed on providing the mechanician with information regarding how tests are performed and what issues to be aware of when interpreting results. It is hoped that experimentalists will take away a new perspective on the types of information that modelers and analysts are looking for from them.

Constitutive Modeling

Model Correlation and Thermal Analysis of xEMU Boot at Lunar South Pole Temperatures

The National Aeronautics and Space Administration (NASA) Artemis program plans to send astronauts to the lunar south pole, a region of the moon that is colder than previous lunar missions and low earth orbit operations. The spacesuit boots that will be used on these missions will be directly impacted by these extremely cold temperatures (down to ~50 K). To assess the performance of the Exploration Extravehicular Mobility Unit (xEMU) lunar boot in these extreme temperatures, the boot was tested at the Jet Propulsion Lab (JPL) in the Cryogenic Ice Transfer, Acquisition Development, and Excavation Laboratory (CITADEL) thermal vacuum (TVAC) chamber. This data was used to correlate thermal models to predict operational performance of the boots on the lunar south pole. This paper documents the data analysis, thermal boot model correlation, and operational predictions conducted using data from the xEMU TVAC test. Data from the test series was used to determine expected thermal conductances within the boot and between the boot and environment. These conductances were used to correlate a Thermal Desktop model of the xEMU boot across 10 different test points which varied external temperature, internal boot ventilation flowrate, and contact pressure. The correlated model was then used to predict operational performance in the lunar south pole. While the predictions indicate promising evidence for performance of the boots at the 100K test point, there is still substantial uncertainty in performance, particularly at the 48K test point. The results of this test series and model correlation stress the importance of improved testing for characterizing the expected thermal resistance between the outside of the boot and the lunar surface.

xEMU

Building Operation Model (Morpheus) for Dallas Fort Worth Airport (CRADA CRD-19-16301 Final Report)

The primary objective of this project was to leverage digital twin technology to enhance the design and operation of DFW Airport terminals and their associated energy systems. To achieve this, Morpheus, a building digital twin, was developed to guide improvements in airport operations, specifically targeting reductions in peak power demand and overall energy consumption.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI

Spacecraft thermal balance testing using infrared sources

A thermal balance test (controlled flux intensity) on a simple black dummy spacecraft using IR lamps was performed and evaluated, the latter being aimed specifically at thermal mathematical model (TMM) verification. For reference purposes the model was also subjected to a solar simulation test (SST). The results show that the temperature distributions measured during IR testing for two different model attitudes under steady state conditions are reproducible with a TMM. The TMM test data correlation is not as accurate for IRT as for SST. Using the standard deviation of the temperature difference distribution (analysis minus test) the SST data correlation is better by a factor of 1.8 to 2.5. The lower figure applies to the measured and the higher to the computer-generated IR flux intensity distribution. Techniques of lamp power control are presented. A continuing work program is described which is aimed at quantifying the differences between solar simulation and infrared techniques for a model representing the thermal radiating surfaces of a large communications spacecraft.

G. B. T. Tan

Predicting Operational Performance of xEMU Boot at Lunar South Pole Temperatures using Thermal Desktop ®

The spacesuit boots that will be used on Artemis lunar south pole surface missions will be exposed to extremely cold temperatures (down to ~50 K). To assess the performance of the government’s Exploration Extravehicular Mobility Unit (xEMU) lunar boot in these permanently shadowed regions, testing was performed at the Jet Propulsion Lab (JPL) in the Cryogenic Ice Transfer, Acquisition Development, and Excavation Laboratory (CITADEL) thermal vacuum (TVAC) chamber. This paper documents the data analysis, thermal boot model correlation, and operational predictions conducted using data from the xEMU CITADEL TVAC test. Expected thermal conductances within the boot and between the boot and environment were calculated from test data, which was then used as an initial guess for conductances within a Thermal Desktop (TD) model. Correlation of the TD model using the internal SOLVER feature was performed across 10 different test points which varied external temperature, internal boot ventilation flowrate, and contact pressure. Operational performance at the lunar south pole was then predicted using results from the correlated model. While the predictions provide evidence for acceptable performance of the boots at the 100K environment test point, there is still substantial uncertainty in performance, especially at the 48K test point. This uncertainty is due in part to testing limitations such as contacting the foot to a hard metal plate rather than granular regolith, and model limitations such as the lack of a realistic foot model. These limitations and their impacts are addressed in detail in this paper. The results of this test series and model correlation underscore the importance of additional improved testing and modeling for characterizing the expected thermal resistance between the outside of the boot and the lunar surface.

Spacesuit

A High Temperature Cyclic Oxidation Data Base for Selected Materials Tested at NASA Glenn Research Center

The cyclic oxidation test results for some 1000 high temperature commercial and experimental alloys have been collected in an EXCEL database. This database represents over thirty years of research at NASA Glenn Research Center in Cleveland, Ohio. The data is in the form of a series of runs of specific weight change versus time values for a set of samples tested at a given temperature, cycle time, and exposure time. Included on each run is a set of embedded plots of the critical data. The nature of the data is discussed along with analysis of the cyclic oxidation process. In addition examples are given as to how a set of results can be analyzed. The data is assembled on a read-only compact disk which is available on request from Materials Durability Branch, NASA Glenn Research Center, Cleveland, Ohio.

Scale Spalling Models

In-Situ Scanning Electron Microscope Experiments for Microscale Mechanical Testing and Validated Modeling of Fiber Reinforced Thermoplastics

A novel, in-situ, scanning electron microscope (SEM) mechanical testing capability for materials at the microscale which provides experimental validation to a machine learning (ML) toolset for full-field validation of physics-based micromechanics models is being developed by researchers at NASA Glenn Research Center. These are enabling technologies for the integration of multiscale digital twins for materials into system level models which will result in the improved performance, material discovery, reduced production cost and time, rapid characterization, and prognostic structural health monitoring (SHM) for materials and structures for extreme environments in support of NASA space exploration missions. In order to bridge the material structure-to-system gap for digital twins, physics-based models must be experimentally validated at multiple length scales. Seminal microscale experiments, conducted at the Air Force Research Laboratory (AFRL), were limited to transverse compression of single-layer, unidirectional thermoset polymer matrix composite (PMC) micropillar specimens [1]. The early phases of the current project followed those initial results and setup to reproduce the compression testing of PMC material on the custom-built piezoelectric actuated micromechanical testing rig built by MicroTesting Solutions LLC. In this work, samples of thermoplastic PMC material were first machined into 3 mm cubes, and then further machining and final milling was done using a Focused Ion Beam (FIB). The initial experiment was done on a pillar roughly 20 µm x 20 µm x 40 µm tall. Additional pillars were milled with final sizes ranging from 20 µm x 20 µm x 40 µm tall to 40 µm x 40 µm x 65 µm tall. A speckle pattern for in-situ full-field measurements using Digital Image Correlation (DIC) was applied with platinum, which was coated on the surface, and then the FIB was used to mill away some of the coating to produce an irregular pattern of Pt on the pillar surface. The samples were loaded into the custom testing rig and placed into the SEM and loaded under compression until failure. Images were collected in the SEM during testing. Post-processing of the images was conducted using DIC to obtain full-field displacement and strain measurements elucidating the role of the matrix as well as fiber-fiber interaction at the microscale within the composite subjected to compression loading well into the non-linear regime of the material. Moreover, the evolution of fiber-matrix debonding and matrix cracking is observed in-situ at the microscale. This data, along with images segmented with a newly developed ML toolset [2], was used to create and validate physics-based micromechanics models. An image of the failed micropillar is shown in Figure 1. The techniques developed in the initial compression experiment was tailored to the validation needs of the models and expanded to include different sized samples as well as possibly tension and fatigue.

Laura Wilson

Thermal Design and Thermal Vacuum Testing of the StarBurst Instrument

The StarBurst Multimessenger Pioneer is a small satellite mission serving as a wide-field gamma-ray observatory designed to capture the initial emissions of short gamma-ray bursts, electromagnetic signatures of neutron star mergers. This paper presents the final thermal design and analysis of the StarBurst Instrument, comprising the bus-to-instrument interface plate, control electronics, and twelve crystal detector units, which form the core of the mission’s science capability. The passive thermal control system design requires consideration of restrictive keep-out zones, unknown orbital parameters, and narrow temperature limits of the detectors. Also summarized is the instrument level thermal vacuum cycle test, correlated model refinements, and updated model results. Following successful completion of the instrument test campaign, the hardware was integrated with the spacecraft bus for spacecraft level testing, including additional thermal vacuum testing. The results from the spacecraft level thermal vacuum test will further inform the instrument thermal model, ensuring accurate flight temperature predictions. StarBurst launches as a secondary payload in 2027 and has a mission duration of at least one year.

StarBurst

NASA's Advanced Control Law Program for the F-8 Digital Fly-By-Wire Aircraft

This paper briefly describes the NASA F-8 Digital Fly-By-Wire (DFBW) program and Langley Research Center's role in investigating and promoting advanced control laws for possible flight experimentation. The primary purpose of the paper is to provide background material for papers describing some of the F-8 DFBW adaptive control law studies. The paper provides a brief description of the Phase II DFBW F-8 aircraft and its control system, discusses some of the advanced control law study objectives and guidelines, and provides some mathematical models which are useful in the control analysis problem.

Optimal Control

A Summary of Test and Analysis Results from a Second Lift+Cruise Full-Scale Drop Test

The realization of advanced air mobility markets is enabling new forms of transportation to take shape in the United States and around the world. Though currently in development, as these markets mature, new types of vertical take-off and landing (VTOL) vehicles have been undergoing development for use. There are many factors which must be addressed prior to these types of vehicles becoming viable alternative forms of transportation in these markets. These factors include incorporation into the existing airspaces, the logistics of operating in urban environments, along with numerous factors associated with safety and reliability. To address some of the safety aspects associated with the development of these new types of vehicles, NASA has been conducting research into the performance of an example electric VTOL (eVTOL) aircraft as a part of the Revolutionary Vertical Lift Technology (RVLT) project. Over the course of this research, many aspects including the development of energy absorbing components, the evaluation of seating systems, the development of advanced finite element material model systems and the acquisition of full-scale vehicle impact data were investigated. The report will discuss aspects related to the acquisition of full-scale vehicle data which occurred in the form of a full-scale impact test conducted in the Summer of 2025. This test was on a NASA designed Lift+Cruise composite cabin test article and represented a partial capstone in the entirety of previous eVTOL research conducted for the project. In this test, a variety of experiments were included in order to investigate the effect of a full-scale environment on the experiment results. In parallel, the development of a computational impact model to simulate the full-scale test will be discussed in this report. A model of the Lift+Cruise test article was developed utilizing data collected from previous sub- and full-scale test data and then simulated in the current test environment. The model development, its use in pre-test predictions, and its use in post-test correlation will all be presented. This report will present the test data acquired from the Lift+Cruise test and document several of the results obtained. One intended result is to determine the effect of a complex full-scale crash impact on the identification of occupant injury risk within seat and vehicle designs. A second intended result is to determine whether high-fidelity models can be used with some confidence in the prediction of test events and can allow for additional test cases to be simulated without the need of having to conduct additional tests. The overall goal of the test is to provide the community with data that can be used for design, development or certification efforts, along with providing data on what an example eVTOL crash incident could entail.

energy storage systems

Mu2e Production Target Thermal Test Project

The Mu2e experiment requires a production target that is capable of operating under extreme thermal conditions caused by an 8 GeV proton beam. This project’s objective supports the development of the Mu2e Pro- duction Target by testing the Stickman model’s thermal behavior. Angel Flores Luviano has assisted Jonathan Williams in progressing this project by contributing to the development of a Radiative Cooling Test Fixture (RCTF) that will be used to evaluate the thermal behavior of the new production target model. Engineering calculations were performed to an- alyze thermal performance and pressure drop within the cold well and wa- ter cooling circuit. These calculations also determined the optimal sizing for key components of the water system. An engineering note was made to document these calculations. CAD models of the water circuit piping, thermocouple mounting bars, and radiator chimney were developed, and prototype test rig components were fabricated using 3D printing. Future work will focus on continued RCTF development which includes control system integration, heater hardware design, and interfaces that can be scaled up to increase thermal capacity.

Flores Luviano, Angel Augusto [Unlisted, US]

GVIPS Prediction of Cyclic Ratchetting Behavior and Cycles with Interrupted Relaxation Periods of TIMETAL 21S at 650 °C

The predictive performance of a multimechanism GVIPS model with saturating hardening function is assessed against a set of high temperature cyclic experiments under both strain-control and stress-control at varying rates of loading as well as several complex interrupted cyclic responses. The material specimens were composed of the titanium alloy, TIMETAL 21S, and tested at 650 °C, see Lissenden et al., 2007. The model did a very good job of predicting the variety of tests, particularly given the fact that only monotonic loading tests (tensile, creep, relaxation) and a single fully reversed cycle was used for characterization. It was particularly interesting that the model was capable of reasonably capturing the rate of accumulated strain during ratchetting under tensile mean stress. Given complex interrupted cyclic response, the model was able to both qualitatively and even quantitatively predict reasonably well both the cyclic and associated relaxation periods (in all quadrants of the stress-strain space) thus confirming the validity of the chosen functional forms for both hardening and thermal recovery. The quantitative inaccuracy is associated with the fact that the material specimens tested by Lissenden et al., 2007 was significantly “softer” than those tested by Castelli in Saleeb et al., 1994 which were used for characterization of the GVIPS model parameters.

Viscoplaticity

Performance Evaluation of Intravehicular Activity Spacesuit Without the Use of a Liquid Cooling Garment

The Orion Crew Survival Systems (OCSS) suit is equipped with safety technology that protects the crew during launch and re-entry and Intravehicular Activities (IVA). It was designed to be used with a Liquid Cooling Garment (LCG), an undergarment with tubes that circulate water to remove excess heat from a crew member. The objective of this study is to determine if the Modified Advanced Crew Escape Suit (MACES), which has very similar material, assembly, and pressure characteristics as the OCSS suit, can be used without the LCG to maintain the crew within their heat storage requirements where exceedances can lead to cognitive and physiological impairment. Testing was completed for both hot and cold environments where test subjects wore varying configurations of the MACES suit ensemble without the LCG. The tests were conducted in a temperature and humidity-controlled chamber with four test subjects ranging from extra small to large. Target metabolic rates were reached using an arm ergometer. To represent the different suit configurations seen in the concept of operations, the suit was tested with visor-down, visor-up, and without helmet and gloves. The test data was analyzed to determine how the environment, test subject size, metabolic rate, and suit configuration affected heat storage. Furthermore, the test data was used to correlate the METMAN model, a transient metabolic man program that simulates the heat transfer within a crew member’s body and from a crew member to the surrounding environment. The METMAN correlation showed good agreement between predicted heat storage and test data at the end of the test duration, with a coefficient of determination (R 2 ) value of 0.8999 for visor-down cases and R 2 of 0.8902 for visor-up and helmet off cases. A correlated METMAN model allows for the analysis and prediction of IVA suit performance without an LCG in additional scenarios.

Spacesuit

Performance Evaluation of Intravehicular Activity Spacesuit Without the Use of a Liquid Cooling Garment

The Orion Crew Survival Systems (OCSS) suit is equipped with safety technology that protects the crew during launch and re-entry and Intravehicular Activities (IVA). It was designed to be used with a Liquid Cooling Garment (LCG), an undergarment with tubes that circulate water to remove excess heat from a crew member. The objective of this study is to determine if the Modified Advanced Crew Escape Suit (MACES), which has very similar material, assembly, and pressure characteristics as the OCSS suit, can be used without the LCG to maintain the crew within their heat storage requirements where exceedances can lead to cognitive and physiological impairment. Testing was completed for both hot and cold environments where test subjects wore varying configurations of the MACES suit ensemble without the LCG. The tests were conducted in a temperature and humidity-controlled chamber with four test subjects ranging from extra small to large. Target metabolic rates were reached using an arm ergometer. To represent the different suit configurations seen in the concept of operations, the suit was tested with visor-down, visor-up, and without helmet and gloves. The test data was analyzed to determine how the environment, test subject size, metabolic rate, and suit configuration affected heat storage. Furthermore, the test data was used to correlate the METMAN model, a transient metabolic man program that simulates the heat transfer within a crew member’s body and from a crew member to the surrounding environment. The METMAN correlation showed good agreement between predicted heat storage and test data at the end of the test duration, with a coefficient of determination (R 2 ) value of 0.8999 for visor-down cases and R 2 of 0.8902 for visor-up and helmet off cases. A correlated METMAN model allows for the analysis and prediction of IVA suit performance without an LCG in additional scenarios.

Human Thermal Modeling

From zonal to nodal capacity expansion planning: Spatial aggregation impacts on a realistic test-case

Solving power system capacity expansion planning (CEP) problems at realistic spatial resolutions is computationally challenging. Thus, a common practice is to solve CEP over zonal models with low spatial resolution rather than over full-scale nodal power networks. Due to improvements in solving large-scale stochastic mixed integer programs, these computational limitations are becoming less relevant, and the assumption that zonal models are realistic and useful approximations of nodal CEP is worth revisiting. Here, this work is the first to conduct a systematic computational study on the assumption that spatial aggregation can reasonably be used for ISO-scale CEP. By considering a realistic, large-scale test network based on the state of California with over 8000 buses, we find that well-designed small spatial aggregations can yield good approximations but that coarser zonal models may result in large distortions of investment decisions, e.g., capacity under-investment of up to 41% for the lowest resolution model considered.

24 POWER TRANSMISSION AND DISTRIBUTION

PROTECT: Production and Reuse of Thermally Efficient Ceramic Thermal Protection Systems

PROTECT (Production and Reuse Of Thermally Efficient Ceramic TPS) is a NASA Early Career Initiative focused on developing the next generation of reusable ceramic thermal protection systems (TPS). This project addresses key challenges in TPS design, including temperature capability, thermal stability, and refurbishment time, by integrating novel material development with predictive modeling. Leveraging enhanced capabilities in NASA’s Porous Microstructure Analysis (PuMA) software, PROTECT introduces new modeling tools to predict the thermal and mechanical behavior of fibrous ceramic materials. These tools enable accurate prediction of performance metrics such as thermal conductivity and structural integrity, reducing reliance on costly physical testing. Preliminary advances in these areas will be presented. To support model validation, PROTECT is building a comprehensive database of raw material properties using advanced characterization techniques, including micro computed tomography (CT) scanning in collaboration with the University of Illinois Urbana-Champaign (UIUC). The presentation will detail the sampling workflows and analysis methods used to generate this detailed microstructural data and how it is used to develop improved models in PuMA. This multi-center collaboration, spanning NASA (JSC, ARC, KSC, GRC), Oak Ridge National Laboratory, UIUC, and SpaceX, is developing tailored TPS solutions for LEO, lunar, and Martian missions. By bridging heritage systems with the demands of modern spaceflight, PROTECT contributes to the advancement of reusable TPS technologies for future exploration missions.

Propulsion, Refractory, and Coating Materials